09/06/07 EFCOG Electrical Safety Task

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1
Battery Safety and Handling

EFCOG Electrical Safety Task Group

Module 9
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Lead Acid Batteries
Typically Lead-
Antimony.
Made up of plates, lead,
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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Posit ive
Pl at e Group
Negati ve
Pl at e Group
Separator
Cell Element
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Hazards Associated With
Industrial Batteries
Hydrogen Gas

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. You can smell
the acid in the battery if it heats up.
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Acid Hazards
Ph <2 (Typically Sulfuric Acid)
Corrosive material
Burns to skin
Burns to eyes
Never open the battery caps with your face
directly over the battery.
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Electrical Hazard
Exposed terminals, even on disconnected batteries,
present an electrical shock 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
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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 covering battery terminals and connectors if
possible with an insulating blanket before overhead
inspections or repairs

Ensure charger is turned off before connecting or
disconnecting a battery to prevent arcing
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Electrical Hazard
DOE Event-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 the sides of the 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 prior to working on
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Battery Explosions
DOE Event-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 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 prompt
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 or in the
work area. After neutralizing, rinse contaminated area clean 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 continuing to add acid.
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Changing Batteries
Industrial batteries used to power mobile equipment can
weight 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 the
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 in using the loading equipment.

Keep tools and other metallic objects away from uncovered
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. Do not
jump start a damaged battery.

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