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EVALUATION REPORT
REPORT 1063
18 AUGUST 1961

Evaluation of External Battery Power Supply for Bathyscaph TRIESTE

L. A. Shumaker

U. S. NAVY ELECTRONICS LABORATORY, SAN DIEGO, CALIFORNIA
A BUREAU OF SHIPS LABORATORY

€901T j10deYy/ TAN

THE PROBLEM

Determine the practicability and effectiveness of using lead-
acid storage batteries as a power supply under high hydro-
static pressures and low temperatures such as are encoun-
tered in the deep sea. Also, determine the magnitude of any
loss of capacity or decrease in discharge rate attributable to
high pressures or low temperatures within the range found
in the deep sea.

RESULTS

Lead-acid storage batteries were found to provide an effective
and practical power source under pressures up to 16, 000 psi
and temperatures down to 35° F. The lead-acid batteries

are cheaper than the silver-zinc cells used and may be mounted
externally to save cabin space.

RECOMMENDATIONS

1. Use externally carried lead-acid storage batteries as the
primary power supply for the TRIESTE.

2. Extend the investigations reported herein to include other
types of ''wet''’ batteries for similar uses.

3. Initiate investigation to determine other areas of use for

this type of power supply, such as unmanned buoys or ocean-
bottom instruments.

ADMINISTRATIVE INFORMATION

Work was performed under SR004 03 01 (NEL L4-1) by mem-
bers of the Services Department and Signal Propagation

WWMM MLO

01 0040

Division. The report covers work from May 1960, at Guam,
through January 1961, at the Navy Electronics Laboratory,
and was approved for publication 18 August 1961.

Grateful acknowledgment is made to E. W. Hutchison and
Charles Hill of the U. S. Navy Electronics Laboratory, who
designed the battery box used during Project NEKTON II,
designed and constructed the test casings used in the tests
presented in this report, and, along with C. M. Adams, EM1,
were responsible for the major portion of the supervision of
those tests. Thanks are also due A. B. Rechnitzer, LCDR
R. D. Plunkett, and LT Don Walsh for their assistance in

the tests and for a critical review of this report.

Previous NEL publications dealing with the bathyscaph and
its operation are the following:

NEL Report 941, The 1957 Diving Program of the Bathyscaph
TRIESTE, by A. B. Rechnitzer, 78 December 1959. UN-
CLASSIFIED

NEL Report 956, Evaluation of the Control Characteristics

of Bathyscaph Ballast, by R. K. Logan, 11 February 1960.
UNCLASSIFIED

NEL Report 1030, Investigation of Window Fracture in
Bathyscaph, by J. C. Thompson, R. K. Logan, and R. B.

Nehrich, 20 March 1961. UNCLASSIFIED

CONTENTS

Page

4 INTRODUCTION
b) TEST CONSIDERATIONS
9 TEST PROGRAM
16 DISCUSSION
18 CONCLUSION
18 RECOMMENDATIONS
TABLE
Page Table
15 1 Schedule of pressure tests
ILLUSTRATIONS
Page Higure
6 1 Schematic cross-section of battery and test
case
ra 2 Photograph of Willard batteries used in tests
7 3 Interior view of battery box used during
Project NEKTON II
8 4 Pressure chamber used in tests
9 5 Control board for pressure chamber
10 6 Exterior views of battery box used during
Project NEKTON II
12 7 Graph of pressure and temperature variations
programmed during simulated dives to
24, 000 feet
12-14 8-12 Graphs of tests
4 18} New battery boxes installed on TRIESTE
17 14 Navy standard battery as modified for use

on TRIESTE

INTRODUCTION

This report discusses the suitability of lead-acid batteries
for use as a power supply on the bathyscaph TRIESTE during
decents into the hostile pressure and temperature environ-
ment of the deep sea. Further information concerning the
bathyscaph itself and its operation is contained in another
report.

The bathyscaph is not, in some ways, a weight-limited vehicle.
It has been designed with buoyancy to support additional bal-
last for deeper dives and the heavy KRUPP sphere. Operating
in depths of 20, 000 feet or less and utilizing the lighter TERNI
sphere or cabin, the bathyscaph has buoyancy to support
additional payload. The main problem is space limitation.

The power supply of the TRIESTE formerly consisted of
small silver-zinc batteries. These were extremely expensive
and occupied a large part of the available cabin space. An
externally mounted power supply would free this valuable
cabin space and greatly increase the power which can be
carried. Only the limitations imposed by the structural
Space available to mount the power supply externally and by
the weight which may be carried restrict the amount of power
supply available. The weight limitation does not become
important except during extremely deep dives. Another
advantage of the externally mounted power supply is the elim-
ination of the need to carry high currents through the wall

of the cabin. With the primary power supply outside the cabin
only small control currents are required for even the heavy
duty propulsion motors. Small control wires may be used,
which require less Space in the available penetration and
eliminate heavy power cables inside the cabin. The present
size and number of penetrations in the cabin are fixed, and

as more and more scientific equipment is added, more cabin
space and penetration are required.

These factors, the extreme urgency of acquiring a larger
power supply, and the much lower cost of lead-acid batteries
prompted the initiation of the tests which will be detailed in
this report.

Navy Electronics Laboratory Report 941, The 1957 Diving

Program of the Bathyscaph TRIESTE, by A. B. Rechnitzer,
28 December 1959.

It should be noted here that the French bathyscaph, FNRS-3,
has had some degree of success in operating with externally
carried batteries, but because there is a lack of information
concerning their methods of operation and because their
dives have been limited to depths of less than 14, 000 feet,

it was decided to complete a full series of tests to evaluate
this type of power supply.

TEST CONSIDERATIONS

It was necessary to insulate the batteries from the water to
prevent shorting and to keep the water from mixing with the
electrolyte. It was also,necessary to transmit pressure

from the water through the insulation to the electrolyte and
thus throughout the battery to prevent the casing from collaps-
ing. This was accomplished by placing the battery in an oil
filled case as shown in figure 1. As the oil and the electrolyte
compress due to pressure, water flows into the bottom of the
case through the equalizing tube, thus retaining a balance of
internal and external pressures. Compressibility tests on

the transformer oil used as the insulating fluid show a volume
loss of only 4.7 per cent at 16,000 psi. Since electrolyte is
even less compressible, the water level in the bottom of the
case could not rise high enough to short the battery as long

as at least 5 per cent of the case volume in addition to that
occupied by the battery itself is located below the battery

top. In the final design of the operational battery cases, the
batteries are supported several inches above the bottom of

the case so that the water can never reach the bottom of the
battery even in the deepest dives.

Because battery electrolyte in the fully charged state (specific
gravity 1.260) sustains a volume loss of 3 per cent at 16, 000
psi, it is necessary to provide a small reservoir of electro-
lyte above the top of the battery plates to prevent oil from
coming in contact with the plates when the electrolyte com-
presses. The batteries used in the laboratory tests already
contained a large enough void area above the plates to con-
tain the needed additional volume of electrolyte, as can be
seen in figure 2. The standard Navy 12-volt automobile
batteries which were obtained for operational use, however,
required an additional reservoir. This was provided for by
attaching small polyethylene bottles to the top of each cell

in place of the filling cap, as shown in figure 3.

PRESSURE EQUALIZING TUBE AND WIRE EXIT

FILLING PLUG

ELECTROLYTE

BATTERY PLATES LIGHT. TIN CASING

OIL

Figure 1. Schematic cross-section of battery and test case.

Because the size of the pressure test facility was limited

(6 inches in diameter), smaller batteries were used during
the test program than were actually used operationally.

Since the general characteristics of lead-acid batteries are
similar, it was not felt that this substitution imposed any
serious limitations on the tests. Three identical Willard,
2-volt, 20 ampere-hour, lead-acid cells were used. These
cells were labeled ''A!' "B,'' and ''C, '' and will be so referred
to in this report.

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SOALE IN INCHES

Figure 2. Photograph of Willard batteries used in tests.

Figure 3. Interior view of battery box used during Project
NEKTON II.

All tests were run under continuous supervision. Readings
of all variables were taken every 15 minutes. Since both
control and test readings were made with the same instru-
ments, and the factors of interest were the differences
between these readings, no attempt was made to obtain
absolute calibration of the instruments. The estimated,
relative accuracy of the readings is given below:

Pressure + 500 psi
Temperature x 1 /Z° ip
Voltage + 0.005 volt
Current + 0.05 ampere

Figures 4 and 5 show the pressure equipment used during
laboratory tests.

Figure 4. Pressure chamber used in tests.

Figure 5. Control board for pressure chamber.

TEST PROGRAM

The first tests of lead-acid batteries were conducted as part
of an operational dive of the bathyscaph. Two 12-volt and
one 6-volt automobile batteries were obtained and encapsu-
lated, using the methods discussed above and shown in
figures 3 and 6. These batteries were wired through means
of relays actuated from within the cabin to power two exper-
imental plankton samplers. The batteries functioned very
well to depths of over 19, 000 feet but were not used exten-
sively because the plankton samplers malfunctioned.

After these tests the batteries were allowed to remain in
their oil bath for some time, and it was discovered that the
oil was slowly dissolving the ''tar'' used to seal the battery
tops. This problem has been solved in succeeding tests by
coating the battery tops with an epoxy resin which prevents
the oil from carrying away the sealant.

10

Figure 6. Exterior views of battery box used during Project
NEKTON II.

The first laboratory tests were run on the Willard cells in
October 1960. They were run primarily to gain familiarity
with the factors involved and are therefore not detailed here.
The significant tests which are detailed in this report (fig. 7-
12) began in November 1960 and continued through January
1961, as shown in table I.

Tests 1, 3, 9, 12 and 13 were conducted in the battery shop
under normal atmospheric conditions of temperature and
pressure.

Tests 2 and 4 were conducted under conditions simulating

a stay of 8 hours at a depth of 36,000 feet. Tests 5 and 6

were conducted to simulate dives to a depth of 24, 000 feet,
as shown in figure 7.

Test 7 was run to determine the IR drop in the added length
of wire, necessitated by the length of the pressure chamber,
used in tests 2, 4, 5and6. This correction was applied

to data of tests 1 and 3 before graphing. Equal lengths of
wire were uSed in all succeeding tests.

After the results of the first six tests were tabulated and
compared, it was considered desirable to obtain curves
which would reflect the complete capacity of the batteries.
This had to be done within the normal limits of a working
day; therefore, tests 8 and 9 were run to determine the
discharge rate necessary to reach the low voltage limit of
the batteries within 7-1/2 hours. Test 9 also served as the
control discharge for battery ''A'' for the 3.5-ampere rate.

Tests 10 and 11 simulated capacity discharges at a depth of
36, 000 feet. At the conclusion of each of these tests the
pressure was removed from the test chamber as rapidly as
possible (about 15 seconds). This rapid pressure release
simulated a far more rapid rise to the surface than would
ever be actually possible with the bathyscaph. The cell
was immediately removed from the chamber and examined
carefully. No evidence of damage to the plates from rapidly
forming and expanding gases was noted, and subsequent
discharges indicated no loss in capacity. Test 12 was run
as a control.

Tests 13 and 14 were run to determine the operability of a
nickel-cadmium cell under the same conditions.

Test number 15 was run to determine the possibility of
delayed effects of operating under pressure and rapid de-
compression. No losses were noted.

11

VOLTAGE

12

4 5
TIME (HR)

Figure 7. Graph of pressure and temperature variations
programmed during simulated dives to 24, 000 feet.

4 5
TIME (HR)

Figure 8. Graph of tests 1 and 4.
Test 1. Normal discharge of battery A at 2.5 amperes
for control.
Test 4. 2.5-ampere discharge of battery A under 16, 000
psi at 35-45° F.

VOLTAGE

VOLTAGE

4 5
TIME (HR)

Figure 9. Graph of tests 1 and 6.
Test 1. Normal discharge of battery A at 2.5 amperes
for control.
Test 6. 2.5-ampere discharge of battery A under con-
ditions simulating a dive to 24, 000 feet.

4 5
TIME (HR)

Figure 10. Graph of tests 3 and 5.
Test 3. Normal discharge of battery B at 2.5 amperes
for control.
Test 5. 2.5-ampere discharge of battery B under con-
ditions simulating a dive to 24, 000 feet.

13

14

VOLTAGE

VOLTAGE

4 5
TIME (HR)

Figure 11. Graph of tests 9 and 11.
Test 9. Normal discharge of battery A at 3.5 amperes
for control.
Test 11. 3.5-ampere discharge of battery A under
conditions simulating submergence to 36, 000 feet.

4 5
TIME (HR)

Figure 12. Graph of tests 10 and 12.
Test 10. 3.5-ampere discharge of battery B under
conditions simulating submergence to 36, 000 feet.
Test 12. Normal discharge of battery B at 3.5
amperes for control.

Test| Date

No. | (1960-61)
7
3
5
;
|
|
9
10
r
12 2 Dec

r
i
15 4 Jan

TABLE

Rate

of

Disch,
Batt.| (amp)

>

>

>

>

Z
Q}a

w)] wi] wy] w w iS) bh ] ho] bw [eb NO] bw
oy oyort a o o o}oy ojo ojo

I, SCHEDULE OF PRESSURE TESTS.

Press.

See pressure-
temperature

chart of sim-
ulated dive

Temp.
(°F)

31-46
68

Disch.
Duration
(hr:min)

8:45

6:45
7:16
7:05
7:30

6:01
7:15

ror)
wo
°

Remarks

Test considered invalid
because battery inadvert-
ently shorted prior to
start of test. No graph.

Bench test to determine
magnitude of error.
(Lengths of test lead used
during previous bench
tests were different than
those used in pressure
chamber. )

No graph plotted for this
test.

Rapid decompression test.

" W W

This test discharge was
run to determine delayed
effects of rapid decom-
pression from test 11.
None noted.

15

16

DISCUSSION

Although minor fluctuations may be noted in the voltages of
the cells, there is no consistent decrease in capacity and it
is believed that these voltage fluctuations can be accounted
for in the normal fluctuation found in any lead-acid cell from
one charge to the next. It should be noted that in some cases
the apparent capacity under high pressure and low temperature
conditions is actually greater than that found in the control
discharges and that in every case except one, the discharge
curve, under pressure, is actually flatter than the control
curve. It is also interesting to note that during the time

that the pressure is being applied, there is an initial voltage
rise significantly higher than normally encountered. This

is probably due to the compression and virtual elimination

of the gas bubbles or film on the face of the battery plates.

Based on the results of these tests, construction of battery
boxes (fig. 13) was begun and sufficient 12-volt automobile
batteries for two complete operational sets (1400 ampere-
hours at 24 volts per set) were obtained. These batteries
were coated with epoxy resin and fitted with the polyethylene
reservoir previously mentioned (fig. 14). They have now
been placed in service and presently are providing a satis-
factory primary power supply for the TRIESTE.

Figure 13. New battery boxes installed on TRIESTE.

Figure 14. Navy standard battery as modified for use
on TRIESTE.

17

CONCLUSION

The tests show that it is practical to use lead-acid batteries

in pressure-equalized, oil-filled cases as the primary power
supply for the bathyscaph or any other deep experimental
submersible craft that can handle their weight. The pressures
and temperatures encountered in the oceans, to any depth,
have no significant effect on lead-acid battery operation,
capacity, or rate of discharge.

RECOMMENDATIONS

1. Use externally carried lead-acid storage batteries as
the primary power supply for the TRIESTE.

2. Extend the investigations reported herein to include
other types of ''wet"' batteries for similar uses.

3. Initiate investigation to determine other areas of use
for this type of power supply, such as unmanned buoys or
ocean-bottom instruments.

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Department of Oceanography (Unc1)
Yale University
Bingham Oceanographic Lab.
Lamont Geological Observatory
Woods Hole Oceanographic Institution
Laboratory of Oceanography (Uncl. only) (2)
Vitro Corp. of America, Silver Spring
Lab, Library

(Uncle only)

VIA ONR NEW YORK

Columbia University, Hudson Labs.

VIA BUSHIPS CODE 670C

Headquarters, U. S.» Coast Guard
Aerology & Oceanography Section

UNCLASSIFIED ONLY

US Naval Academy
Civil Engineering Laboratory,
Office of Naval Research

L54

Contract Administrator, S. BE. Area
Chicago Boston
New York

San Francisco
Allan Hancock Foundation
Arctic Research Laboratory
US Geological Survey
US Fish & Wildlife Service
Point Loma
Stanford
Washington, D. Co. (2)
Woods Hole
Geophysics Research
Narragansett Marine Laboratory
Waterways Experiment Station
Navy Weather Research Facility
Cornell University, Department of Conservation
Florida State University,
Oceanographic Institute
University of Hawaii, Marine Lab.
Oregon State College, Dr. Burt
Rutgers University, Dr. Haskins
AWS, Scott AFB, Illinote
General Precision Laboratory,
The Martin Company, Baltimore
Sylvania Electric Defense Labs, Dre Beard
Bureau of Comm. Fisheries, Bio. Lab.
Wash D. Co Point Loma Sta.

Inc.

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