Over two decades of rail reliability in India

In 2002, Saft provided backup battery systems for India’s metro systems, and some of those very first batteries are still in operation today. Over 20 years and around 4,000 train batteries later, we have diversified our presence to include service and trackside batteries. Learn more about Saft’s journey to rail success in India.

India’s metro system is constantly expanding to meet the country’s population growth. Today, 17 cities are served by some of the busiest metro systems in the world. These connect major urban centers and facilitate seamless travel for an average of 10 million commuters daily. Among these is the Delhi Metro, India’s largest and busiest metro, with an extensive network spanning 393 kilometers.

Our journey in India’s rail sector began with the Delhi Metro RS1 cars in 2002, when we supplied SRM sintered technology nickel cadmium (Ni-Cd) batteries for onboard backup. They ensured the continuity of essential communication, control and safety functions should the main power supply be interrupted. These batteries are still in operation today despite the city’s climate, where the highest temperature ever recorded was 52.3°C. This is a challenge as heat impacts battery life.

Today, we are still working with the Delhi Metro and are preparing to start deliveries of batteries that will run on several lines to support the needs of the one million people who use the network daily. India’s overall metro system expansion also aims to reduce congestion by taking more cars off the road and creating additional links within cities.

A trusted partner in the rail industry

Today, some 2,000 of our nickel-cadmium batteries system are in service on Indian metros. In addition to the Delhi Metro, networks such as the Bangalore Metro and Chennai Metro rely on our technology. Our batteries are also present in the country’s largest cities such as Hyderabad, Mumbai, Kolkata, and others.

We also provide Ni-Cd batteries for Indian Railways’ three-phase locomotive project, a longstanding contract that was signed in 2016. To date, we have installed batteries in almost 1,500 locomotives for various OEMs, batteries that deliver reliable auxiliary power for periods from 60 to 180 minutes in demanding conditions where the external temperature can often exceed 45°C. These initiatives demonstrate our long-lasting relationships with metro and rail operators both in India and globally. Our batteries also provide backup power for critical trackside signaling and control systems for smooth operation during power outages.

The journey continues, according to Kulkarni: “Over two decades of operation on India’s metro network have established us as a trusted manufacturer for rail power backup among many operators. Some of our batteries operate in difficult and demanding conditions, for example, at subzero temperatures in the Himalayas (Leh Ladakh, Jammu and Kashmir), the hot climates of the Thar and Kutch deserts and in the hot and humid conditions of the western and eastern coasts.”

A key benefit of our batteries is that they drive down the Total Cost of Ownership (TCO) for operators, as they provide a lifetime of up to 15-20 years – which is much better than competing lead-acid batteries. Our Ni-Cd batteries also require less maintenance, reduce operational costs and downtime.

Service excellence and battery optimization

In addition to supplying battery systems, Saft unique service offering helps metro operators optimize their battery life, reduce lifetime costs, cut maintenance intervals and minimize spares inventory.

We have qualified and experienced service experts strategically located to serve all the metro networks across India. For example, the Bangalore metro has over 200 MRX series Ni-Cd batteries that we have installed since 2011 which benefit from our service support. More recently, we have introduced extended health check services that analyze customer usage patterns so that corrective actions can be taken to extend their battery life.

Localization and innovation

By establishing a manufacturing base in India, we align with the government’s ‘Make in India’ initiative, which aims to revive domestic manufacturing, boost investment, and position India as a global manufacturing hub.

Saft’s manufacturing facility in Bangalore, with support from our facility in Bordeaux, France, offers an end-to-end solution – from design engineering to production, assembly, and services. The team produces battery cells and builds them into complete battery systems to provide the necessary power and energy storage capacity to support specified loads for the required backup time of typically 1 to 3 hours.

The site employs over 230 people, who also work on batteries that will be exported for metro projects in Sydney and Montreal.

The future for rail batteries in India

Looking ahead, the prospects for metro systems across India are incredibly promising. The network is expected to expand to 20 cities in the coming years, with the length of track in each city continuing to grow. This rapid expansion not only highlights the growth of urban transportation but also supports local job creation.

Beyond metro systems, an exciting project is the supply of batteries for a semi high-speed 160 kilometer-per-hour train to connect Delhi with the commuter town of Meerut, about 80 kilometers northeast of the capital.

At Saft in India, we’re all about engineering excellence and we serve as a hub that supports all major rail OEMs in India. We also support Saft’s railway production sites around the globe.

In summary, Saft’s unwavering commitment to sustainable battery performance has played a crucial role in India’s metro rail networks, ensuring safe and reliable transportation for millions of commuters every day.