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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Cell Element

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Hazards Associated With Industrial Batteries

• Hydrogen Gas

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• Sulfuric Acid

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• Shock

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• Weight of the Battery

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Hydrogen Gas

• A by-product of the battery’s charging process.

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• Lighter than air.

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• Flammable in nature.

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• Explosive mixture at 4 – 74% by volume of air.

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• 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!

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• 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.

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• 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

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• 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.

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• Prevent open flames, sparks or electric arcs in battery charging areas.

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• Do not strike the sides of the battery with any spark producing item.

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• Keep tools and other metallic objects away from uncovered batteries.

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• 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

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• 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 solution—such as baking soda readily available�
• Always wear proper eye, face and hand protection.�
• Use non-metallic containers to handle liquid

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• 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.

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• Ensure the battery is securely locked in place prior to pulling away from the battery changing area.

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• 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

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• 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.

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• Ensure you are trained in using the loading equipment.

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• Keep tools and other metallic objects away from uncovered batteries.

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• 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

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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

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• 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)

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• 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.

Battery Safety

Know the Hazards

Use the required PPE

No Open Flame

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