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Different types of battery used for auxiliary power supply in

substations and power plants
Asif Eqbal

Different types of battery used for auxiliary power supply in substations and power plants

In industrial or substation applications mainly three types of batteries are used namely:
1. Vented / Flooded Lead Acid batteries
2. Sealed maintenance free batteries/Valve Regulated Lead Acid
3. Nickel Cadmium (Ni-cd) batteries
For UPS applications batteries are the most popular and hence are widely used. Hence, in this detailing, mainly
emphasize has been put on these type of batteries.

Vented / Flooded Lead Acid Batteries

There are two types for vented or flooded lead acid batteries namely tubular and Plante. The difference between
the two is the construction. For tubular battery normal life is 8-10 years. The Plante battery is both mechanically
and electrically more durable. The normal life for Plante batteries is 15-20 years. Because this type of battery
generates corrosive fumes when charging and because the sulfuric acid electrolyte does evaporate to some
extent, these batteries must be used in a special room, which is well ventilated to the outside and kept away from
delicate electronic equipments.

It needs separate room/racks with acid proof tiles for installation. Because of evaporation, it needs regular
maintenance to check specific gravity, to add water and acid.
These batteries can withstand high temperature, voltage, and
deep discharge with minimum damage to itself. A notice should be
exhibited in the battery room prohibiting smoking and use of
naked flames. These batteries cannot be transported in charged
condition and therefore need charging at site.
Typical initial charging of the battery will take about 55 to 90
hours. Nominal cell voltage is 2V/cell. The charger for this battery
should be able to provide the first charge at 2.6 to 2.7 V/cell.
These types of batteries are typically used for UPS Systems of
very high rated capacity, typically engaged for plant application,
wherein maintenance and space is not really an issue.

Sealed Maintenance Free batteries (SMF)

These are also known as Valve Regulated Lead Acid (VRLA)
batteries. These batteries are the most popular for usage with
UPS systems for computer or commercial application. Being
sealed, these batteries do not emit any fumes and hence can be
very well installed next to electronic equipment. These batteries
also can be housed in a close enclosure
if necessary. These batteries are also
maintenance free and avoid any hassles
of checking specific gravity, adding water
or acid, etc.

Vented / Flooded Lead Acid Batteries

These batteries have a relatively lesser

life of approx. 3-5 years. The life
expectancy typically depends on the
number of charge/discharge cycle
experienced by the batteries and the
ambient temperature in which the
batteries are used. These batteries are
primarily the most popular for commercial
applications due to Install and forget
approach.
Tubular Type Lead acid battery

The Performance and service life of

these batteries can be maximized by observing the following guidelines:
1. Permissible operating temperature range of SMF batteries is 15 deg C to 50 deg C , but using within an
operating range 5 C to 35 C will extend service life. Below 15 deg C, the battery changes its chemical
composition and cannot hold a charge. You will enjoy longer service life, if batteries are operated in ambient
temperature range of 20 deg C to 25 deg C (68F to 77F) . At lower temperature they have longer life and lower
capacity while at higher temperature they have higher capacity and lower life.
2. A good rule of thumb when determining battery service life in relation to temperature is that for every 8.3 deg C
(15F) average annual temperature above 25 deg C (77F), the life of the battery is reduced by 50%. Therefore
warranty of the battery should be ideally reduced to 50% for every 8.3 deg C (15F) increase in operating
temperature above 25 deg C (77F).

3. SMF batteries are designed to have a float voltage of 2.3 V/cell. This means that a 12 V battery (with 6
internal cells) has a float voltage of 13.8 Volts. Most of the battery manufacturers recommend float voltage of 2.25
2.3 volts per cell. When there are more cells (generally >120) in series, to compensate for higher temperatures,
float voltage should be decreased by approx. 3 mV per cell per deg C above 25 deg C. It should be increased by
the same amount when operated at a temperature less than 25 deg C to avoid undercharge. The Cutoff voltage is
1.67 V/cell for high rate of discharge (
4. It is recommended that SMF batteries should not be left in totally discharged state more than 72 hrs. The
batteries may get partially or fully damaged due to SULPHATION if charging does not start within 72 Hrs from
totally discharged state. Sulphation is the formation of lead sulphate on negative plates which acts as an insulator
and has a detrimental effect on charge acceptance.
5. In normal float / equalize use (2.25 to 2.35V/cell), gas generated inside battery is recombined into negative
plates, and return to water content of the electrolyte. Thus
electrical capacity is not lost because of this recombination.
There is no need to add external water, but due the corrosion of
the electrodes battery will eventually lose capacity.
6. At ambient temperature of 30 40 deg C, the shelf life of
batteries is 5-6 months only. A freshening charge must be given
to the batteries every 6 months, if needed to be stored for longer
periods. Batteries should be kept in dry, cool place. At ambient
temperature of 20 deg C (68F), the self-discharge rate is 3-4%
(approx.) of rated capacity per month. The self-discharge rate
varies with ambient temperature.
VRLA/SMF type Lead acid battery

7. SMF batteries are equipped with a safe, low pressure venting

system, which operates at 7 psi to 10 psi (can vary slightly from
manufacturer to manufacturer), automatically releasing excess gas in the event that gas pressure rises to a level
above the normal rate ensuring no excessive buildup of gas in the batteries. Resealing is automatic once the
pressure is returned to normal.
8. Cyclic life of the battery depends on ambient operating temperature, the discharge rate, the depth of discharge,
and the manner in which the battery is recharged. The most important factor is the depth of discharge. At a given
discharge rate and time, the shallower the depth of discharge, the longer is the cyclic life.
9. Failure mode at the end of life includes:
1. Capacity decrease
2. Internal short circuit
3. Damage to container/lid
4. Terminal corrosion
5. Reduced open circuit voltage.
10. The IEEE defines B (Bend of useful life) for a UPS battery as being the point when it can no longer supply 80
percent of its rated capacity in ampere-hours (AH). The relationship between AH capacity and runtime time is not
linear, a 20% reduction in capacity results in a much greater reduction in runtime. When battery reaches 80% of
its rated capacity, the aging process accelerates and the battery should be replaced. Some UPS/ Battery
manufacturers define B (Bend of useful life) for a UPS battery when battery capacity reaches 50-60% of its rated
capacity.
11. Mixed use of batteries with different capacities, different makes should be avoided as it will cause accelerated
aging of the whole string.
12. If two or more battery groups are to be used, connected in parallel, they must be connected to the UPS

through lengths of wires, cables or busbars that have the same loop line resistance as each other. This makes
sure that each parallel bank of batteries presents the same impedance to the UPS as any other of the parallel
banks thereby ensuring correct equalization of the source to allow for maximum energy transfer to the UPS load.
13. The normal life SMF battery will support approx. 200 charge/discharge cycles at 25 deg C (77F) and 100%
depth of discharge.
14. The term B (Bend of useful life) for a UPS battery refers to the fact that these batteries do not require fluid.
But preventive maintenance like checking for cracks and deformation of the container & lid, electrolyte
leakage/spills tightening of the connection etc, particularly for higher AH capacity batteries should be done to
prevent any damage.

Nickel Cadmium Batteries (Ni-Cd)

Ni-cd batteries do emit hydrogen and oxygen gas, products of electrolysis, but there are no corrosive gases as
lead acid batteries, so these can be installed near electronic equipment. Water consumption is relatively low and
so therefore maintenance is low. Normal service life is 20-25 years. These are most expensive of the various
types of batteries previously discussed. Initial cost may be approximately three times that of lead acid battery
depending upon their AH capacity.
These batteries do not experience the severe shortening of life when operated at elevated temperatures and
perform better at low temperatures than do the lead acid batteries. Nominal cell voltage is 1.2 V/cell. The battery
chargers and inverters have to be designed to operate with low end cell cutoff voltages and higher recharging
voltages needed for such batteries.
These batteries occasionally demand boost charging and typically find their applications wherein UPSs support
critical equipment in hazardous environment such as chemical, fertilizer, cement industry.

Merits/demerits
As spelled earlier, all the above discussed types of batteries have their own merits and demerits. Let us now look
at them individually.

A) Vented / flooded Lead acid batteries

Merits
1. Most economical among three types of batteries.
2. Life is higher than SMF batteries.
3. Robust- not much sensitive to temperature.

Demerits
1. Needs periodic maintenance- twice a month.
2. Emits corrosive fumes.
3. Needs special battery room with acid proof tilling.
4. Cannot be transported in charged condition, initial charging takes 55 to 90 hours.
5. Needs specially trained persons for handling due highly hazardous sulphuric acid.

B) Sealed maintenance free batteries / Valve Regulated Lead Acid

Merits
1. No maintenance as far as water filling, specific gravity check etc is concerned.
2. Can be shipped in charged conditions so ready to use.
3. User friendly.

Demerits
1. Leaving batteries in discharged state for longer life will reduce life significantly or can damage them
permanently.
2. Very sensitive to temperature
3. Service life lowest among the three types
4. Costlier than flooded / vented lead acid battery

C) Nickel Cadmium (Ni-cd) batteries

Merits
1. Moderate maintenance
2. Higher service life
3. less sensitive to temperature
4. Fumes not corrosive so can be installed near electronic equipment

Demerits
1. Most expensive among three types
2. Cannot be transported in charged conditions.
3. Compatibility with respect to charger and inverter needed to be considered.

Summary of Techno-Commercial Analysis between Ni-Cd & Lead acid Batteries

No.

Description

Ni-Cd

Lead acid

Remarks

Reliability
Criteria

Worst case failure is cell

short circuit. Result is
reduced performance. The
battery will continue to
support the system.

Worst case failure is cell

open circuit. Result is
complete loss of battery,
known as sudden death,
resulting in an unpredicted
system failure.

This point makes NiCd to be

superior in terms of purpose

Requirement
of AirConditioning
& additional
cost of
Electrical
Energy

Nil

Yes

Additional Cost due to Air

conditioning equipment and
running cost-For VRLA

Battery Life as 20 Years

claimed by
UK
manufacturers
(Industrial
Batteries)

5-7 Years

Replacing cost of VRLA after

every 5-7 years will involve
manufacturing cost
escalation during that year.
Eg.at 6th year, 12th year
and 18th year.

Battery Cost

Approximately 3 times than

VRLA

Relative
Costs Initial &
Life Cycle

Ni-Cd cells have a higher

initial cost than lead acid
but superior lifetime and
characteristics, giving a
lower life cycle cost in
many applications.

Lead Acid has a low initial

cost but a restricted
lifetime. In many
applications they can have
a poor life cycle cost.

Physical Size

Ni-Cd cells are generally

larger than VRLA cells.

In terms of Ah, Lead acid

(VRLA) is the most
compact battery.

Water Topping

Occasionally Required

Not Required

Summary of Comparison between tubular flooded (ordinary Lead-acid) battery

with SMF Lead Acid Battery
No.

Tubular Lead Acid battery

VRLA Battery

Tubular positive Plates:

The positive active material is held in a
polyester tube. This does not allow the
materials to shed during charge-discharge
cycling resulting in long cyclic life- minimum
1200 cycles at 80 % depth of discharge.

Flat pasted positive plates:

The positive active material is a paste form pasted over a
lead alloy grid. This results in a shorter cyclic life
compared to tubular construction.- minimum 500 cycles at
80% depth of discharge

Electrolyte: Stationary batteries of UPS

and Power plant back up works on low
specific gravity (1.200) electrolyte and
larger in volume. This results in less
corrosion of grids and longer life. The larger
volume keeps the battery comparatively
cooler which also adds to life.

Electrolyte: VRLA batteries work on high specific gravity

electrolyte (1.280 to 1.300) and less volume. The cells get
heated up during charging and high rate discharges which
affects the service life.

Separators: Micro porous poly ethylene

separators are used. This permits the ion
movement and positive to negative plate
separation.

Separators: Adsorptive glass mat separators are used in

these batteries with a closer spacing between the positive
and negative plates. Chances of cell shorting are therefore
more.

Charging compatibility: Tubular stationary

lead acid batteries can be charged with
constant current and constant voltage
mode. Flooded electrolyte batteries can
withstand more abuses during charging.
Water lost in electrolyte during such
abusive overcharging could be easily made
up manually by periodic top-up. Lagging
cells could be brought to normal life by an
extended equalizing charging without
significantly affecting the other cells.

Charging compatibility: VRLA batteries require constant

voltage charging with a specified limit only specifically to
avoid overcharging. If by any chance, the charging
conditions are altered, the battery will get heated up which
will deteriorate the battery life. Though there is no need to
top-up due to the recombination principle, it is not always
100% efficient, so some water loss during use is not
avoidable. This results in a further increase in electrolyte
specific gravity and life reduction. Equalizing (Extended)
charging in VRLA batteries results in some cells getting
heated up and life reduction.

Containers: We use transparent SAN

containers. The electrolyte level is easily
seen for topping up needs and ease of
maintenance. Low maintenance.

Not applicable: Cannot monitor Electrolyte

Need for temperature control: Due to the

large electrolyte volume the temperature of
the cells generally do not rise abnormally
during charging. No need for Air
conditioning.

Need for temperature control: The close packing

arrangement and compactness of the stack in the cell
assembly rises the temperature sharply during charging.
Due to this, VRLA battery manufacturers invariably
recommend the need for air conditioned environment for
the battery compartments. This adds to the cost of
maintenance.

Asif Eqbal - Bachelor of Engineering in Electrical & Electronics engineering, from Manipal
University, (Karnataka), India in 2006. Presently involved in the design of EHV outdoor substation
and coal fired thermal power plants for more than seven years. Motto of joining EEP as a
contributor is to share my little engineering experience and help the budding engineers in
bridging the conspicuous gap between academics and Industrial practice. If you have
knowledge, let others light their candles with it, so that people who are genuinely interested in
helping one another develop new capacities for action; it is about creating timeless learning processes".