Battery Safety and Handling EFCOG Electrical Safety Task Group Module 9

1. Battery Safety and HandlingEFCOG Electrical Safety Task GroupModule 9 EFCOG Electrical Safety Task Group

2. 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. EFCOG Electrical Safety Task Group

3. Cell Element EFCOG Electrical Safety Task Group

4. Hazards Associated With Industrial Batteries • Hydrogen Gas explosion • Sulfuric Acid • Shock • Weight of the Battery EFCOG Electrical Safety Task Group

5. Hydrogen Gas • A by-product of the battery’s 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. EFCOG Electrical Safety Task Group

6. AcidHazards • pH <2 (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). EFCOG Electrical Safety Task Group

7. 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 EFCOG Electrical Safety Task Group

8. 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. EFCOG Electrical Safety Task Group

9. 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 EFCOG Electrical Safety Task Group

10. 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 EFCOG Electrical Safety Task Group

11. 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. EFCOG Electrical Safety Task Group

12. 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 EFCOG Electrical Safety Task Group

13. 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 Battery Explosions EFCOG Electrical Safety Task Group

14. Handling Battery Acid • Use extreme caution when handling electrolyte and keep an acid neutralizing solution—such 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. EFCOG Electrical Safety Task Group

15. 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. EFCOG Electrical Safety Task Group

16. 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. EFCOG Electrical Safety Task Group

17. 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. EFCOG Electrical Safety Task Group

18. 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. EFCOG Electrical Safety Task Group

19. 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. EFCOG Electrical Safety Task Group

20. Jumping a Battery EFCOG Electrical Safety Task Group

21. 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. EFCOG Electrical Safety Task Group

22. PROTECTIVE CLOTHING General Requirements for Handling For general handling of batteries with terminal post taped PPE Requirements: • As specified in local AHA or procedure EFCOG Electrical Safety Task Group

23. PROTECTIVE CLOTHING Requirements for Electrolyte Handling PPE Requirements: • Safety Glasses/goggles • Rubber Gloves • Face Shield • Chemical Apron • Boots EFCOG Electrical Safety Task Group

24. 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. EFCOG Electrical Safety Task Group

25. Battery Safety Know the Hazards Use the required PPE No Open Flame EFCOG Electrical Safety Task Group