5.

Hybrid Power Systems Deliver Efficient Energy

Management for Off-Grid BTS Sites
1

Massimo Ombra , Francesco Di Noto , Johann Jaffrain , Stuart Lansburg and Jol Brunarie
1

Ausonia S.r.l. Italy

SAFT Industrial Battery Group, France
E-mail: francesco.dinoto@ausonia.net or joel.brunarie@saftbatteries.com
2

Abstract The continuous increase in fuel costs for

generators is driving organizations that use power in off-grid
locations to search for more cost-effective ways of powering
their sites. This is especially the case within the telecoms
sector where grid supply is unreliable. Therefore, choosing a
reliable method (including equipment) to generate electricity
to run sites is vital to successfully operate equipment.
In the case of telecoms operators this means ensuring
the Base Transceiver Station
(BTS) has power and
functions. However, choosing the right technology to achieve
this can have a major impact on the sites operating costs.
Furthermore, the wrong choice of technology can not only
be expensive to run, but also have a negative impact on a
sites environmental footprint which is not ideal when you
consider the wireless industry is striving to play a
positive role in dealing with climate change by reducing its
CO emissions.
One solution to this problem is for organizations to use a
hybrid system that integrates a variable speed diesel DC
generator (genset) with a deep cycling Li-ion battery. This can
offer an extremely energy efficient alternative to using an
AC generator operating 24/7. The generator simultaneously
charges the battery and powers the site load. When the
battery has been fully charged the generator shuts down
and the battery takes over as the primary source of power.
By reducing the genset runtime down to typically 4 hours
per day, this approach offers major savings in fuel
consumption usually up to 74 percent savings compared with
a standard genset. It also reduces CO2 emissions while
increasing refuelling and service intervals.
A complete hybrid system of this type can be packaged in
a compact and light energy container to offer a turnkey
solution that is quick and easy to install in remote locations.
Moreover,
achieving
both
optimum
system
efficiency ratings and Total Cost of Ownership (TCO)
reductions comes down to a careful selection of the right
equipment making up the hybrid system. This includes
selecting the right sub- systems comprising the best DC
diesel generator, controller and battery for the task at
hand. Typical factors that need to be considered include:
The
high-density cycling
battery must
be
temperature- resistant, maintenance free, highly
energy efficient, charge quickly and deliver a large
number of deep discharge cycles
The DC generator must be based on Permanent
Magnetic Generation (PMG) technology so that the

978-1-4673-1000-0/12/$31.00 2012 IEEE

system can keep its weight and size to a minimum. This

helps achieve an overall compact design that achieves
optimum global efficiency and system reliability
The controller must be equipped with its own dedicated
software that enables the operating profile of the
battery and generator to be optimized, thus delivering the
lowest possible operating cost.

The addition of PV (photovoltaic) panels or possibly wind

turbines will allow further significant reductions in operating
costs (OPEX) while also increasing environmental benefits.
This paper discusses technical aspects of hybrid systems such
as application needs; complete system design and optimization
including DC generator, advanced battery, and controller
choices. It will also review and analyse the results of various filed
tests implemented to validate this concept. It concludes with a
Total Cost of Ownership (TCO) analysis of a proposed hybrid
system compared with existing systems based on continuously
operating diesel generators.
Keywords Hybrid system, Battery, deep cycling and long duration
life, off-grid telecom sites.

I.

INTRODUCTION

Over the last decade the telecoms sector has witnessed

fantastic developments. One particular part of this sector that
has excelled is wireless communications. Today the wireless
industry represents a market of more than 5 billion subscribers
across the world.
Evidence of the explosion of wireless and how operators are
rolling it out can be witnessed in how telecom operators have
approached the management of their networks. For instance,
they have extended their reach in more remote areas to offer
mobile access to rural populations.
Furthermore, the widespread installation of mobile
telecommunication networks has always resulted in the need
for specific infrastructures that are capable of adhering to strict
industry quality standards; that can be rapidly installed; are
cost effective, and which limit negative affects on the

5.2

environment by reducing the construction of civil works and

foundation.

time when the wireless industry is striving to reduce its CO

emissions.

Typically in urban environments, BTSs are placed on the roofs

of buildings, while in semi-urban and rural areas they are
mostly located on hills and open areas, clear of vegetation.
However, there is another common trend we are seeing, with
the placements of BTSs, is known as co-sitting this type
of scenario usually occurs when different Mobile Operators
share the same site, which is typically owned by a Tower
Operator.

So, the goal of this paper is to introduce you to an efficient

hybrid solution called Hybrid Integrated Module (HIM),
which is based on innovative technologies that are more cost
effective in comparison with traditional conventional power
supply systems and which are able to limit the impact power
generation has on the environment by helping reduce CO2
emissions produced.

Besides the physical location of telecoms equipment, grid

connectivity in rural areas cannot be guaranteed. Whats more,
even when there is a connection, there is no certainty this is
reliable. Therefore, this means radio base stations that cannot
connect to the electrical distribution network will generally be
powered by diesel generators making the telecom industry
one of the worlds major users of diesel generators. For
example, the mobile networks of telecom operators consist of
thousands of antennas in many countries, in both urban and
rural conditions, resulting in strong demands for sites powered
by diesel generators.
In addition, according to estimates by the GSM Association,
about 640,000 new BTSs are due for installation during 2012,
located across "off-grid" sites. Of these, about 118,000 are
expected to be powered by renewable energy. At this stage,
making the assumption that 500,000 diesel generators will be
installed over this period is a bit too simplistic, but what is
clear is that the increase in fuel costs and environmental
constraints CO emissions, noise and other environmental
impacts will certainly influence the specifications of the
outdoor plants.

A HIM can largely satisfy a large range of client demands by

configuring the system correctly alongside a limited number
of standard modular systems. Due to its specific design, and
also thanks to the use of variable speed generators, this system
can achieve outstanding performance levels in terms of
logistics, operational activities and cost drivers.
II.

DESCRIPTION OF THE HYBRID SOLUTION

The HIM consists of a variable speed DC generator which

charges a battery bank and powers the load at the same time.
When the battery is charged, the DC generator is designed to
shut down and the power is provided to the load by the battery
bank. Due to the variable speed feature of the DC generator
which allows the engine speed to vary and operate the closest
to its most efficient power generation point it is possible to
get a reduction of fuel consumption as the load decreases.

Furthermore, the worlds 5 billion mobile phone mobile

subscriptions are expected to increase by 50% over the next 5
years. In parallel to this, it is also estimated that 1.6 billion
people are living in non-electrified areas and that an additional
one billion people are living in regions where the grid is
unstable. It is also worth considering that the worlds wider
population not served by the commercial grid is living today
in South Asia (614 million people about 40% of the
population).
It can also be said that, in principle, the greatest needs for
stable power supplies resides in developing areas (Africa,
India, South Asia) or across locations that comprise distinct
geographical complexities (Middle East, Russia). In these
regions it also happens to be the case that the majority of the
BTSs are powered by diesel generators and often, to ensure a
minimum level of reliability, the sites also have a second
back-up generator.
Therefore, in the case of such off-grid sites, the choice of a
reliable method of generating electricity is vital to operate the
Base Transceiver Station (BTS). But, this choice of power
generation can also significantly impact the sites operating
costs as well as the environmental footprint of the site at a

Figure 1: Overview of the Hybrid Integrated Module (HIM)

Further energy optimization can be achieved by connecting

the HIM directly to the BTS DC loads and totally relying on
HIMs battery pack. Doing this makes it possible to eliminate
the AC/DC rectifiers and relevant battery packs from the BTS
shelter. Another advantage of this configuration is that the
need for air conditioning decreases because the heating inside
the BTS shelter significantly reduces the need for air
conditioning, meaning that further power optimization and
cost savings can be achieved.

5.2

The following graphic shows the operational cycle profile and

average fuel consumptions of a Hybrid Integrated Module.

production requirements. They are also fully compatible with

the requirements of hybrid systems for off-grid BTS power
supply.

Figure 3: view of Permanent

Magnetic Generator
Figure 2: Operating cycling profile.

The battery operating time and consequently the number of

daily cycles depends on the average BTS loads. Due to the
variable speed of its generator, the HIM is able to maintain a
constant fuel consumption of about 0,4 l/kWh (for DC load
components) and about 0,44 l/kWh (for AC load components),
regardless of the load requirements of the BTS.
The HIM has been designed to supply DC power directly to
the BTS. If necessary, DC/AC inverters could also be installed
on the already available 19 modular rack, in order to cope
with AC power needs.
grid BTS power supply has led to the development of various
system configurations and prototypes, using a range of
different components and technologies. However, all tests
conducted worldwide through the simple assembly of standard
AC generator units coupled through using a commercial
AC/DC generator with a battery pack resulted in
unsuccessful trials in terms of system efficiency and
reliability. In our view, the answer to this is to make the
correct choice of, and include, the full integration of
subsystem technologies in one single design.
As a result of these experiments and tests, it has been recorded
that a deep integration between diesel generator and battery
pack technologies is mandatory if the aim is to achieve
significant performance ratings. For example, by doing this
effectively it is possible to achieve savings of up to 80%. This
includes fuel savings, life cycle and logistic optimizations.
A. Advantages of Permanent Magnetic
Generators
Within the HIM hybrid system the generator is only used
during a cycling mode to charge the battery pack. There are
several reasons and advantages to using a Permanent Magnetic
Generator (PMG) compared with a standard AC generator.
PMG technology evolved from wind turbine solutions and has
been recently adapted for use across a variety of different
industrial applications with medium / low power (6 10kW)

The system is made using a

permanent
magnetic
alternator, coupled with an
AC/DC converter, so that a
regulated DC output voltage
can
be
provided
independently of the engine
speed. This makes it possible
to automatically regulate the
engine speed so that fuel
consumption is optimized at
different output loads.

Typically, these high-quality generators are very reliable and

offer high power density capabilities in reduced weight /
volume ratios. For BTS applications this represents an
additional -- and significant -- logistical advantage from an
operational point of view compared with AC generators.
B. Advantages of Li-Ion batteries
The overall performance of a hybrid system also depends on
the right choice, dimensioning and integration, of the battery
pack. Since there are many different battery technologies
available on the market the choice of battery must be oriented
to the one which best meets the specific needs of the BTS
reliability, operational temperature, energy storage density,
energy efficiency, fast charging, smart management
capabilities, battery
life-cycle and the
cycling duration.
We
would
recommend using a
Li-Ion battery with a
HIM. Saft was the
first to pioneer and
offer
a
Li-Ion
battery
to
the
telecom
industry
almost 10 years ago.
Safts Evolion is
the new generation
Li-ion battery that
Figure 4: The Saft Evolion module.
has been specifically
designed to offer a
more compact and
cost effective battery solution to the telecom industry
compared with predecessors.
The development of this new battery system (see Fig. 4) has
been based on meeting the following usage criteria:

For use across indoor and outdoor sites

5.2

Long product lifecycle: in terms of calendar months and

cycles, even at high temperatures

Compatibility with the existing telecom power systems

Easy installation in 19 and 23 equipment racks and in

remote cabinet compartments

Safe and reliable to install and use

It needs to be a smart battery and allow

communication with the application (BTS) it has been
designed for

Compliance with industry standards including UN3480,

GR3150, NEBSL3, CEI 60950-1, ETSI300019

Maintenance free

A design that could be easily mass produced

A cost effective battery solution

Figure 5: The discharge voltage as a function of the rated capacity is shown

from 2 h to 16 h or runtime

Evolion is designed with the highest safety standards in mind.

It concentrates 3,9 kWh (48V with 77Ah at the 8h rate) in an
optimized volume. The Evolion module has a width of 216
mm, a height of 260 mm (equivalent to 6RU) and a depth of
404 mm. The energy density is 176 Wh/L and its dimensions
are suitable for most telecom equipment compartments.
In addition the module width allows efficient use of space on a
19 rack by setting 2 modules side by side on each shelf level.
It is light-weight, i.e., less than 30 kg and 133 Wh/Kg of
specific energy, helping make it easier for operators to install.
Evolion provides application runtimes of 2h and higher. The
nominal discharge voltage is 50.4V and its capacity is rated at
485 W (8h runtime). The 14 cell series delivers a capacity
with excellent utilization to a cut-off of 42.0V across all
discharge rates. Figure 5 shows the voltage versus percentage
of rated capacity for discharge rates ranging from 241 W (16h
runtime) to 1752 W (2h runtime) at 25 deg C (77 deg F).

Figure 6: The CC/CV re-charge characteristics of Evolion show where the

available current is less than the maximum allowed current.

Evolion re-charges and float charges according to a fixed

voltage level. The full State of Charge (SoC) is reached when
charging the battery at 56.0V for as long as is necessary to
charge the battery to a full 100% power capacity. During the
re-charge phase, cell balancing circuits are active. See Figure
6 for typical fastcharge characteristics.
The time required to fully charge the battery depends on
Depth of Discharge (DoD) or the equivalent SoC when
charging begins. Figure 7 shows the relationship between
available charge current, the DoD percentage and the
charge time.

the
rethe
re-

During all phases of CC/CV charge mode, the Evolion battery

re-charges close enough to a 100% columbic efficiency and
more than 97% energy efficiency. It also functions at this
high efficiency rating regardless of the various operating
temperature ranges.
Evolions product lifespan is dependent on the reliability and
aging characteristics of the systems components, which
include the electronics and the electrochemical cells. During

Figure 7: Shows the length of time (hours) it takes to reach a full SoC across
various current ratings at 20 deg C. It also takes into account the DoD.

its cycling operation and/or standby mode, aging progresses

according to factors such as the temperature, the SoC
percentage and the levels of the re-charge current.

5.2

If we compare Evolions calendar life with its cycling life

each one demonstrates excellent capabilities. Assuming 100%
SoC for both, Table 1 summarizes the calendar life capability
(without cycling) of the Evolion system when operating at
various temperatures. Figure 8, on the other hand, shows the
expected product life expectancy during the cells cycling
phases at a fixed temperature of 20 deg C (77 deg F).

For instance, all unnecessary controls were eliminated from

the standard system and new functions required by hybrid
plants have been incorporated into new designs (e.g. variable
speed control, DC voltage and current controls for the PMG,
battery pack operational parameters and alarms). This has
resulted in the creation of one single control management
system integrated into the overall Hybrid Integration Module.
Furthermore, while developing this control system, another
critical issue was taken into account: remote monitoring and
management features. So the software utilities used to control
the system were developed in conjunction with use across
GSM / GPRS technologies. This means operators have one
control system for all the different components under their
control, simplifying the management of the unit.
III.

Figure 8: The expected number of cycles, with 100% SoC, at 20 deg C and
at 0.75x (max. charge current) is shown as a function of the %DoD.
Table 1: Calendar lifetime of Evolion.
Temperature (deg C/deg F)

Calendar life (years)

20 / 77

20

30 / 86

14

40 / 104

10

Performances of the Hybrid Integrated Module

The HIM system meets client demands in several ways. By

configuring it properly alongside a limited number of standard
modular systems, various performance efficiencies can be
achieved. And, because of its variable speed generator, the
HIM can achieve many kinds of optimum performance levels
from several different perspectives including logistical, across
various operational activities and cost effectiveness.
For example, Table 2 (below) provides the main operational
parameters, at different BTS average loads (including factors
like generator running hours and battery cycles, fuel
consumption, refuelling intervals and expected life time) using
a 9kW variable speed generator and a 48V - 308Ah Li-Ion
battery pack.
Table 2: Performance of the HIM.

Therefore it is clear the Evolion system delivers a high charge

efficiency, fast re-charge capabilities and high discharge
utilisation. Combine this with its high energy density and long
product lifetime (especially in terms of its cycling capabilities)
the Evolion system is well-designed to function within hybrid
telecom applications (e.g. a BTS).
C. Control system
A dedicated control system is extremely important to help
integrate the hybrid module correctly into any system, so that
it performs optimally from both operational and economical
stand points. Typically, the market offers a wide range of
control units that are dedicated to managing standard
generators. Some of these have suitable characteristics that can
be used as a starting point to develop hybrid applications.

FUEL CONSUMPTION
AVERAGE
LOAD
[kW]

INDEPENDENCY

PER DAY
[LITERS/DAY]

PER
kWh supplied
[LITERS/kWh]

with STD tank

1500 lt [DAYS]

PMG GENERATOR

BATTERY

RUNNING
HOURS
PER DAY

LIFETIME
[YEARS]

CYCLES
PER
DAY

LIFETIME
[YEARS]

1,0

9,6

0,400

156

4,17

11,8

4,2

12,4

1,5

14,4

0,399

104

5,98

8,2

3,2

16,3

2,0

19,6

0,408

76

7,65

6,4

6,4

6,8

2,5

24,2

0,403

62

8,46

5,8

6,4

5,2

3,0

28,3

0,393

53

9,2

5,4

7,4

4,5

Note: The above data refers to average DC loads at an environmental

temperature range of 20 - 30C, using a 40% battery DOD figure.

However, unfortunately, these products also have their limits,

which can be attributed to the fact that they have been
developed to manage standard AC generators. So, to counter
these limitations and increase various efficiencies, a new
product was developed that considered all the variables that
have an impact on efficiency, such as hardware and software
requirements.
Figure 9: System life and daily fuel consumption.

5.2

Another dimensioning principle was also considered when

designing the HIM. All the operational parameters were set so
that it would be possible to synchronize the generator and
battery life time independently from the average power load
as shown in the graph in Figure 9.
A. Total Cost of Ownership Case of Study
Table 3 shows a case study that compares operational and
economical performances between a Hybrid Integrated
Module and a conventional solution made by a standard AC
diesel generator working 24 hrs a day. The study is based on a
typical 1,5 kW BTS average load and a fuel price of 1.2 per
litre.
Table 3: Comparative TCO Analysis for 1,5kW load BTS

Table 4: Savings with HIM compared to conventional Diesel TCO

Analysis

It is important to note, in particular, that the use of the Hybrid

Integrated Module allows for a 60 % Total Cost Of
Ownership, inclusive of all OPEX and CAPEX savings over
14 years of the product life cycle, with a pay-back period of
only 1 year for the investments required to swap from the
standard technology to the Hybrid Integrated Module solution.
B. Integration with renewable sources
The growing demand to reduce carbon emissions, along with
the rapid increase in diesel prices, has forced the telecoms
sector to reconsider the role it is playing in sustainable
development.
The hybrid concept and the modular design of the Hybrid
Integrated Module allows it to be directly integrated with
external sources including unreliable commercial grid and/or
renewable energies supplies (through photovoltaic modules
and micro-wind turbines) so that integrated turn-key
applications can be created.
Depending on the circumstances, the HIM can be configured
in such a way that both wind and solar power can be used
together to charge the internal battery pack a diesel
generator can also be included in this configuration.
Depending on the weather conditions, this type of
configuration automatically recharges the battery pack using
the most cost effective energy source available at the time.
Standard applications, including photovoltaic modules and/or
micro-electric turbines come pre-installed with the HIM.
Alternatively, it is also possible to easily integrate the HIM
with external renewable energy plants that may already exist.
IV.

Figure 10: Comparison of the cumulative TCO between HIM and conventional
Diesel system

The case of study is based on data achieved at a real site and

shows the huge operational and economical advantages of the
Hybrid Integrated Module (HIM) compared with conventional
solutions made by a standard AC generator working 24/7.

CONCLUSIONS

This paper demonstrates the benefits of selecting the right subsystems to generate and store power. Systems focused on
include permanent magnetic engines, li-Ion battery technology
and optimized control systems that can be used to design
hybrid systems relevant for the telecoms industry especially
within a BTS.
The benefits of the HIM, when compared to conventional pure
diesel generator systems, are evident both in terms of technical
and performance features and abilities. Furthermore, a HIM
system can save weight, space and offer a longer operating
life.

5.2

[13] Joel Brunarie, Anne-Marie Billard, Stuart Lansburg,

Telecoms operators are all engaged in programs to minimize
the energy consumption of their sites and reduce their carbon
emissions. The different tests performed with a HIM have
demonstrated that hybrid system significantly reduce the fuel
consumption by up to 0,4 l/kWh and that they reduce daily
carbon emissions by more than 60%.
Importantly, a TCO analysis performed in a field trial reveals
the payback period for hybrid systems vary from 1 2 years.
The trial also confirms it is economically viable for a telecoms
operator to swap from using existing standard technologies to
using Hybrid Integrated Module solutions.

ABBREVIATIONS
BTS : Base Transceiver Stations
BSC : Base Station Controllers
CO : Central Offices
DG : Diesel Generator
DoD : Depth of Discharge
GWP : Global Warming Potential
HIM : Hybrid Integrated Module
LA : Lead Acid
LCA : Life Cycle Assessment
MSC : Mobile Switching Center
PMG : Permanent Magnetic Generator
SOC : State of charge
SOH : State of health
TCO : Total Cost of Ownership
VRLA : Valve regulated Lead-Acid (battery)

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