Battery Safety and Handling

EFCOG Electrical Safety Task Group

Module 9

09/06/07

EFCOG Electrical Safety

Task Group

Lead Acid Batteries

Typically LeadAntimony.
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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EFCOG Electrical Safety

Task Group

Cell Element
Sepa ra tor
N eg a ti ve
Pl at e Group

Posit ive
Pl at e Gro up

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EFCOG Electrical Safety

Task Group

Hazards Associated With

Industrial Batteries
Hydrogen Gas
Sulfuric Acid
Shock
Weight of the Battery

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EFCOG Electrical Safety

Task Group

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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EFCOG Electrical Safety

Task Group

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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EFCOG Electrical Safety

Task Group

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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EFCOG Electrical Safety

Task Group

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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EFCOG Electrical Safety

Task Group

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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EFCOG Electrical Safety

Task Group

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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EFCOG Electrical Safety

Task Group

10

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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EFCOG Electrical Safety

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11

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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EFCOG Electrical Safety

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12

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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EFCOG Electrical Safety

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13

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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EFCOG Electrical Safety

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14

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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EFCOG Electrical Safety

Task Group

15

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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EFCOG Electrical Safety

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16

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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17

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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EFCOG Electrical Safety

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18

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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EFCOG Electrical Safety

Task Group

19

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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21

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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EFCOG Electrical Safety

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22

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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24

Battery Safety
Know the Hazards
Use the required PPE
No Open Flame

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