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Different types of battery used for auxiliary power

supply in substations and power plants
Home / Technical Articles / Different types of battery used for auxiliary power supply in
substations and power plants

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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

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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.

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Tubular Type Lead acid battery

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)

 VRLA/SMF type Lead acid
battery

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

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of checking specific gravity, adding water or acid, etc.

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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.

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

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capacity.

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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.

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.

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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

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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.

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3. Compatibility with respect to charger and inverter needed to be considered.

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Summary of Techno-Commercial Analysis between Ni-Cd &
Lead acid Batteries
No. Description Ni-Cd Lead acid Remarks
Worst case failure is
Worst case failure is
cell open circuit.
cell short circuit.
Result is complete
Result is reduced This point makes
Reliability loss of battery,
1 performance. The NiCd to be superior
Criteria known as ‘sudden
battery will continue in terms of purpose
death’, resulting in
to support the
an unpredicted
system.
system failure.
Requirement
of Air- Additional Cost due
Conditioning to Air conditioning
2 & additional Nil Yes equipment and
cost of running cost-For
Electrical VRLA
Energy

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Replacing cost of

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VRLA after every 5-7
Battery Life as
years will involve
claimed by UK
manufacturing cost
3 manufacturers 20 Years 5-7 Years
escalation during that
(Industrial
year. Eg.at 6th year,
Batteries)
12th year and 18th
year.
Approximately 3
4 Battery Cost – –
times than VRLA
Ni-Cd cells have a
higher initial cost Lead Acid has a low
than lead acid but initial cost but a
Relative Costs
superior lifetime and restricted lifetime. In
5 Initial & Life –
characteristics, many applications
Cycle
giving a lower life they can have a poor
cycle cost in many life cycle cost.
applications.
In terms of Ah, Lead
Ni-Cd cells are
acid (VRLA) is the
6 Physical Size generally larger than
most compact
VRLA cells.
battery.
 Occasionally
7 Water Topping Not Required
Required

Summary of Comparison between tubular flooded (ordinary

Lead-acid) battery with SMF Lead Acid Battery

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No. Tubular Lead Acid battery VRLA Battery
Tubular positive Plates:
Flat pasted positive plates:
The positive active material is held in a
The positive active material is a paste
polyester tube. This does not allow the
form pasted over a lead alloy grid.  This
1 materials to shed during charge-
results in a shorter cyclic life compared
discharge cycling resulting in long cyclic
to tubular construction.- minimum 500
life- minimum 1200 cycles at 80 % depth
cycles at 80% depth of discharge
of discharge.
Electrolyte:  Stationary batteries of UPS
and Power plant back up works on low
Electrolyte: VRLA batteries work on high
specific gravity (1.200) electrolyte and
specific gravity electrolyte (1.280 to
larger in volume. This results in less
2 1.300) and less volume. The cells get
corrosion of grids and longer life. The
heated up during charging and high rate
larger volume keeps the battery
discharges which affects the service life.
comparatively cooler which also adds to
life.

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Separators: Adsorptive glass mat

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Separators: Micro porous poly ethylene
separators are used in these batteries
separators are used. This permits the
3 with a closer spacing between the
ion movement and positive to negative
positive and negative plates. Chances of
plate separation.
cell shorting are therefore more.
Charging compatibility:  VRLA batteries
require constant voltage charging with a
Charging compatibility: Tubular specified limit only specifically to avoid
stationary lead acid batteries can be overcharging.  If by any chance, the
charged with constant current and charging conditions are altered, the
constant voltage mode. Flooded battery will get heated up which will
electrolyte batteries can withstand more deteriorate the battery life. Though there
abuses during charging. Water lost in is no need to top-up due to the
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electrolyte during such abusive recombination principle, it is not always
overcharging could be easily made up 100% efficient, so some water loss
manually by periodic top-up. Lagging during use is not avoidable. This results
cells could be brought to normal life by in a further increase in electrolyte
an extended equalizing charging without specific gravity and life reduction.
significantly affecting the other cells. 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 Not applicable: Cannot monitor
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seen for topping up needs and ease of Electrolyte
maintenance. Low maintenance.
Need for temperature control:  The
close packing arrangement and
compactness of the stack in the cell
Need for temperature control: Due to
assembly rises the temperature sharply
the large electrolyte volume the
during charging. Due to this, VRLA
6 temperature of the cells generally do not
battery manufacturers invariably
rise abnormally during charging. No
recommend the need for air conditioned
need for Air conditioning.
environment for the battery
compartments. This adds to the cost of
maintenance.

Asif Eqbal

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Bachelor of Engineering in Electrical & Electronics engineering, from Manipal University,

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(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".