Battery Safety and Handling EFCOG Electrical Safety Task Group Module 9

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Battery Safety and HandlingEFCOG Electrical
Safety Task GroupModule 9
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Lead Acid Batteries

• Typically Lead-Antimony.
• Made up of lead plates, lead oxide with 35
  sulfuric acid and 65 water solution.
• The solution is called electrolyte, which causes
  a chemical reaction that produces electrons.

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Cell Element
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Hazards Associated With Industrial Batteries

• Hydrogen Gas explosion
• Sulfuric Acid
• Shock
• Weight of the Battery

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Hydrogen Gas

• A by-product of the batterys charging process.
• Lighter than air.
• Flammable in nature.
• Explosive mixture at 4 74 by volume of air.
• Can not taste or see the gas vapors.

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Acid Hazards

• pH lt2 (Typically Sulfuric Acid)
• Corrosive
• Burns to skin
• Burns to eyes
• Never open the battery caps directly over the
  battery without proper PPE (faceshield, safety
  glasses, etc).

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Electrical Hazard

• Exposed terminals, even on disconnected
  batteries, present an electrical hazard.
• Some battery systems are capable of discharging
  at extremely high rates of current. Accidental
  shorting of terminals or cables can result in
  severe electrical arcing, causing burns and
  electric shock to nearby personnel.
• Shrapnel from explosion

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Electrical Safety Precautions

• Never touch both battery terminals with your bare
  hands at the same time!
• Remove rings, watches and dangling jewelry when
  working with or near batteries. The metal in the
  jewelry can cause a shock or burn if they contact
  the battery terminals.
• Only use insulated/non-conducting tools to remove
  cell caps. Never lay tools or other metal parts
  on top of a battery.

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Electrical Safety Precautions

• Consider protecting battery terminals and
  connectors with an insulating blanket prior to
  working above batteries
• Ensure charger is turned off before connecting or
  disconnecting a battery to prevent arcing

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Electrical Hazard

• Worker lost control of a jumper wire while
  working above battery bank
• Ends of jumper were not insulated and blanket was
  not installed over battery terminals
• Event resulted in severe arcing and potential for
  injury to worker

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Fire and Explosion Precautions

• Do not smoke in battery charging areas.
• Prevent open flames, sparks or electric arcs in
  battery charging areas.
• Do not strike a battery with any spark producing
  item.
• Keep tools and other metallic objects away from
  uncovered batteries.
• Have an ABC dry chemical fire extinguisher in
  charging areas or readily available.

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Fire and Explosion Precautions

• Neutralize static buildup just before working on
  battery by contacting nearest grounded surface
• Ensure battery area ventilation is operating
• Only charge in well ventilated area

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Battery Explosions

• This starting battery exploded during a load test
  for a diesel generator
• Explosion can expel debris and battery acid
  resulting in burns and injury to nearby personnel

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Handling Battery Acid

• Use extreme caution when handling electrolyte and
  keep an acid neutralizing solutionsuch as baking
  soda readily available
• Always wear apron and proper eye, face and hand
  protection.
• Use non-metallic containers to handle liquid
• If the electrolyte is splashed into an eye,
  immediately force the eye open and flood it with
  clean, cool water for at least 15 minutes. Get
  medical attention.

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Handling Battery Acid

• If electrolyte is taken internally, drink large
  quantities of water or milk. DO NOT induce
  vomiting. Call a physician immediately.
• Neutralize with baking soda any electrolyte that
  spills on a vehicle work area. After
  neutralizing, rinse contaminated area with
  water.
• To prepare electrolyte of a desired specific
  gravity, always pour the concentrated acid slowly
  into the water DO NOT pour water into the acid.
  Always stir the water while adding small amounts
  of acid. If noticeable heat develops, allow the
  solution to cool before adding acid.

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Changing Batteries

• Industrial batteries used to power mobile
  equipment can weigh upwards of 1,500 lbs.
• Ensure the battery is securely locked in place
  prior to pulling away from the battery changing
  area.
• Do not attempt to stop a battery if it slides out
  of equipment.

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Changing Batteries

• Work on Batteries requires Non-Sparking and
  Insulated tools.
• Insulation must be listed for the voltage present
• Taped wrenches are not listed
• Batteries should never be lifted by the post.

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Safe Handling of Batteries

• Use appropriate equipment to load/unload
  batteries from mobile equipment.
• Ensure you are trained and qualified in using the
  loading equipment.
• Keep tools and other metallic objects away from
  batteries.
• Use Baking Soda or cleaning agent specified in
  AHA to neutralize spilled acid.

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Jumping a Discharged Vehicle Battery

• When jump starting a vehicle, always wear proper
  eye protection and never lean over battery.
• Inspect both batteries before connecting booster
  cables.
• Be sure vent caps are tight and level.
• Make certain that the vehicles are not touching
  and both ignition switches are turned to the OFF
  position.
• Refer to the vehicle owners' manual for other
  specific information.

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Jumping a Battery
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Battery Jumping Sequence

• Connect positive () booster cable to positive
  () terminal of discharged battery.
• Connect other end of positive () cable to
  positive () terminal of assisting battery.
• Connect negative (-) cable to negative (-)
  terminal of assisting battery.
• MAKE FINAL CONNECTION OF NEGATIVE (-) CABLE TO
  ENGINE BLOCK OF STALLED VEHICLE, AWAY FROM
  BATTERY.
• Start vehicle and remove cables in REVERSE order
  of connections.

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PROTECTIVE CLOTHING General Requirements for
Handling

• For general handling of batteries with terminal
  post taped
• PPE Requirements
• As specified in local AHA or procedure

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PROTECTIVE CLOTHING Requirements for Electrolyte
Handling

• PPE Requirements
• Safety Glasses/goggles
• Rubber Gloves
• Face Shield
• Chemical Apron
• Boots

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Safety Eye Wash Shower Requirements

• An eyewash facility should be capable of flushing
  both eyes simultaneously for fifteen minutes and
  a water hose or safety shower that, if portable,
  is capable of drenching the body.
• Eyewash and drenching facilities are to be
  located as close to the point of exposure as
  possible of battery handling areas (not to exceed
  25 ft.) (OSHA)
• If Acid comes in contact with eyes, flush for 15
  minutes and report to medical immediately.
• If acid comes in contact with skin or clothing,
  rinse off for several minutes and try not to
  spread the electrolyte. Report to medical after
  rinsing.

Note Eyewash and drenching facilities are not
required for non-vented batteries.
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Battery Safety

• Know the Hazards
• Use the required PPE
• No Open Flame