Indian Institute of Science

Office of Laboratory Safety & Environmental Health

Email: [email protected]
Phone: +91-80-2293-3199
Emergency: +91-80-2293-5555

Guidelines for UPS & Battery Storage

Document number OLSEH/2022/GL/002(A
Version 2.0
Issued on 19th May 2022
Supersedes Version 1.0 of Battery guideline
Changes from previous version Added requirement for Li-ion batteries
Author Alen Abraham, Sushobhan Avasthi

1 Battery Overview
There are primarily three kinds of batteries used in UPSs—vented lead acid (VLA) (also
called flooded-cell),valve-regulated lead-acid (VRLA), and sealed or maintenance-free lithium-
ion batteries.VRLA batteries usually have lower up-front costs but have a shorter lifetime of
around five years.Flooded-cell batteries require more maintenance but have a longer lifetime,
up to 20 years.Lithium-ion batteries are smaller and lighter than the above types and have
changed the traditional status quo for UPS use.Costs are like VRLA, and new energy storage
applications with UPS systems, such as gridsharing and peak shaving, are now viable.These new
capabilities provide more than just backup time and can now contribute to significant cost
savings for the user in their day-to-day operations.

2 Lead-Acid Batteries
Lead-acid batteries are the most widely used electrical energy storage, primarily for
uninterrupted power supply (UPS) equipment and emergency power system (inverters). Lead-
acid batteries release hydrogen gas that is potentially explosive.The battery rooms must be
adequately ventilated to prohibit the build-up of hydrogen gas.The hydrogen generation is
relatively small during normal operation.However, significant hydrogen can be produced during
rapid and deep discharge of the battery.
2.1 Types Of Lead-Acid Batteries
2.1.1 Vented Lead-acid (VLA) Batteries
Vented Lead-acid Batteries are commonly called “flooded” or “wet cell” batteries. VLA is
an exceptionally reliable design, so failures are uncommon until halfway of their 20-year pro-
rated life. The most common failure mode is a short circuit and even that is not an emergency,
as long as the fault is localized. However, there are downsides to flooded-cell batteries. VLA
batteries require more maintenance,safety and space. VLA batteries have thick lead-based
plates that are submersed in an acid electrolyte. The electrolyte depletes over time so distilled
water must be added periodically. Also, hydrogen is produced during charging. The hydrogen is

evacuated through vents. Hydrogen is highly flammable and explosive, so these batteries must
be installed in a ventilated room. OLSEH mandates 6 air-changes per hour in the battery room.
2.1.2 Recombinant Valve-Regulated Lead-acid (VRLA)Batteries
VRLA batteries are sealed, usually within polypropylene plastic, so there is no sloshing
acid that can leak or drip when inverted or handled roughly.The term “valve-regulated” refers
to the method of gas release.If the gas pressure becomes too great inside the battery, the valve
will vent when it reaches a certain pressure.
Recombinant cells have a starved or gelled electrolyte.The oxygen generated from the
positive electrode during charging diffuses to the negative electrode producing water:
Pb + H2SO4 + ½O2 → PbSO4 + H2O
The recombinationreaction suppresses hydrogen evolution at the negative electrode,
thereby allowing the cell to be sealed.In practice, the recombination efficiency is not 100% and
a pressure relief valve regulates the internal pressure at a relatively low value, generally below
10 psig.
2.2 Comparison between flooded and sealed batteries
The diagram below shows a comparison between vented battery gassing and VRLA
battery recombination.

Guideline for UPS and Battery Storage 2 of 11

 Both the vented and the VRLA batteries work on the principle of chemical reactions
between positive and negative plates. But there are some key differentiating characteristics:
a. In flooded cell batteries the electrolyte is in liquid form, while in VRLA batteries it is
immobilized in a gel or absorbent glass mats.
b. The flooded cell batteries release hydrogen continuously during charging while the VRLA
batteries release hydrogen only when overheated and/or overcharged. The flooded cell
batteries emit approximately 60 times more hydrogen than comparably rated VRLA
batteries.
c. The flooded cell batteries require dedicated ventilation system to maintain hydrogen
concentration below the lower explosive limit. VRLA batteries have lesser risk, and these
can be housed without mechanical ventilation. Supplier guidance must be applied.
d. The flooded cell batteries should be installed in dedicated rooms physically separated
from other areas. Room construction shall be designed to meet the required fire
resistance rating for the application. VRLA batteries have less risk and can be used in the
same room as the equipment they support.
e. VRLA batteries are prone to failure condition known as “thermal runaway.” It is a
condition when the heat generation rate inside the battery is faster than the heat
dissipation. To prevent the failure and the battery dry out, the safety valves open and
the battery vents hydrogen until temperature and/or voltage are reduced. This
condition can be triggered by charger over-voltage. Flooded cell batteries are immune
to thermal runaway condition.
f. Flooded lead-acid batteries can be charged at high voltage settings which improve
performance. VRLA batteries are usually set to a lower voltage limit, which shelters the
battery but produces poor performance. Check with your battery vendor for guidance.
g. VRLA batteries usually have lower up-front costs but have a shorter lifetime than wet
cell, usually around five years. Flooded cell batteries require more advanced
maintenance but have a longer lifetime, up to 20 years

3 Lithium-Ion Batteries
Lithium batteries have significant benefits over lead-acid batteries for UPS, for
example,smallsize, light weight, high cycle-count (charge-discharge cycles), faster recharge
times, and built-in battery management (not just monitoring). The technology is
underactivedevelopment due to the demand fromheavy-duty sectors like e-mobility.

Guideline for UPS and Battery Storage 3 of 11

 Li batteries have a battery management system in each battery, as well as in a system-level
master controller.It manages charge current, voltage, and cell voltage balance, while adjusting
as necessary to eliminate any chance of overtemperature.If temperatures rise above safe
levels, the management system will independently disconnect the battery or string via multiple
different disconnection means, and notify the user via the battery cabinet monitor, and an
alarm on the UPS.

4 Battery Hazards

4.1 Thermal Runaway

Batteries are designed to operate in a relatively narrow temperature range. Thermal
runaway occurs when the heat generated in a battery exceeds its ability to dissipate it. Thermal
runway can occur without warning, with the battery cell temperature rises incredibly fast
(milliseconds). The energy stored in that battery is released suddenly. The chain reaction
creates extremely high temperatures (around 752 degrees Fahrenheit / 400 degrees Celsius),
causing a fire that is nearly impossible to extinguish. Thermal runaway in lithium-ion batteries
has receiveda lot of attention due to fires in cell phone and hoverboard batteries.However,
thermal runway can happen in all battery types.In extreme cases, thermal runaway can cause
batteries to explode and start fires.In minor cases, it can cause batteries to melt or be damaged
beyond repair.
Several conditions can cause thermal runaway in a battery. Thermal runaway can occur
due to an internal short circuit caused by physical damage to the battery or poor battery
maintenance. The same type of scenario could cause an external short circuit which could also
kick off the chain reaction. Overcharging a battery beyond its safe max voltage (to extend the
distance an electric car will run, for example) can permanently damage the battery and lead to
thermal runaway. Rapid charging can also lead to thermal runaway because rapid charging can
lead to excessive currents. Finally, temperatures outside of the safe region on either the low or
high side degrades a battery’s performance. This leads to irreversible damage to the battery
and possible triggering of the reaction. While the danger of excessive heat may be obvious, the
danger of excessive cold may be confusing. The functioning of lithium-ion batteries depends on
chemical reactions. Excessive cold can slow or stop those chemical reactions from occurring.

Guideline for UPS and Battery Storage 4 of 11

4.2 Overcharging and Undercharging
Modern batteries have an efficiency of > 90%. To fully charge a battery one only requires
107% to 115% of the rated energy.For example, 10.7 ampere-hours is sufficient to fully charge a
10-ampere-hour battery.Pushing more than 107% energy or charging at too high a rate,
constitutes overcharging. Overcharging is a common cause of premature battery failure.
Undercharging of the battery occurs when a battery is not fully recharged during the
recharge cycle. The residual lead sulphate (PbSO4) remains on the positive and negative plates
and eventually ‘hardens’.With successive cycles of undercharging, the layer of residual lead
sulphate becomes thicker, the electrolyte specific gravity decreases, and the battery cycles
down in capacity.In the ‘hardened’ condition, it may not be possible to convert the residual
lead sulphate back into the original lead dioxide, sponge lead and sulphur acid active materials,
even with higher voltage charging efforts.In this case, the battery will suffer a permanent loss in
capacity.

4.3 Electrical hazards

a. Electric shock may occur when one makes direct contact with the exposed battery
terminals stayed at different potential or with the exposed conductor ofcables or
conductive parts connected with the battery, resulting in the passing of electric current
through the body of the victim.
b. Short-circuit of the battery terminals or other electrical conductors stayed at different
potential would cause a high current flow.The sudden release of energy stored in the
battery in a short time and under an uncontrolled manner may cause a flashover and
explosion, thus resulting in the rupture of battery housing, spillage of electrolyte,
melting down of battery terminals or other metal parts, and subsequent splashing of
molten metal, etc.

Guideline for UPS and Battery Storage 5 of 11

4.4 Fire and explosion hazards
a. When the charging operation is close to completion, explosive gas may be generated
from the battery due to the action of electrolysis of water contained in the electrolyte
solution.
b. The gases produced are hydrogen and oxygen.The former is much lighter than the air
and would accumulate in the air space above the electrolyte solution inside the
battery.These gases may also leak through the battery vents and disperse to the
surrounding of the battery room or workplace.
c. Hydrogen gas when mixed with oxygen or air can be explosive.Any spark or naked flame
present may cause a fierce explosion of the explosive mixture.Sparks may be generated
by electrostatic discharge, abrasion of some metals, normal switching, or abnormal
tripping of electrical equipment, etc.A smoldering burn may turn into a blaze in the
presence of enriched oxygen.Any combustibles in the vicinity, which are not ignited in
the air normally, may ignite by itself in the presence of enriched oxygen.
4.5 Chemical hazards
a. Electrolyte (Sulfuric acid) is combustible. Contact with organic materials may cause fire
and explosion. It also reacts violently with strong reducing agents, metals, sulphur
trioxide gas, strong oxidizers, and water. Contact with metals may produce toxic sulphur
dioxide fumes and may release flammable hydrogen gas. Workers may suffer from skin
burn or eye injury caused by spillage or splashing of electrolyte. It is important to take
precautionary measures likePPE, ventilation,housekeeping, and personal hygiene.
b. For lead compounds, avoid contact with strong acids, bases, halides, halogenates,
potassium nitrate, permanganate, peroxides, nascent hydrogen and reducing agents.
c. For lithium-ion batteries, consult the vendor’s Material Safety Data Sheet (MSDS) for list
of hazards.

5 Battery Safety
5.1 Prevent thermal runaway
a. Proper Storage Temperature: Always store batteries at safe temperatures.The ideal
storage temperature for most lithium-ion batteries is between 40-70 degrees
Fahrenheit (5-20 degrees Celsius).However, this can differ based on the battery and
manufacturer, so consult the label for your specific battery.
b. Proper Ventilation: One of the easiest ways to maintain a safe operating temperature is
properly ventilation.All the electronics needed to manage your battery system, plus the
batteries themselves, produce heat.The heat generated by the batteries and electronics
must be dissipated.
c. Replace Old Batteries:Old battery must be replacedbefore end-of-life.If you have an old
battery that has been uncharged or undercharged, it may have built up gasses within
the casing, which can easily cause an explosion.If you see a deformed or “bubbled”
battery, do not attempt to charge it.Properly dispose of and replace any deformed
batteries.

Guideline for UPS and Battery Storage 6 of 11

 d. Don’t Overcharge:Overcharging a battery can cause an electrochemical reaction that
may result in thermal runaway.Monitoring the charge status of your battery is essential
for this reason.
e. Battery Management System(BMS):Battery management systems (BMS) monitor and
manage cell voltage, cell current, cell temperature, cell charge balancing, charge control,
and internal short circuit detection.Essentially, the BMS is an electronic system that
manages either a single cell or an entire battery pack.It monitors the state of the battery
and reports the data.It also protects the battery (or cell) by controlling or balancing the
environment of the battery (or cell).
5.2 Manage spills or leaks for lead acid batteries
Stop the flow of materials and contain/absorb small spills with dry sand, earth, or
vermiculite. Don’t use combustible materials. If possible, carefully neutralize spilled electrolyte
with soda ash, sodium bicarbonate or lime. Wear acid-resistant clothing, boots and gloves, and
a face shield. Do not allow discharge of un-neutralized acid to get to the sewer.
5.3 Read MSDS
The materials in batteries make them volatile and therefore potentially hazardous.
Performing regular periodic maintenance on your batteries can go a long way in preventing
unsafe situations before they occur. Aways refer to the material safety data sheet for specific
precautionary measures. Sample MSDS of the three types of batteries are available in the links
below:
Type of battery MSDS
1 Lithium Ion Battery 1935761.pdf
2 VLA Battery VLA Batteries.pdf
3 VRLA Battery MSDS-VRLA-Non-Hazardous.pdf

5.4 Proper storage

The batteries need to be stored as per the following rules.
a. Always store the battery in cool and covered areas.Do not keep the battery in direct
sunlight, dust, or moist place.
b. Keep the battery away from sparks, heat source or fire.Do not store batteries near other
hazards like cylinders and chemicals. There must be a separation like a physical barrier
or 20 ft of space.
c. Do not let dust accumulate on the battery. Clean the dust with a dry cloth, not wet.
d. Provide proper isolation between battery and battery rack.Do not allow any metal
object to rest on the battery - this may cause short circuit.
e. Do not add acid or distilled water in VLRA or lithium ionbattery
f. Do not mix batteries with different capacities, different make, different types (VRLA,
Flooded/ Tubular batteries) and different manufactures' batteries in the same circuit.
g. Never install any type of battery in a completely sealed enclosure or room. Sufficient
ventilation must be provided.

Guideline for UPS and Battery Storage 7 of 11

 Table 1: Summary of storage requirement for batteries.

Vented Lead-acid Valve Regulated Lead- Lithium-Ion Batteries

(VLA) acid (VRLA)

Storage area Separate storage area Separate storage area Separate storage
(cabin) required not required area not required
Ventilation Forced ventilation for Room/lab should be Room/lab should be
the separate cabin is adequately ventilated adequately
required ventilated
Ideal temperature 25 C 25 C 25 C
Flammable Gas 20 Ft clearance 20 Ft clearance 20 Ft clearance
cylinders/pipelines distance required distance required distance required
Housekeeping Dust accumulation Dust accumulation Dust accumulation
should be prevented should be prevented should be prevented
PPE required for Electrical safety shoes Electrical safety shoes Electrical safety
accessing the & acid resistant gloves are required shoes are required
storage area are required
Sign boards Entry restricted; Electrical hazard Electrical hazard
required Electrical hazard

Guideline for UPS and Battery Storage 8 of 11

6 Some Common Issues Related to Storage of Batteries & UPS in IISc

 Storage of batteries in poor ventilated

area
 Matal toolbox stored near to batteries.
 Batteries should not be kept beneath
any table, closed cabinets, etc .

 Storage of wet lead acid batteries in

poor ventilated area
 Poor housekeeping near battery
storage area.
 Wet lead acid batteries should be
stored in separate cabin with forced
ventilation

 Storage of VRLA batteries in poor

ventilated area
 Poor housekeeping near battery
storage area.
 Wet lead acid batteries should be
stored in separate cabin with forced
ventilation

 Dust accumulation
 Poor housekeeping near battery
storage area.
 Wash basin near the battery storage
area

 Storage of VRLA batteries in poor

ventilated area
 Storage of compressed gas cylinder
near battery

 Storage of other equipment ups and

battery storage area
 Poor housekeeping near battery
storage area.

Guideline for UPS and Battery Storage 9 of 11

7 References
[1] Battery Room Ventilation and Safety, Continuing Education and Development, Inc.

[2] Bro, P. and Levy, S., 2006. Battery Hazards and Accident Prevention. New York, NY: Springer.
[3] Exide's Do's and Don'ts for Sealed Maintenance Free Batteries, 2022
[4] The large UPS battery handbook, EATON
[5] Technical Bulletin, 41-2128, Charging Valve Regulated Lead Acid Batteries, C&D Technologies

8 Appendix
8.1 Typical Layouts of a Battery & UPS Room
Below if sample layout of the battery room in a lab. The layout is exemplary. It does not include
dimensions because details will be different for each lab.
8.1.1 For Vented Lead-acid Batteries

Guideline for UPS and Battery Storage 10 of 11

8.1.2 For Recombinant Valve Regulated Lead-acid-VRLA (Dry type) or Lithium-ion batteries

Guideline for UPS and Battery Storage 11 of 11