POWER PLANTS

______________________________________________________________________________

Evaluation of
Different Battery Technologies
Used in Indian Telecom Network

_____________________________________________________________________________

Telecommunication Engineering Centre

Khurshid Lal Bhavan, Janpath
New Delhi-110001, India

CONTENTS

S. No Topic

Page No.

1.

Introduction

2.

Chronicle

3.

Comparative analysis of VRLA (AGM and GEL) technology

with respect to Flooded type batteries (Tubular/Flat pasted)

4.

Tabular comparison of batteries based on different

technologies (VRLA AGM, Tubular VRLA GEL and Flooded)

5.

Present Field Scenario

6.

Conclusions

7.

Suggestions of TEC

Introduction
This paper details the chronicle of developments in technology of batteries used in Indian
Telecom Network. It deliberates on the comparative study of various technologies used. It gives
the present state of batteries under use in the telecom network. It also analyses the scope of
switchover from one technology to another.
Chronicle
The battery has been the integral part of the telecom system since the beginning. It was used as
the main power source in the initial stages, and as standby power source, later on.
In the initial stages of standby power source, flooded flat-pasted type batteries were used in the
Indian telecom network. Later on flooded tubular positive plates batteries were used. All these
batteries were being procured and tested as per respective IS standard IS-1650. The
certification of these batteries was being done by QA wing of DoT (presently BSNL).
Both these type of batteries require a separate battery room, because they release a significant
amount of sulphuric acid fumes.
These batteries also require periodical special charging process at comparatively higher voltage
of 2.7V/cell (a total voltage of 65 V), also known as boost-charging, to agitate the electrolyte
thoroughly to prevent stratification of electrolyte, as well as to reduce sulpahtion of plates. As
the telecom equipment can not withstand such a high voltage, the battery under boost-charging
and the charger have to be isolated from the exchange equipment.
Maintenance of these batteries needs more efforts and is more labour oriented.
With the expansion of telecom network, large number of small exchanges came into existence.
These exchanges were mostly installed in the rented buildings of one or two rooms. It became
necessary to explore the battery technology which can be accommodated with the power plant,
if possible with the telecom equipment also.
In 1991 TEC was entrusted the job of studying the various technologies and also prepare the
GR of the battery technology after approval.
In 1992 first edition of the GR (No. GR/BAT-01/01 AUG 1992) for VRLA batteries based on
AGM (Absorbent Glass Mat) technology was issued. The department started procuring the
batteries instantly on experimental basis and later on in bulk.
It is understood that the department for the last so many years has not procured any Power
Plants compatible with conventional flooded type batteries, it appears that department, long
back, has decided to go for Power Plants compatible with VRLA Batteries only. Moreover,
presently except for a few conventional (SCR/Thyristor Controlled) Power Plants, all the Power
Plants in the field are SMPS Power Plants compatible with VRLA Batteries only.
TEC studied the VRLA battery technology in detail and issued a Monitoring and planning
guidelines for VRLA batteries in 2003. The same was circulated to all the telecom circles.

Malfunctioning of some of the VRLA batteries were reported from the field units. On analysis by
TEC it was found that in most of the cases, the failures were due to shortcomings in the
manufacturing designs of a manufacturer.
At the time of revision of the GR issued in 2004, manufacturing design parameters were also
included in the GR. Since then, procurements of batteries have been as per the new GR and no
field complaints has been received by TEC.
TEC has also issued a GR for Tubular VRLA batteries based on GEL technology (No. GR/BAT03/01 MAR 2006) in March 2006, which has been introduced, in BSNL /MTNL on experimental
basis. This technology has been chosen because it can work with the existing SMPS Power
Plant in the field, irrespective of the version of the existing Power Plant. It is also claimed that it
has all the advantages of AGM VRLA technology, along with the following additional
advantages :
a. Better thermal management, because of more electrolyte.
b. Better performance at high temperature as the life loss for every 10 C is 30% against
50% for AGM batteries.
c. Cyclic life is 20% to 30% higher than AGM batteries (1400 cycles in AGM and 2100
cycles in Tubular GEL).
d. Self discharge is lower than AGM batteries and can be stored up to one year against six
months as in AGM.
e. Same charging techniques as for AGM but slightly low float and charge voltage.
f. Slow rate of discharge performance is excellent, suits rural application.
Decision to make bulk procurement shall be taken after successful completion of field trials and
subsequent evaluations.
Comparative analysis of VRLA (AGM and GEL) technology with respect to flooded type
batteries (Tubular/Flat-pasted) :
a. VRLA batteries have a pressure regulated valve which does not allow the gasses to
escape unless the set pressure is exceeded. As the charging voltage is kept at lower
level, there is negligible gassing. Moreover, recombination of hydrogen and oxygen is
achieved by, which further results in reduction in loss of water. As the amount of
released gasses is negligible, release of acid fumes is also reduced. Hence these
batteries can also be installed in the equipment room. Whereas, in flooded batteries
(tubular/flat-pasted batteries) a large amount of sulphuric acid fumes are released, due
to which a separate battery room with exhaust fans is essential.
b. Use of VRLA batteries results in :
Saving in space as the battery, power plant and equipment can be installed in the
same room.
Saving in bus-bar/cable material.
Low voltage drop resulting in better utilisation of battery capacity and increase in
efficiency of equipment.
c. Charge efficiency of VRLA batteries is excellent, i.e., 6 to 8 hours for 90% recovery, as
against 12 to 14 hours for flooded batteries. Recouping of capacity is quicker as shorter

time is sufficient as compared to flooded batteries, suiting the rural power supply
conditions particular.
d. VRLA batteries have high charge density, resulting in smaller battery size. Moreover, the
battery can be discharged to lower end-cell voltage, viz., 1.75V/cell against 1.85V/cell for
flooded batteries.
e. VRLA batteries can be stacked horizontally and the cell can be stacked one above the
other, which reduces the battery space requirement by 30-60%.
f.

VRLA battery performance is better under partial state of charge condition as these
batteries are less prone to sulphation. They suite the telecom requirements, where
partial state of charge of batteries is quite common.

g. VRLA batteries have high cyclic life - 1400 cycles for AGM and 2100 cycles for GEL- at
an average temperature of 35C, as compared to 2000 cycles at 27C for flooded
batteries.
h. Longer storage in charged condition for VRLA batteries, up to six months for AGM and
one year for Tubular GEL at 35C, is possible without permanent loss of capacity,
against 28 days at 27C for flooded batteries.
i.

VRLA batteries can be transported in the charged condition as there is no danger of the
spillage of the electrolyte, and hence, initial charging at site is not required. Flooded
batteries can not be transported in charged condition, hence assembly and charging at
site is essential. Moreover, it will be more difficult for the flooded batteries to meet the
pollution norms, issued by Ministry of Environment and Forest.

j.

Capacity of VRLA batteries can be recovered even after a storage period of six
months/one year within three to four charge discharge cycles, while in flooded batteries
it very difficult even after one month, due to sulphation of the plates while in idle
condition.

k. Stratification is unavoidable in flooded batteries because of the settling down of the acid
in the lower portion of the cell which causes sulphation in both lower and upper parts of
the plates. To avoid stratification, periodic boost-charging of these batteries at 2.7V/cell
is absolutely essential, for agitating the electrolyte. In VRLA batteries stratification is
ruled out as electrolyte is captive either in AGM or in Gel.
l.

In VRLA batteries, internal short-circuiting does not occur, while it is quite common in
flooded batteries due to sedimentation of shed active material of the positive plate.

Tabular comparison of Batteries based on different technologies (VRLA AGM, Tubular

VRLA GEL and Flooded)
S.No.
Feature
1.
Gassing/
fuming

VRLA (AGM)
No gassing/fuming,
can be installed
anywhere

Tubular GEL VRLA

No gassing/fuming,
can be installed
anywhere.

Topping up of
electrolyte
Charging
current level
Space
requirement
Stacking

No topping-up required
normally
High

No topping-up
required normally
Lower

Small cell size, Low

space requirement.
Horizontal or vertical

6.

Transportation
in charged
condition

Easy

Small cell size, Low

space requirement.
Up to 1500 AH :
Horizontal or vertical
>1500 AH: Vertically,
in tiers
Easy

7.

Self-discharge
during storage,
at an average
temperature of
35C.
Cyclic Life
(to 80% DoD).

50% self-discharge in
6 months. Recovery
easy.

50% self-discharge in
one year. Recovery
easy.

2.
3.
4.
5.

8.

9.
10.

11.

12.

13.
14.

15.

16.

1400 cycles at an
average temperature
of 35C in normal
environmental
condition
Float life at 35C. Good
High
Average, but
temperature
temperature
performance
compensation
provision made in the
Power Plants
Low
Good
temperature
performance
Stratification
Negligible, no boost
charging required.

Better than 2100

cycles at an average
temperature of 35C in
normal environmental
condition
Good
Good

End cell
1.75V/cell
voltage
Capacity at
Good
very low rate of
discharge
Deep discharge Average, after 4 to 5
recovery
charge/discharge
cycles
Charge
Excellent, 6 to 8 hours
efficiency
for 90% recovery.

Tubular Flooded
High gassing/fuming,
separate battery room
with exhaust system is
essential.
Topping up required
frequently
Lowest
Large cell size, Large
space required.
Vertical stacking only.
Tier stacking not
practical for large size.
Not possible.
Transportation in
uncharged (unfilled)
condition recommended.
Self-discharge is very
high. Long duration
storage not
recommended.
Recovery difficult.
Theoretically maximum
2000 cycles at 27C.

Not known
Good

Good

Poor

Negligible, no boost
charging required.
1.75V/cell

Prominent, requires
frequent boost charging
for prevention.
1.85V/cell

Good

Average

Average, after 4 to 5
charge/discharge
cycles
Slightly poor, 8 to 10
hours for 90% recovery

Poor, hard sulphation

prevents recovery.
Poor, 12 to 14 hours for
90% recovery.

S. No.
Feature
17. Under-charged
performance
18. Overcharging

19.

20.

21.
22.

Performance
under partial
state of charge
Charging
Requirement
Thermal
runaway
Risk of internal
short-circuiting

VRLA (AGM)
Average

Tubular GEL VRLA

Good

Tubular Flooded
Poor

Poor, damages the

battery.
Over charge protection
provision made in
SMPS Power Plants.
Good

Good

Good

Good

Poor

Constant voltage
charging by SMPS
Power plants
Probable, yet rare

Constant voltage
charging by SMPS
Power plants
Not possible

Periodical boost
charging at 2.7V/cell
essential
Not found

Remote

Remote

High, due to active

material shedding.

Present field scenario:

Presently in both BSNL and MTNL, most of the batteries are based on AGM VRLA
technology.

Almost all the Power Plants in the field are SMPS Power Plants, compatible with VRLA
batteries.

The SMPS Power Plants in the field are as per five GRs issued from 1994 to 2005. Upgradation or modification of the earlier version SMPS Power Plants, to make a provision
for boost charging may not be feasible.

Replacement of these power plants may require a huge investment.

Conclusions
Change-over to flooded batteries (low maintenance or otherwise) may not be feasible, because
of the following reasons:

Flooded batteries cannot work with the existing SMPS Power Plants because the latter
cannot provide output of 65 V required for boost-charging.

Replacement of existing SMPS Power Plants may not be feasible as it shall involve a
huge investment. It may also not be possible and practical to modify the existing power
plants.

Sufficient man-power may not be available to maintain flooded batteries as it requires

more stringent maintenance schedule of periodic monitoring of SG, electrolyte level, and
periodic boost-charging.

 There may be problems in compliance of pollution norms because of fuming in flooded

batteries.

There may be problems in providing a separate battery room in rented buildings.

Suggestions of TEC

Power plant must be fully compatible with the battery, and all the parameters must be
set at desired levels.

It must be ensured that both float and charge voltages of the Power Plants are set at
desired levels.

Charge current to each battery must be set as per the battery capacity.

It must be ensured that temperature compensation mechanism is installed and is

functional. Voltages must be set at desired levels commensurate with the temperatures,
as mentioned in monitoring guidelines.

Maintenance and planning guidelines issued by TEC may be followed to ensure proper
functioning of the batteries and power plants.

Places where electric supply condition is erratic, the charge condition of the battery must
be monitored. If required, the batteries should be refurbished by charging it fully
periodically with the help of mobile DG set, for a group of exchanges.

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