Lithium Battery Manual

Update May 2007 version 3.0

Approvals Contributing Date

Name Date Author(s)
Technical Writer
T.Z. RA
Craig Million 14-May-2007
Clay Guinn 19-Jul-00 J.L. TK
71278LM
Technician(s) TA Approved By Date
Tom Knode 14-May-2007
Craig Million 14-May-07 Revision

Richard Arsenualt 14-May-2007 Cliff Salawage 14-May-07

Update Resperator �����������
Terry Byerley 14-May-2007
Approval Signatures Date “The information contained herein shall be considered the sole
property of Halliburton Energy Services, a division of Halliburton
Checked By Company, and the recipient thereof agrees not to disclose said
information to parties outside the recipient’s organization and not to
use or duplicate said information for any purpose except as specified
by Halliburton Energy Services without the written permission of
Originating Engineer Halliburton Energy Services.”

Document Number Rev.

Approval D00030124 C
Sheet 1 of 49
E00007 Rev. F
Note This page must be read and filled out prior to use or posting in the area.

IMPORTANT MESSAGE ABOUT LITHIUM BATTERIES

When handled correctly, they pose no risk.
IF MISHANDLED, lithium batteries may leak or vent, sometimes violently, releasing acid and
toxic fumes that pose a risk to health and that may cause serious bodily injury.

◊ Do not puncture, crush, drop, pull tabs, short, incinerate, or recharge cells.
◊ Do store batteries in a cool, dry place for safety reasons and to prevent deterioration in
performance. Clearly mark the contents of the storage area and the location of the exit.
◊ Spent lithium batteries are a hazardous waste. Dispose of them correctly, in accordance with
local and all other applicable regulations.
◊ Without exception, only personnel who have received appropriate training can
assemble/disassemble, package, handle, ship, or use lithium batteries.
◊ At all times when working with lithium batteries, ensure that an additional person is in the
vicinity and able to respond quickly to any incident.
◊ In all areas where lithium batteries are being assembled/disassembled, used, or stored, a
complete LITHIUM BATTERY SAFETY KIT (P/N 016361) must be close at hand.
◊ Only extinguishers designed for use on metal fires may be used to control a lithium fire.
◊ Under no circumstances will anyone attempt to deal with a fault condition (leak, vent, short,
etc.) without first evacuating and securing the area, notifying the appropriate person, getting
the assistance of a trained employee, and donning full personal protective equipment. See
Lithium Battery Safety Procedure P00193 for more detailed instructions.
◊ Should one be overcome with fumes vented from a lithium battery, protect yourself first, then
quickly remove the victim to fresh air. Call for medical help and, if trained, treat the victim
for asphyxiation. Do not attempt mouth-to-mouth resuscitation. Administer nothing by mouth
to an unconscious person.
If you have a lithium battery fault condition in your area, call

or

on Ext. on Ext.

P01791 Rev.C

D00030124 Rev. C Sheet 2 of 49

 Table of Contents

1. Introduction and General Safety ............................................................................................. 4

1.1. Purpose.......................................................................................................................... 4

1.2. Scope............................................................................................................................. 4

1.3. General Safety............................................................................................................... 4

1.4. Safety Precautions......................................................................................................... 4

2. Storage .................................................................................................................................... 6

2.1. Purpose.......................................................................................................................... 6

2.2. Scope............................................................................................................................. 6

2.3. Storage Precautions....................................................................................................... 6

2.4. Temperature and Environment...................................................................................... 6

2.5. Hazard Considerations .................................................................................................. 7

3. Handling Procedure ................................................................................................................ 7

3.1. Purpose.......................................................................................................................... 7

3.2. Scope............................................................................................................................. 7

3.3. Routine Cell Handling Procedures................................................................................ 7

4. Damaged or Possibly Damaged Cell Procedures.................................................................. 10

4.1. Initial Check for Possibly Damaged Batteries at a Job Site........................................ 10

4.2. Before Confirmation of Leakage at a Job Site............................................................ 10

4.3. After Confirmation of Suspected Leakage at a Job Site ............................................. 12

4.4. At an R&M Facility .................................................................................................... 13

4.5. Handling Inserts Stuck Inside Collars......................................................................... 14

4.6. Preparing Leaking Cells for Shipment........................................................................ 14

5. Transportation ....................................................................................................................... 16

5.1. Purpose........................................................................................................................ 16

5.2. Scope........................................................................................................................... 16

5.3. Battery Classification and Labeling............................................................................ 16

5.4. Packaging and Labeling Procedures ........................................................................... 17

6. Waste Management Recycling and Disposal ........................................................................ 29

6.1. Purpose........................................................................................................................ 29

6.2. Scope........................................................................................................................... 29

6.3. Waste Management Vendor Options........................................................................... 29

6.4. Procedures................................................................................................................... 30

7. Appendix............................................................................................................................... 36

7.1. Layout of Cell ............................................................................................................. 36

7.2. Equipment/Materials................................................................................................... 37

7.3. Reference Documents ................................................................................................. 39

7.4. Contacts....................................................................................................................... 40

7.5. Features of Lithium Batteries...................................................................................... 42

7.6. Benefits of Lithium Batteries...................................................................................... 44

8. Lithium Power Source Encyclopedia.................................................................................... 45

D00030124 Rev. C Sheet 3 of 49

1. Introduction and General Safety

Warning Without exception, only personnel who have received appropriate training can
assemble/disassemble, package, handle, store, ship, or otherwise use lithium
batteries.

1.1. Purpose
The purpose of this section is to provide an introduction to lithium batteries and
outline some general safety precautions.
1.2. Scope
This section discusses lithium battery procedures for all HES facilities worldwide.
1.3. General Safety
Under normal handling and storage conditions, lithium batteries pose no hazard;
however, improper handling will cause damage to batteries. Damaged cells can
violently vent toxic vapors and caustic liquids. Batteries that are heated, reverse
charged, crushed, punctured, or short circuited may ignite and possibly explode.
Anyone working with lithium batteries must comply with all safety precautions.
1.4. Safety Precautions
1.4.1. Material Safety Information
Material Safety Data Sheet (MSDS) information is available in the work
center for review before the use of any hazardous chemical or solvent. If
you cannot find the appropriate MSDS, contact the import specialist at
(281) 871-4493.
1.4.2. Vermiculite Hazard
The lithium battery safety kit
contains the TC–21C–371 canister (Item 26) for this purpose.
1.4.3. Lithium Battery Hazards

Warning Do not use water on a lithium battery fire. Lithium will react vigorously with
water and produce explosive H2 gas.

A lithium fire is a metal fire. Standard extinguishers will not work. Fire
that spreads from a lithium fire may be put out with other appropriate
extinguishing methods.

D00030124 Rev. C Sheet 4 of 49

Lithium cells contain highly reactive lithium metal and a very corrosive
liquid electrolyte. Special safety precautions ensure that the cells remain
undamaged and intact. In the unlikely event of a lithium fire, a class D
fire extinguisher (Item 4) or lith-x powder (Item 23) must be used.
An electrolyte leak must be neutralized and the leaking cell must be
properly packaged for disposal. The liquid electrolyte emits toxic,
corrosive gases and liquids when exposed to air. The gases formed are
HCL, CL2, SO, and SO2. Liquid decomposition products (hydrochloric or
sulfurous acid) and other corrosive products are formed when the gases
contact moisture.
General safety guidelines require that lithium cells never be punctured,
crushed, recharged, disassembled, short-circuited, immersed in liquids, or
heated above their rated temperature. See S00557 for information on
rated temperature per battery type. The solid lithium metal anode is
sealed within the cell and poses a significant fire hazard if the cell is
physically damaged or exposed to temperatures above 180°C.
There are five general conditions that you must avoid in dealing with
lithium batteries:
• Impact and puncture

Be extremely careful not to drop batteries on the floor.

Do not jab at or pry stuck batteries with screwdrivers or other

implements.
• Overheating (incinerating)
Do not apply solder to the cell cases and use special care when
applying shrink tubing.
Do not place a battery in an oven heated above the battery’s rated
temperature.
• Charging

Do not attempt to recharge batteries.

Do not connect cells in reverse or to power supplies.

• Short circuiting (dead shorting)

Never place batteries on metal benches.

Arrange cells so that (+) to (-) contact does not occur.

• Moisture (especially exposed lithium)

Moisture can cause short circuits.

Exposure to moisture can lead to severe galvanic corrosion of the

feed-through pin, thus compromising the hermetic seal of the battery.
Remember that these are power sources, and galvanic corrosion, if
allowed to start, will corrode the connectors very quickly.

D00030124 Rev. C Sheet 5 of 49

2. Storage
2.1. Purpose
This section describes practices to be followed when storing nonventing lithium cell
battery packs.
2.2. Scope
This section covers lithium battery storage procedures for all HES facilities
worldwide.
2.3. Storage Precautions
• Restrict lithium battery storage areas to AUTHORIZED PERSONNEL ONLY.
• Maintain an accurate inventory of all cells and batteries, including those that are
defective or discharged.
• Store lithium cells in their original shipping containers to keep them isolated from
each other and to prevent external short circuits. To avoid short circuit hazards, do
not store batteries outside of their packaging or on bare metal surfaces.
• Separate discharged or damaged cells and batteries from fresh cells. For disposal
instructions, see Section 6, Waste Management Recycling and Disposal.
• Prolonged storage should not exceed the optimum range. The maximum limit for
brief storage is 1 to 2 days.
• Post MSDS information in the area.
• Ensure that a Lithium Battery Safety Kit or, at least, a gas mask/SCBA system is
available nearby. All employees that are expected to respond to a venting lithium battery
must be trained on the use of respiritaory protection, and they must be fit tested respirat
-s, and must be worn in accordance with any local respitory protection programs.
Temperature and Environment
• Protect storage areas from moisture.
• Ensure that automatic sprinkler systems are not installed in areas used for
assembling, handling, or sheltering lithium batteries.
• Protect batteries from excessive humidity. Take all necessary actions to prevent
moisture from forming an electrical pathway between the connector contacts or
the feed-through terminal and the battery cover.
• Store cells, batteries, and assembled inserts in a dry place, well away from
Flammable solvents, oxidizing agents, flammable gases, ovens, and other sources
• The optimum storage temperature is 4.4°C (40°F) to 21°C (70°F). The maximum
storage temperature should never exceed 49°C (120°F) and is not recommended
for storage longer than a few days.

D00030124 Rev. C Sheet 6 of 49

 2.5. Hazard Considerations
• Store batteries in an explosion-proof container, similar to those used for the
storage of explosives.
• Install wheels on the container to allow easier removal from the building in the
event of fire.
• Clearly mark lithium battery storage areas and provide them with lith-x fire
extinguishing material and a class D fire extinguisher.
• Clearly mark the area to warn that water is not to be used in the event of a fire.
3. Handling Procedure
3.1. Purpose
This section describes practices to be followed when testing and otherwise handling
lithium cell battery packs manufactured by or for HES. It includes instructions
regarding those venting, not venting, or suspected of venting. This document
contains recommendations by personnel who have been involved in several venting
battery situations. It is intended to provide guidance for handling future occurrences.
3.2. Scope
This section covers lithium battery handling procedures for all HES facilities
worldwide.

Note
This document is not intended to address government regulations and/or

requirements concerning the protection of personnel performing these actions.

All local regulations supersede this document.

3.3. Routine Cell Handling Procedures

Note Each supervisor should review the proposed flow of batteries throughout his/her
department/location to identify and eliminate potential sources of electrical and
physical damage to the batteries.

Warning Wear all safety equipment when handling cells.

Warning All personnel handling cells or batteries during assembly procedures must
wear safety glasses (Item 15).

D00030124 Rev. C Sheet 7 of 49

Warning If at any point a cell appears to be self-heating, leaking, venting, or
behaving in an unusual manner, immediately evacuate all personnel from
the area and notify the proper supervisory and safety personnel.

3.3.1. Individual Cells

Before using the batteries, carefully remove any tape, tubing, or other
protective jackets from the cells or tabs as described in the procedure for
the assembly.

Warning
Ribbon leads (tabs) are very flexible and can be adjusted by bending; however,

breaking may result from overhandling. If the leads break off during installation,

make no attempt to reattach them by soldering.

3.3.2. Battery Assembly

• Ensure that workbenches are covered with nonconductive materials
and are perfectly level to keep round cells or modules from rolling
off.
• Work only on a dry, nonconductive surface. If the plastic insulation
has been removed from the cells, take special care to prevent shorts.
• Do not apply solder to the cell cases. Special spot welders are used
to attach nickel tabs to the cans. Wires may be soldered to these tabs,
not the cans themselves.
• When cutting or trimming positive and negative leads, do so
separately to avoid a short circuit.
• If, during assembly, you encounter a problem that does not represent
a hazardous situation, identify and correct it before continuing
assembly.
3.3.3. Voltage Check
3.3.3.1. To ensure proper battery assembly, check the cell voltage
immediately prior to battery assembly (positive terminal to
negative terminal).
3.3.3.2. Check the voltage of the assembly immediately after
completion to ensure a proper polarity.
3.3.3.3. Ensure that the open-circuit string voltage is the open-circuit
voltage of each cell times the number of cells in the series. A
lower voltage indicates either a defective cell or an improperly
installed cell. If there are diodes in the assembly, a 0.7 V drop
per diode may be observed, under load.

D00030124 Rev. C Sheet 8 of 49

 3.3.4. Shrink Tubing

Warning Use extreme caution when applying heat to shrink tubing on cells.

• After the shrinking process has been completed, check the surface
temperature of each cell in the battery pack by touch. Cell
temperature should not differ significantly from one cell to the next,
or be much above room temperature.
• When shrinking with a hot air gun, be sure not to overheat any one
area. Do not allow the gun to remain on any one spot longer than it
takes to shrink the tubing (a few seconds).

D00030124 Rev. C Sheet 9 of 49

4. Damaged or Possibly Damaged Cell Procedures
4.1. Initial Check for Possibly Damaged Batteries at a Job Site

Note These procedures assume that you suspect that a pulser (MPT), CIM, BM, EMT,
or SP4 battery insert is damaged inside the collar. Your assumption could be
based on the following:
• Abnormal values seen on the FEWD tool report during or after the
run
• Shop floor HTZ test (Item L)
• Detection of acid-like aroma around a collar or insert
• Excess heat at the battery end of the collar–

4.1.1. Inform another field operator, technician, or anyone who can watch you from
a distance (25' to 50') that you are going to take a closer look for potential
battery problems.
4.1.2. Approach the back of the collar carefully and try to visually confirm that the
battery has a problem.
4.1.3. Move right up to the end of the sub or until you see or sense confirmation of
a malfunction.
• IF you do see confirmation, THEN go to Section 4.3.
• IF you do not see confirmation, THEN go to Section 4.2.
4.2. Before Confirmation of Leakage at a Job Site

Note IF you confirm leakage at any point in this procedure, THEN go directly to
Section 4.3.

4.2.1. Put on the rubber gloves (Item 14), the full rubber apron (Item 16), and the
respirator with an acid mist canister (Item 11) contained in the Lithium
Battery Safety Kit.Note: the respirators must be worn in accordance with any local
respiratory protection program. At a minimum user must complete training and
must be fit tested.

D00030124 Rev. C Sheet 10 of 49

Warning When you initially check the safety vent, your entire head must be to the
side and next to the collar, never at the end where gases can vent into your
face or ear. Refer to Figure 1.

Figure 1

4.2.2. Approach the end of the collar, but withdraw if you detect a sign of battery
venting. IF you confirm venting, THEN go to Section 4.3.
4.2.3. Place the safety vent check tool (Item 3) into the safety vent.
4.2.4. Push the rubber, stopper-like washer against the battery and pull the safety
vent to release the valve. IF you hear gases venting, THEN try to push the
vent tool back in and go to Section 4.3.
4.2.5. With the safety equipment still on, remove the battery slowly from the collar
in accordance with standard removal procedures and carefully inspect the
insert as it comes out.
4.2.6. IF you detect signs of a venting cell or cells, THEN stop immediately, push
the insert back in as far as possible, and go to Section 4.3.
4.2.7. Do not stand directly behind the extraction tool. Pressure contained within
the collar can force the insert out and cause injury.
4.2.8. IF the insert appears to be OK, THEN follow normal removal and
replacement procedures and go to Section 4.3. Replace all safety equipment
in the Lithium Battery Safety Kit case and notify all personnel that there is no
emergency.

D00030124 Rev. C Sheet 11 of 49

 4.3. After Confirmation of Suspected Leakage at a Job Site
4.3.1. IF you have seen or smelled something that confirms that the battery is
venting or abnormal in some way, THEN get away from it.
4.3.2. Notify fellow workers, people at risk of exposure to fumes, the company
man, and/or your supervisor that you have a potentially hazardous situation.
4.3.3. Ensure that a second person is wearing the other set of safety clothing and is
equipped with a full faced respirator with an acid gas cartridge or self contained
breathing apperatus from the Lithium Battery Safety Kit in the event that you need
assistance getting away from the collar.
4.3.4. Move the entire collar to a dry, well-ventilated place that is away from heavily
trafficked areas.
4.3.5. Post warning signs and restrict access to authorized personnel only.
4.3.6. If possible, push the battery insert back into the sub and lock it in place with
a locking ring assembly.
4.3.7. Transport the collar to the local Repair and Maintenance (R&M) facility,
closely following all shipping regulations (Section 6).

Warning IF the fumes coming from the end are heavy enough and you can obviously
smell the venting gas, the collar needs to be quarantined and inspected
every 24 hours until it appears safe to transport. Under no circumstances
should an actively venting battery be transported.

Caution Depending on the severity of the reactions seen on the battery, it may also be
advisable to put on the plastic coverall clothing and additional safety equipment
before attempting to reinstall the battery into the collar.

4.3.8. IF the battery insert will not go back into place, remove it from the collar and
place it in a remote, well-ventilated area until all visible reactions have
ceased.
4.3.8.1. Use the dark-colored lith-x powder (Item 23) only if flames are
coming from the cells. To smother the fire fully, apply the
lith-x powder directly to the flames and completely cover them.
Do not simply sprinkle the powder around the flame.
4.3.8.2. Use the vermiculite to soak up any leaking electrolyte. Try to
keep all moist vermiculite with the insert so it can be disposed
of properly.
4.3.8.3. Use the sodium bicarbonate to neutralize any acid spills or
leaks.

D00030124 Rev. C Sheet 12 of 49

 4.3.8.4. Only when the insert seems to have stopped spewing and
leaking, place the battery into the appropriate lithium battery
shipping box.
4.3.8.5. Pour any remaining vermiculite and sodium bicarbonate into
the inner box with the insert.
4.3.9. Send the insert to the nearest R&M facility, being sure to follow all local
shipping regulations (Section 6).

Note All materials used for neutralization are hazardous waste and must be disposed
of properly. See Section 6, Waste Management Recycling and Disposal.

4.4. At an R&M Facility

Note This procedure assumes that you suspect a problem due to the tool report or
some abnormal behavior or condition.

4.4.1. Two trained personnel should put on all the protective clothing; rubber gloves
(Item 14); rubber aprons (Item 17); and self-contained breathing apparatus
(SCBA), if available, or respirators (Item 11), if not. Note: respirators must be worn
in accordance with local resiratory protection programs, see 4.2.1 for detail.
.
4,4,2
Check the safety vent as detailed in Sections 4.2.3 and 4.2.4 to ascertain the reactive
condition of the pack.
. 4.4.3 Isolate the collar until the reactions have ceased. Check the collar at least
once every 24 hours.
4.4.4. Using the buddy system (i.e., a second person ready to assist), remove the
insert from the collar and place it on a cart or bench. Use the same
precautions if the insert is in a shipping box. If the cell is stuck in the collar, go to
section 4.5
. 4.4.5 Inspect the insert for leaking electrolyte and spewing material.
. 4.4.6 Use a class D fire extinguisher (Item 4) or the dark-colored lith-x powder
(Item 23) from the Lithium Battery Safety Kit on any open flames, only in an
attempt to smother the fire. Do not proceed until all fire is extinguished.

Note If the insert is in a well-ventilated area and away from other flammables, it is
generally advisable to let the lithium fire burn itself out. Ensure that the fire is
not heating other cells.

4.4.7. Apply vermiculite to any liquids discharging from the cells.

4.4.8. Apply sodium bicarbonate to neutralize the acids.

D00030124 Rev. C Sheet 13 of 49

 4.4.9. Move the insert to a remote, dry, well-ventilated place where the reactions
can subside.
4.4.10. Inspect the insert every 24 hours.
4.4.11. Reapply the sodium bicarbonate, if necessary, until it appears all reactions
have stopped.
4.4.12. When it is assumed that the reactions have stopped, two people should put on
the plastic suits, rubber gloves, rubber aprons, and either SCBA or
respirators, as necessary, to begin removal of the cells. Proceed to
Section 4.6.
4.5. Handling Inserts Stuck Inside Collars

Caution Scrap the toolstring only if the tool is stuck and cannot be removed, even with a
hydraulic press, or if you cannot identify the exact battery location.

4.5.1. Determine the exact location of the battery inside the collar.
4.5.2. Mark the location of the battery on the collar.
4.5.3. Using the buddy system, slowly and carefully cut the collar using an
appropriate saw, being careful to avoid generating extreme heat.
4.5.4. Once the collar is cut, move the section without the battery away.
4.5.5. Attempt to remove the battery from the collar system.
• If you cannot remove the battery, scrap the section in accordance
with regulations (Section 6).
• If you can remove the battery, go to Sections 4.4.5 through 4.4.12.
4.6. Preparing Leaking Cells for Shipment
4.6.1. Using the buddy system and all protective equipment, follow the normal
process of disassembly (Section 6.4.3) as closely as possible, cutting the
shrink tubing and tape to gain access to the cells.
4.6.2. Cut any loose wires as close to the stave assemblies as possible.
4.6.3. Back out the locking screws in the full bore insert to access and remove the
stave tubes. IF the tubes have been damaged, or if the locking screws will not
come out, attempt to break the tube wall with a screwdriver to gain access to
the cells. Do not risk puncturing the cells!

Warning If at any time you smell acid, get away and let the fumes clear. Faint
detection of the acid smell will not hurt, but it does indicate that the fumes
are too strong for your equipment, your equipment does not fit properly
or that your equipment is faulty.

D00030124 Rev. C Sheet 14 of 49

4.6.4. Disassemble the cells to their lowest practical level. IF there are bags
available that will contain the two-cell stick of the CIM insert, THEN do not
separate these.
4.6.5. Put each cell into its own individual, sealable plastic bag. Place a small
amount of sodium bicarbonate in the bag along with the cell. Seal the bag.
4.6.6. Place all of the plastic bags carefully into a CIM insert inner shipping box,
either the 63/4" or the 91/2", (Item 34) with enough vermiculite to cover them.
If all of the cells will not fit into one box (common occurrence with 48 CC
cells), then use a second inner box.
4.6.7. Seal the box with tape and place it into the outer box with the proper packing
material.
4.6.8. Write the quantity and type of cell in each box assembly somewhere on the
outside of the box.
4.6.9. Place this shipping box assembly in a remote, dry location to await proper
packaging and shipment to an approved disposal company (Section 6).
4.6.10. Clean any remaining residue off the insert body by rinsing it with large
amounts of water.
4.6.11. Rerinse the iron as the positioning ring and locking ring are removed.
4.6.12. Be sure to thoroughly dilute all residue that is washing off the insert.
4.6.13. Strip the insert completely and dry it thoroughly. Scrap all parts except for
the iron itself.
4.6.14. Use a wire brush with an air motor or electric drill to brush any burned spots
and to remove any scale not removed with the water. Do not use the wire
brush on O-ring groves or other close tolerance seal areas, as this could
damage seal integrity. Use a very fine sandpaper (Item 36) to polish the seals.
Be sure to report any questionable seal areas on the build up/tear down check
sheets.
4.6.15. Rebuild the battery insert using the appropriate assembly procedure.

D00030124 Rev. C Sheet 15 of 49

5. Transportation
5.1. Purpose
This section describes practices to be followed when transporting lithium cell battery
packs.
5.2. Scope
This section covers lithium battery transportation procedures (either alone or within
equipment) by domestic highway or international freight for all HES facilities
worldwide.
5.3. Battery Classification and Labeling
5.3.1. Batteries Not Restricted for Transportation
• Batteries with a liquid cathode content of 0.5 g or less or a solid
cathode content of 1.0 g or less of lithium are not restricted for
transportation.
• Some batteries with 5 g or less lithium content per cell and not more
than 25 g total lithium content per battery may also be classified as
not restricted. For these batteries to be classified as not restricted
they must have passed additional performance tests as specified by
the UN Recommendation on the Transport of Dangerous Goods, Test
and Criteria. The battery manufacturer must provide written
certification stating that its batteries have passed these additional
tests.

Caution Lithium batteries that are not regulated for transportation must be packaged
with strong inner packagings and with sufficient cushioning material to prevent
movement in both the inner and outer packagings. Batteries must also be
protected from short circuits. (Leads protected to prevent arcing.) Batteries
must be placed in plastic bags in case of leakage. Lithium content is not to
exceed 500 g per inner package. Note: Boxes must be marked as follows.

These shipments may not be transported aboard passenger aircraft when being shipped to,
from or through the United States even if meeting the above requirements for
not regulated.

D00030124 Rev. C Sheet 16 of 49

 5.3.2. Batteries – UN3090
Batteries may not have contents of more than 12 g lithium per cell and
500 g lithium per battery.
Batteries must be properly packaged, marked, and labeled for the specific
mode of transportation (Section 5.4.1).
5.3.3. Batteries Contained in Equipment – UN3091
Lithium batteries contained in equipment may not exceed 5 kg total
battery weight.
Lithium batteries contained in equipment must be properly marked and
labeled for the specific mode of transportation (Section 5.4.2).
5.3.4. Batteries – Universal Waste
Lithium batteries that are returned under Universal Waste rules are not
subject to hazardous waste regulations.
Batteries will be shipped in accordance with the specific model
packaging instructions and with the following additional marking:
UNIVERSAL WASTE – BATTERIES. See Section 6 of this manual for
more information.
5.4.0 Packaging and Labeling Procedures
5.4.1. Domestic Highway, Lithium Batteries Not in Equipment

Note
Cells and batteries for disposal may be offered for transportation or transported

to a permitted storage facility and disposal site by motor vehicle only.

Vented or damaged cells/batteries are prohibited via air or ocean freight.

5.4.1.1. Place batteries in inner packagings to prevent short circuits.

5.4.1.2. Place batteries either in a UN4G fiberboard box or other UN
approved packaging tested to packing group II. The maximum
quantities for each package are as follows:
• 5 kg GRWT – Passenger

• 35 kg GRWT – Cargo

Other approved UN packaging includes the following:

• UN1A1, steel drum (Item 33)

• UN1H2, plastic drum

• UN1G, fiber drum

Change the shipper’s declaration as required.

5.4.1.3. Fill any remaining space with vermiculite.

D00030124 Rev. C Sheet 17 of 49

5.4.1.4. Mark and label each outside package to display the following:
• Name and address of the consignee
• “LITHIUM BATTERIES – UN3090”
• A MISCELLANEOUS HAZARD label (Item 25)
• IF the gross weight exceeds 5 kg, THEN “CARGO
AIRCRAFT ONLY”
• Place the New Caution Label near the Hazard Class and
Handling Labels

• WHEN TRANSPORTING TO, FROM OR WITHIN

THE UNITED STATES, SHIPMENTS MUST BE
LABELED “CARGO AIRCRAFT ONLY”
5.4.1.5. Have the person preparing the shipping document inspect the
packages to ensure that the above requirements are met.

Shipper and Consignee

Address

Lithium Batteries
UN3090 Gross Weight 15 KG

U 4G/ Y 40/ S/ 06/ USA/ M7474

N

D00030124 Rev. C Sheet 18 of 49

5.4.1.6. Ensure that the shipping paper contains the
EMERGENCY RESPONSE TELEPHONE number. Make sure
the number contained on all hazard documents is +1-281-575­
5000. For emergency response information see the 2004
Emergency Response Guide 138.
5.4.1.7. Enter the DOT Shipping Paper: LITHIUM BATTERIES –
9 UN3090 – II.

D00030124 Rev. C Sheet 19 of 49

D00030124 Rev. C Sheet 20 of 49
HAZARDOUS MATERIAL PACKING INSTRUCTIONS
Product Name: Lithium Battery
Shipping Data: IATA/ ICAO PROVISIONS USED
SHIPPER’S DECLARATION FOR DANGEROUS GOODS
“NATURE AND QUANTITY OF DANGEROUS GOODS”
UN # Proper CL PKG SUB RSK Qty & Type PKG INS Authoriz
Shipping GRP of Packaging
Name
UN 3090 LITHIUM 9 II 1 Fiberboard 903
BATTERIES Box x __ kg
Gross
Weight
Additional Handling Information:

Additional information to be supplied by the SHIPPER:

Shipper Full name and address of the shipper

Consignee Full name and address of the consignee
Airway Bill No. (May be completed by the freight forwarder)
Page __ of __ Pages Enter the page number and total number of pages
Aircraft Limitations Passenger aircraft (<5 kg GRWT)(Secondary Rechargeable)
Cargo aircraft only (5 kg – 35 kg GRWT)
Note: “Cargo Aircraft Only” when shipping to, from or within the United States.
Airport of Departure Enter the full name of the airport or city of departure (may be amended
by the forwarder or the carrier).
Airport of Destination Enter the full name of the airport or city of destination (may be
amended by the forwarder or the carrier).
Shipment Type Nonradioactive
Additional Handling
Information Enter “Emergency Contact Number + 1-281-575-5000'
Person certifying shipment must enter the following:
• Name
• Title
• Place
• Date
• Signature

Note No corrections or errors are allowed on dangerous goods certification.

D00030124 Rev. C Sheet 21 of 49

D00030124 Rev. C Sheet 22 of 49
5.4.2. Domestic Highway, Lithium Batteries Contained in Equipment
5.4.2.1. Product Name: LITHIUM BATTERIES CONTAINED IN
EQUIPMENT. Shipping Regulations/ MOT:DOT /
DOMESTIC HIGHWAY.
5.4.2.2. The quantity of lithium metal contained in any piece of
equipment must not exceed 12 g per cell and 500 g per battery.
Not more than 5 kg of lithium batteries may be contained in
any piece of equipment.
5.4.2.3. Battery terminals must be protected from short circuits.
5.4.2.4. Outside packages must be waterproof or made waterproof
with plastic wrapping.
5.4.2.5. Each outside package must be marked with the name and
address of the SHIPPER OR CONSIGNEE.
5.4.2.6. Each outside package must be marked: LITHIUM
BATTERIES CONTAINED IN EQUIPMENT – UN3091.
5.4.2.7. Each outside package must display the following hazard label:
MISCELLANEOUS (CLASS 9).
5.4.2.8. Emergency Response information: 2004 ERG GUIDE NO. 138
Every shipping paper must display a 24-HOUR EMERGENCY
RESPONSE TELEPHONE NUMBER.
5.4.2.9. DOT Shipping Paper Entry: LITHIUM BATTERIES
CONTAINED IN EQUIPMENT, 9, UN3091,II

D00030124 Rev. C Sheet 23 of 49

HAZARDOUS MATERIAL PACKING INSTRUCTIONS

Product Name: Lithium Battery (Contained in Equipment)

Shipping Data: IATA PROVISIONS USED

SHIPPER’S DECLARATION FOR DANGEROUS GOODS

“NATURE AND QUANTITY OF DANGEROUS GOODS”

UN # Proper CL
PKG
SUB RSK
Qty & Type PKG INS Authoriz
Shipping GRP
of Packaging
Name
UN 3091 LITHIUM 9
II 1 Fiberboard 912
BATTERIES Box x __ kg
CONTAINED Gross Weight
IN
EQUIPMENT
Additional Handling Information:
Additional information to be supplied by the SHIPPER:
Shipper Full name and address of the shipper
Consignee Full name and address of the consignee
Airway Bill No. (May be completed by the freight forwarder)
Page __ of __ Pages Enter the page number and total number of pages
Aircraft Limitations Passenger aircraft and cargo aircraft
Note: “CARGO AIRCRAFT ONLY” WHEN TRANSPORTED TO, FROM OR WITHIN THE
UNITED STATES
Airport of Departure Enter the full name of the airport or city of departure (may be amended
by the forwarder or the carrier).
Airport of Destination Enter the full name of the airport or city of destination (may be
amended by the forwarder or the carrier).
Shipment Type Nonradioactive
Additional Handling
Information Enter “EMERGENCY CONTACT +1-281-575-5000.”
Person certifying shipment must enter the following:
• Name
• Title
• Place
• Date
• Signature
The quantity of lithium metal contained in any piece of equipment must not exceed 12 g per cell
and 500 g per battery.

D00030124 Rev. C Sheet 24 of 49

Not more than 5 kg of lithium batteries may be contained in any piece of equipment.
Battery terminals must be protected from short circuits.

Each outside package must be a WOOD BOX or other suitable outside packaging.

Each outside package must be marked with the name and address of the SHIPPER and

CONSIGNEE.
Each outside package must be marked: LITHIUM BATTERIES CONTANIED IN

EQUIPMENT – UN3091.

Each outside package must display the following hazard label: MISCELLANEOUS

(CLASS 9).

Each outside package must display a CARGO AIRCRAFT ONLY handling label.

Each outside package must also display the Yellow Lithium Battery Caution handling label.

Emergency Response Information: 2004 ERG GUIDE NO. 138

Every shipping paper must display a 24-HOUR EMERGENCY RESPONSE TELEPHONE

NUMBER.

NOTE: YOU MUST OBTAIN AUTHORIZATION FROM THE HSE TRANSPORTATION

GROUP TO SHIP LITHIUM BATTERIES ABOARD PASSENGER AIRCRAFT OUTSIDE

UNITED STATES JURISDICTION. PLEASE NOTE SOME AIR CARRIERS AND COUNTRIES

HAVE ALSO ADOPTED SHIPPING ONLY ON CARGO AIRCRAFT.

Sipper and consignee Address

Lithium Batteries contained in Equipment

UN3091 Gross Weight 75 KG

D00030124 Rev. C Sheet 25 of 49

Note No corrections or errors are allowed on dangerous goods certification.

D00030124 Rev. C Sheet 26 of 49

 5.4.3. International Ocean Freight
5.4.3.1. Place batteries in inner packagings to prevent short circuits.
5.4.3.2. Place batteries in a UN4G fiberboard box or other UN
approved packaging that is tested to packing group II
Shipper and Consignee
Address
Lithium Batteries
standards. The maximum quantities for each package are as
U
UN3090 Gross Weight 15 KG
follows:
4G/ Y 40/ S/ 06/ USA/ M7474

•
N
Fiberboard box – 500 g lithium
Shipper and Consignee

Address
Other UN approved packaging includes the following:
• UN1A1, steel drum (Item 33)
Lithium Batteries

UN3090 Gross Weight 75 KG

OVERPACK

• UN1H2, plastic drum

Example of an Overpack
• UN1G, fiber drum
Change the IMO entry as required.
5.4.3.3. Fill any remaining space with vermiculite.
5.4.3.4. Overpack into a wood box. Mark each overpack with
“OVERPACK.”
• No lithium limit for overpack
5.4.3.5. Mark each package and overpack to display the following:
• Name and address of the consignee
• “LITHIUM BATTERIES – UN3090”
• MISCELLANEOUS (CLASS 9) HAZARD label (Item 25)
• New Yellow Caution Label
• The Gross Weight of the Overpack

5.4.3.6. Have the person preparing the shipping document inspect the
packages to ensure that the above requirements are met.
5.4.3.7. Ensure that the shipping paper contains the EMERGENCY
RESPONSE TELEPHONE number, 1 (800) 666-9260. For
emergency response information, see the 2004 Emergency
Response Guide 138.
5.4.3.8. Fill out the IMO shipping paper as follows:
• UN3090, Lithium Batteries, Class 9, II
• EMS F-A, S-1
• ___ Fiberboard Boxes x ___ kg GRWT each
• Overpack used – ___ kg GRWT

D00030124 Rev. C Sheet 27 of 49

When ordering new boxes or foam inserts, see Figures 2 and 3 or order through the
local/district R&M.

Shipping Case Assembly (P/N 032954/120166000)

with Overpack (P/N 023695/120160583)

Figure 2

Shipping Box Assembly (P/N 032958/120166004)

with Overpack (P/N 023694/120160582)

Figure 3

D00030124 Rev. C Sheet 28 of 49

6. Waste Management Recycling and Disposal
The United States Environmental Protection Agency (USEPA) or local environmental
government agencies may classify lithium batteries that are no longer usable due to damage,
leakage, age, or depletion (below 2.0 V) as hazardous waste. Even cells with 0 V are
considered hazardous material. However, under USEPA Universal Waste rules, spent or
waste lithium cells may be treated as Universal Waste if they are to be recycled or
reclaimed. Nevertheless, they must be managed as hazardous substances until they are
shipped offsite. There are specific packaging, labeling, and documentation requirements
whether cells are disposed of as Hazardous Waste or recycled as Universal Waste. These
documents outline the approved methods of management and disposal within the United
States, as well as in international districts.
6.1. Purpose
This section describes the process for collecting, storing, and preparing lithium cells
for shipment to a vendor who either recycles or disposes of the cells.
6.2. Scope
This section covers lithium battery waste management and disposal for all HES
facilities worldwide.
6.3. Waste Management Vendor Options
Currently, HES has a contract with Toxco Waste Management Ltd., a Canadian
company, to recycle our waste lithium cells on a global basis. It is not mandatory that
a region/district use these services; they are only an available option. As an added
service, Toxco has prearranged with Concord/Combined Logistics, a shipping firm,
to handle transport of the waste cells by ocean freight. Using Concord/Combined
Logistics for transport is not mandatory even if a region/district decides to employ
the services of Toxco to recycle cells.

Note For contact numbers on Primary Waste Vendors, see Section 7.4.1 of this
document. For a global listing of Concord/Combined shipping agents, see
Section 7.4.3.

Note Toxco’s Profile Approval Number TBC00074 (reference on all shipments) only
covers the following cell chemistries:
• lithium/thionyl chloride
• lithium/sulfuryl chloride
• lithium/carbon-monoflouride
Do not send other types of cells for recycling, as our government permit does
not cover them.

D00030124 Rev. C Sheet 29 of 49

Note Various international trade agreements which control the shipment of hazardous
waste currently restrict Brunei, Thailand, and Venezuela from shipping cells
directly to Toxco in Canada. Instead, cells from these countries must be shipped
via the U.S. to Kinsbursky Brothers, a sister company of Toxco. They, in turn,
will transfer the cells to Toxco for recycling. Kinsbursky Brothers’ contact
information is given in Section 7.4.1. Toxco must still be notified 30 to 45 days
prior to shipping cells to Kinsbursky Brothers so arrangements can be made for
their eventual export to Canada.

6.4. Procedures

Warning Without exception, only personnel who have received appropriate training can
assemble/disassemble, package, handle, store, ship, or otherwise use lithium
batteries.

6.4.1. International Waste Lithium Battery Disposal Procedure

Step Responsible Party Action

1 Generating Location Notify HSE Waste disposal Manager of
of Lithium Batteries to be disposed.
2 HSE Send #1 Formatted Menu requesting the
following information:
• Contact Person
• Contact Person’s Memo ID
• Contact Person’s Phone #
• Contact Person’s Fax #
• Physical Location of Lithium Batteries
• Mailing Address
• Complete Charge Code # SAP Cost Center
3 Generating Location Supply requested information.
4 HSE Verify charge code (GLMENU).
5 HSE Notify ENSCO by certified mail of a pending
shipment. See Section 7.4.2 for contact
information.
6 ENSCO Notify EPA of pending shipment.
7 HSE Receive certified mail receipt from ENSCO.

D00030124 Rev. C Sheet 30 of 49

 Step Responsible Party Action
8 HSE Calculate and specify shipping date on #2
Formatted Memo and send with prepared
information packet, including the following:
• Completed manifest (with exception of
boxes 12 and 13 to be supplied by
Generating Location)
• Land Disposal Restriction
• Completed Hazardous Waste Labels
• Misc. Class 9 Markings
• Proper Shipping and Packaging Information
• Instruction for Import into U.S.
• IMO Dangerous Goods Declaration
(completed, except for the # of crates and
the weight in kg)
9 Generating Location Arrange for transportation and submits Pre Alert
to broker. See Section 6.4.2. for information on
Pre Alerts.
10 Broker Notify ENSCO of shipment and estimated time of
arrival. Contact the Customer Service
Representative.
11 Generating Location Proceed with shipment of approved load to
carrier/transporter.
12 Broker Process shipment through customs.
13 ENSCO Pick up load and transport to ENSCO facility for
final disposal.
14 ENSCO Process the disposal invoice and forward it to
HSE Waste manager.

6.4.2. Pre Alerts must contain the following information:

• Commercial Invoice – Provided by Generating Location
• SAP Cost Center Number for Freight and Disposal
• MSDS – Provided by Generating Location
• Bill of Lading (original) – Generated by Freight Forwarder

Note All locations with the exception of Mexico must use Diversified Freight
Logistics as a broker. See Section 7.4.2 for contact information. Mexico
locations may use Jimmy Santos Customs Brokers. See Section 7.4.2 for contact
information.

D00030124 Rev. C Sheet 31 of 49

6.4.3. Disassemble and properly package waste lithium cells.
6.4.3.1. Inspect the cells and battery subassemblies to be disposed of. If
leaking cells are observed, put on appropriate protective
equipment and clothing.
6.4.3.2. Trim the wires extending from the CIM stave assemblies to
prevent short circuits. Do not disassemble the staves.
6.4.3.3. For pulser stave assemblies or cells in a pulser pack case,
remove the individual cells from the stave tube.
6.4.3.4. If a cell is leaking, cover it with sodium bicarbonate (Item 28)
to neutralize any caustic material before placing it in a plastic
bag. See Section 4 for detailed instructions.
6.4.3.5. To prevent shorts, place each stave or cell in a separate plastic
bag (Item 29).
6.4.3.6. Roll the bag into the smallest shape possible. Use the bag
sealer (Item 30) to seal the plastic bag.
6.4.3.7. If the bag contains a leaking cell, place it inside a second,
larger plastic bag. Cover the first bag with sodium bicarbonate.
Roll the second bag into the smallest shape possible and use a
bag sealer to seal the second bag.
6.4.4. Pack the cells in an approved shipping container.
6.4.4.1. If the drum has old labels, eliminate them by scraping them
off or painting over them. Place the words "Universal Waste –
Batteries" along with the "Accumulation Start Date" on the
drum to meet EPA requirements and "Lithium Batteries –
UN–3090" along with a miscellaneous class 9 label to meet
DOT requirements.
6.4.4.2. Place a “Universal Waste – Batteries” label on the drum and fill
in the “Accumulation Start Date.”
6.4.4.3. Cover the bottom of a UN 1A2 or 1B2 metal drum (Item 33)
with at least 1" of vermiculite.

D00030124 Rev. C Sheet 32 of 49

 6.4.4.4. Place the plastic bags containing the waste lithium cells or
staves onto the vermiculite in the drum.

Caution All plastic bags containing leaking cells must be placed in a separate UN 1A2 or
1B2 metal drum (the 5 gal size may be used) prepared as above with
vermiculite. Mark the drum and its paperwork “Leaking Cells.”

6.4.4.5. Continue placing bags on the vermiculite layer until the layer
of cells is complete, ensuring that no cells overlap.
6.4.4.6. Add a 1" layer of vermiculite (Item 1) over the bags containing
the cells.
6.4.4.7. Continue to alternate layers of vermiculite and cells to within
1" of the top of the drum.
6.4.4.8. When the drum has reached capacity, or the scheduled shipping
date arrives, cover the final layer of cells with vermiculite,
filling the drum to the top.
6.4.4.9. Place the lid on the drum and install the lid-locking ring.
6.4.5. Place the partial or filled drum(s) in a hazardous waste storage area.

Note It is recommended that waste cells not be accumulated for more than 90 days
prior to shipping them for disposal. If waste cells are to be recycled, do not
accumulate them for more than 12 months, according to USEPA Universal
Waste Rules (USA only).

• Leave lids on drums except when adding waste cells.

• Keep the storage area cool and dry to reduce the likelihood of a cell
vent during storage.
• Isolate the storage area from vehicular and personnel traffic.
• Cordon off the area. Secure and properly mark it to indicate storage
of WASTE LITHIUM CELLS or HAZARDOUS WASTE.
• Restrict access to AUTHORIZED PERSONNEL ONLY.
• Post NO SMOKING signs as an added precaution.
• Limit traffic to the drum storage area to exclusively when
performing one of the following actions:
– Adding drums to the storage area.
– Adding cells to partially filled drums.
– Removing drums for shipment for recycling or disposal.

D00030124 Rev. C Sheet 33 of 49

 • When accessing the drum storage area, use the buddy system to
ensure that the employee entering the drum storage area is observed
by another designated employee. The purpose of this is to provide
rapid assistance to the employee in the event of an emergency.
• In the event of an emergency, a class D fire extinguisher (Item 4) and
a Lithium Battery Safety Kit should be easily available, but stored
away from the battery storage area.
6.4.6. Inspect the waste cell drum storage area for evidence of cell leakage on at
least a weekly basis as follows:
• Use the buddy system during storage area inspection (see above).
• Review the local Lithium Cell Emergency Response plan, including
identification of backup response personnel.
• Ensure the availability and access of a class D fire extinguisher and a
Lithium Battery Safety Kit.
• Odors, vapors, visible signs of drum deterioration, or the unexpected
presence of fluid flowing out of a drum may be indications of a
venting cell. Implement the local Lithium Cell Emergency Response
plan.
6.4.7. Prepare the drum(s) for shipment.

Caution Vented or damaged cells/batteries are restricted from air or ocean freight.

6.4.7.1. Contact Toxco Waste Management Ltd. or the disposal vendor

and notify the vendor of the intent to ship. (See Section 6.4.1
for International Waste Lithium Battery Disposal Procedure.)
Inform the vendor of the contents and quantity of drums.

Note If shipping cells to Toxco, contact them 30 to 45 days in advance of the

anticipated ship date to allow time for processing of export/import permits,
transfer documents, etc. To avoid substantial government fines and holding
charges, under no circumstances should a shipment to Toxco be made without
the prior consent of Toxco.

6.4.7.2. Contact a shipping agent, either Concord/Combined Logistics

or a local shipper, to schedule pickup; inform the shipper of the
contents and quantity of drums.
6.4.7.3. Obtain a time estimate from the shipper for transport to Toxco
or the disposal vendor.

D00030124 Rev. C Sheet 34 of 49

 6.4.7.4. In accordance with local shipping regulations, complete all the
necessary paperwork and keep a copy of all documents. The
shipping agent will be able to assist in this process.
6.4.7.5. File document copies in the “Lithium Battery Recycling/
Disposal” file for future reference.
6.4.7.6. Affix all required labels to the drum, in accordance with local
shipping regulations.
6.4.7.7. Ensure the drum lid-locking ring is secure.
6.4.8. Ship the drum(s).
6.4.8.1. When the shipper or his agent arrives, complete the shipping
manifest and retain a copy for the file.
6.4.8.2. Ensure that the drum is properly loaded and secured on the
transport.
6.4.8.3. Attach a copy of the Bill of Lading to the existing paperwork in
the “Lithium Battery Recycling/Disposal” file.
6.4.8.4. Notify Toxco or the disposal vendor that shipment has occurred
and provide an estimated date of arrival.
6.4.9. Confirm the arrival of the shipment at Toxco or the disposal vendor.
6.4.9.1. On the anticipated date, contact Toxco or the disposal vendor to
confirm that the shipment has indeed arrived.
6.4.9.2. In the “Recycling/Disposal” file, make a note of the phone
conversation confirming arrival, indicating the time and date of
the call.
6.4.9.3. Request evidence, via facsimile or return mail, of recycling or
disposal (Certificate of Recycling, Certificate of Disposal,
Certificate of Destruction, etc.) as a record of proper
disposition of the waste cells.
6.4.9.4. Receive evidence from Toxco or disposal vendor confirming
proper disposition.
6.4.9.5. When received, attach the “Evidence of Disposition” to the
shipping paperwork in the “Recycling/Disposal” file.
6.4.9.6. Mark “CLOSED” on the paperwork bundle. Sign and date for
future reference.

D00030124 Rev. C Sheet 35 of 49

7. Appendix
7.1. Layout of Cell
The harsh downhole environment in which HES’s tools operate requires a power
source that can withstand both high temperature and a certain degree of mechanical
abuse without sacrificing performance. Lithium batteries/cells are able to work in
this environment. A high-energy lithium cell (Figure 4) consists of the following:

�����������������
������������������������
�������������

����� �������������������
�������������

��� ���������
����� �������

���������

����������������� ����������������

Figure 4

Lithium Foil – (Used as the anode and swagged against the inner wall of the
cylindrical can.) This provides good thermal, electrical, and mechanical contact and
is attractive due to its high potential and light weight. The anodic reaction is the
oxidation of lithium metal to lithium ions. This is the main temperature limit on the
cell. Melting the foil can cause violent vents.
Anode Reaction: Li = Li+ + e-
Carbon – (Used as the cathode.) It is highly porous and acts as a catalyst upon which
the reduction of the thionyl chloride takes place when a load is connected. The
flexibility of this type of cathode ensures a minimum anode-to-cathode distance,
thereby increasing resistance to shock, vibration, and other mechanical properties of
the cell.
Cathode Reaction: 2SOCl2 = SO2 + S + 4Cl– – 4e–

D00030124 Rev. C Sheet 36 of 49

 Electrolyte – (Consists of a solution to provide electrical conductivity.) In most of
HES’s applications, cells with thionyl chloride (SOCl2) are used as the liquid
electrolyte. Other electrolyte formulations can change the open circuit voltage and
operating voltage of lithium cells.
Separator – (The separator between the anode and cathode, made of nonwoven
glass.) This allows ions to pass freely between the electrodes but prevents internal
short circuits from occurring.
Collector – The collector is made of stainless steel and provides the electrical
connection from the carbon cathode to the positive terminal.
7.2. Equipment/Materials

Item # Part Number Equipment/Material Name

1 120137727 Vermiculite Asbestos Free (maintain a bag in battery
rebuild area)
2 120139231 Paper – Litmus pH A–979
3 120140577 Safety Vent Check Tool
4 120140750 Class D Fire Extinguisher
5 120142414 Wrench 9/32" Combo 0X19
6 120142468 Wrench 9/16" Modified CC Bat
7 120143794 Label Battery Shipping CIM
8 120144659 Kit Lithium Battery Safety
9 120149546 Wrench 11/16" Open End
10 REMOVED
11 101419450 Mask
12 120145089 Attachment – Hard Hat Huntsman
13 120145090 Faceshield Universal Acetate
14 120145091 Gloves – Neoprene Edmont (Rubber)
15 120145092 Soft Frame Goggles
16 120145093 Apron – Hycar CPP Inc. BH45M
17 120145094 Sleeves – NeoPrene
18 120145095 Bottle Eyewash
19 120145096 Cup Eyewash Top
20 120145097 Coverall – Large Lakeland
21 120145098 Coverall – X Large Lakeland
22 120145099 Cover Shoe – Lakeland
23 120145115 Extinguishing Powder – Lith-X

D00030124 Rev. C Sheet 37 of 49

Item # Part Number Equipment/Material Name
24 1230159460 Label Lithium Battery Shipping
25 120159545 Label Hazard Class 9
Removed
27 120160899 First Aid Kit Refill Pack
28 120160901 Sodium Bicarbonate Powder 500 g
29 120162344 Bag Roll Sk. ESO
30 120162345 Sealer Bag 12" Wide
31 120162782 Knife X-Acto Chest Kit (These procedures only require
a single knife from the kit.)
32 120163949 Ship Box Assembly Lithium Cells
33 120164662 Drum Open 55 gal D.O.T.
34 120166000 Shipping Box Assembly, CIM Battery
35 120166004 Shipping Box Assembly, MPT/EWR
35a 82147 UN 4G Fiber Board Box
36 120150503 Paper, Emery, 9" x 11" 400 Grit
37 BM Battery Sondes
120165671 Assembly Sonde CC Cell BM SOL 175
75323 Assembly Sonde CC BM Slim SL175
38 Pulser (MPT) Battery Inserts
120148457 Insert Lithium Battery Assembly Full Bore
120159647 Insert Lithium Battery Assembly MPT 9.5"
120164581 Insert Battery Assembly Hi-Flow
120166915 Insert Battery Assembly Full Bore 22 V
120167794 Assembly Battery Full Bore Insert Nonmag
120168046 Assembly Battery Insert 9.5 MPT Nonmag
120173078 Numar Battery Assembly 22 V 8 Stave
90909 Assembly Insert Battery 8" HF BAT
99236 Assembly Insert 25 ksi Battery 22 V
39 SP4 Battery Inserts
120162120 Insert Lithium Battery Assembly 43/4"
120171959 Insert Battery Assembly 43/4" EWR–P4 S175
72093 Insert Assembly 4.75" SOL Battery 25 ksi

D00030124 Rev. C Sheet 38 of 49

 Item # Part Number Equipment/Material Name
40 CIM Battery Inserts
120147425 Insert Lithium Battery Assembly CIM 9 Pocket
120159001 Assembly Lithium Battery CIM 9.5"
120159024 Insert Lithium Battery Assembly CIM/FED 9 CL
120159822 Assembly Lithium Battery CIM (No ISB) 9.5
120161528 Insert Lithium Battery Assembly SLD with Vent
120167419 CIM Battery Insert Assembly 63/4" and 8" (Nonmag)
120173371 Assembly Lithium Battery CTN 8" High-Flow
80958 CIM Battery Insert Assembly 63/4" 25 ksi
89584 Assembly Battery CIM 9.5" Nonmag 25 ksi

7.3. Reference Documents

Item # Reference # Document Title
A B00029 Transportation Data Sheet for Lithium Battery
B B00031 Material Safety Data Sheet for Vermiculite
C P00193 Lithium Battery Safety Procedure
D P00894 Procedure 9 Cell Battery Insert Assembly
E P00900 Procedure Installation and Removal of the Pulser
Battery
F P00965 Full Bore Battery Top Level Assembly Procedure
G P00987 Disassembly Procedure MPT Full Bore Battery
H P01057 CIM FED Battery Insert Assembly Procedure
I P01104 Procedure Installation and Removal of the CIM Battery
J P01109 CIM 91/2" Battery Assembly Procedure
K Shop Floor Maintenance Procedure
L T00356 Shop Rack Procedure

D00030124 Rev. C Sheet 39 of 49

7.4. Contacts
7.4.1. Primary Vendor Contacts
Toxco Waste Management Limited (Recycling)
9384 Highway 22A
Trail, British Columbia, Canada V1R2Y8
Plant Manager: Kathy Charlebois
Phone: (250) 367-9882
Fax: (250) 367-9875
e-mail: toxco@netidea.com

Concord/Combined Logistics
#130 5200 Miller Road
Richmond, British Columbia, Canada V7B1K5
Manager: Graham Cooper
Phone: (604) 270-8554
Fax: (604) 270-0895
e-mail: GCooper@ydr.comlog.net

Kinsbursky Brothers
1314 North Lemon St.
Anaheim, California 92801
Director, Env. Affairs: Paul Johnson
Phone: (714) 738-8516
Fax: (714) 441-0857
e-mail: PJohnson@kinsbursky.com

7.4.2. Notification of Pending Disposal Contacts

ENSCO (Disposal)
Theresa Evans
309 American Oil Road
Eldorado, AK 71730
Phone: (870) 864-3680

Diversified Freight Logistics

ATTN: Robert Rico
P.O. Box 60907 AMF
Houston, TX 77205
Phone: (713) 821-2929
Fax: (713) 821-7009
USERID: EXPDHOU

D00030124 Rev. C Sheet 40 of 49

 Jimmy Santos Customs Brokers (Mexico only)
ATTN:

1202 High Lowe Dr.

Hidalgo, TX 78557

Phone: (956) 843-2761

Fax: (956) 843-2711

7.4.3. List of Global Contacts for Concord/Combined Logistics

Note If your country is not listed, if you have difficulty reaching the individual listed
for your country, or if you merely have shipping questions, please contact
Concord/Combined Logistics headquarters, at the top of the list.

Location Office Telephone Contact

Corp HQ Concord Logistics (604) 270-8554 Graham Cooper
Australia TQM Cargo Logistics 612 9667 3577 Steve Anderson
Bolivia Servin SRL 5912 311651 Juan Luis Mejia
China Beijing Fullcome Int’l 8610 64370312 Robin Lin
Colombia Panatlantic 571 263 9369 Berta Gonzales
Denmark Ace Air Cargo 45 32 860333 Fleming Johansen
Egypt Not Available
Germany Concord (DE) 49614294750 Heino Barthold
Holland Concord 20 653 3806 Francois Muge
Indonesia Pt. Faria Indah 6221 5662159 Wukdab Gibabhar
India Concord Logistics 9122 8380830 R. S. Sandhu
Malaysia Concord Logistics 6046 439348 Ismail
Norway Nor-Air Forwarding 47 67 120 077 Egil Steen-Iverson
N. Zealand C.T. Freight 649 875 1634 Mathew Martin
Oman National Travel 968 566046 Shakti Ghosal
Pakistan Taq Cargo 9221 4541301 Shamsul Khan
Peru Transber SA 511 572-1312 Antonio
Russia Not Available
Saudi Al Awsat Transport 9663 8910036 Ihsan Husseini
Syria Not Available
Thailand Concord Logistics 622 650 8040 Pratan
Tunisia Not Available
UAE Concord Logistics 9714 822444 Derek Kett
Venezuela Concord Logistics 582 731 6113 Natty Moreno
Vietnam TWT Transport 848 822 1396 Daniel You

D00030124 Rev. C Sheet 41 of 49

7.5. Features of Lithium Batteries
7.5.1. General Safety
This cell is hermetically sealed at atmospheric pressure. As a result of its
sealing, gases generated during the reaction are contained by the cell. The
low rate and moderate rate discharge construction reduces the risk of
explosion due to exothermic reactions associated with high-rate discharge
construction.
Other advantages include low sensitivity to shock or vibration and high
reliability.
7.5.2. Cell Design Considerations
The rate of discharge of a cell is wholly dependent on the surface area of
the lithium foil anode. To this effect, there are three different
configurations of the anode: bobbin, split bobbin, and spirally wound
(Figure 5).

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Figure 5

7.5.2.1. Bobbin – The bobbin configuration is used for low-rate cells.

One wrap of lithium foil is swagged against the inside of the
cell wall. The bobbin is the most inherently safe cell to be used
in the case of abusive conditions due to its lower surface area.
The typical discharge rate for low-rate cells is from 1 mA to
100 mA.
7.5.2.2. Split Bobbin (or partial spiral) – The split bobbin configuration
is used for medium rate cells. The lithium foil is placed in the
cell in an out-of-shape S. This increases the anode area by
approximately 50% over the bobbin configuration. The typical
discharge rate for medium-rate cells is between 200 mA and
500 mA.

D00030124 Rev. C Sheet 42 of 49

 7.5.2.3. Spirally Wound – The spirally wound configuration is used for
high-rate cells. The lithium foil is wound into a tight spiral
around a mandrel inside of the cell. This winding greatly
increases the anode; therefore, the cell is capable of sustaining
higher currents and releasing more energy in a given time
frame. High-rate cells may be capable of supplying several
amps of continuous discharge.
7.5.3. Safety Incorporations
7.5.3.1. Fuse
A fuse can be added to the cell to prevent it from discharging at
too high a rate, which could lead to cell overheating and
associated problems. Fuses are included in cells depending on
their design and the design of the battery packs.
7.5.3.2. Diode
To prevent reverse discharging:
A diode may be incorporated into any series string of cells
(stave) in a battery pack having parallel circuits. This will
prevent the discharge of one parallel circuit into another
parallel circuit (reverse charging) if the two parallel circuits
become unbalanced. This is most likely to happen in
applications where the two parallel circuits contain different
date codes and one date code has less capacity than the other.
To prevent forced overdischarge:
Forced overdischarge (pushing current through a spent cell)
can cause a cell to have unpredictable and erratic behavior.
Diodes placed in parallel with individual cells prevent current
from passing through the cell should it reach end of its life
before the adjacent cells do.

D00030124 Rev. C Sheet 43 of 49

7.6. Benefits of Lithium Batteries
7.6.1. High Cell Voltage
Lithium thionyl chloride cells have an open-circuit voltage of
approximately 3.6 V and an operating voltage of 3 V, which is
considerably higher than other commercially available cells. These cells
also have a flat voltage discharge curve, which leads to uniform
performance (Figure 6). Different electrolyte formulations will result in a
variety of open-circuit and operating voltages.
7.6.2. Flat Voltage Discharge Curve
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Figure 6

7.6.3. Wide Operating Temperature Range

The low freezing point and high boiling point of the electrolyte in the
lithium cell enables efficient operation over a wide range of temperatures.
Some cell designs are capable of operation at temperatures ranging from
0°C to 150°C, with particularly good performance in the 25°C to 75°C
temperature range. Others cells are capable of operation from 75°C to
200°C.
7.6.4. High-Energy Density
The lithium cells used by HES exhibit three to six times the energy
density of a typical silver-zinc cell.
7.6.5. Long Shelf Life
The cells HES uses also have an extremely low self-discharge
characteristic, and their hermetically sealed construction requires no
circulation of fluid. These aspects give a projected 10 years shelf life at
room temperature.

D00030124 Rev. C Sheet 44 of 49

8. Lithium Power Source Encyclopedia
Amp Hour – The equivalent of drawing 1 A out of a power source for 1 hour. Cell capacity
and life expectancy are rated by this concept. Cells that provide 0.5 A would require 2 hours
to equal 1 A-hr.
Anode – The negative terminal of a lithium cell.
Battery – A collection of staves, packs, or cells that provide power output at higher voltage
or current levels. A battery is capable of providing more power than a single cell because it
contains cells connected in series (for more voltage), in parallel (for more current), or both.
Cathode – The positive terminal of a lithium cell.
Capacity – The life expectancy of a lithium cell or battery. Capacity is measured by
monitoring the loaded circuit voltage of a lithium cell and performing an A-hr calculation
based on the current draw. A battery is considered at end of life when it reaches a 2.0 V
loaded circuit voltage.

Capacity Testing Done at BEI

Figure 7

D00030124 Rev. C Sheet 45 of 49

Cell – One lithium power source unit. This is the smallest unit capable of acting as a power
source. It contains an anode, cathode, electrolyte, and a container to house the separate parts.
Characteristics include an open circuit voltage of approximately 3.6 V.

Several Cells from Wilson Greatbatch Ltd. Electrochem

Figure 8

Closed-Circuit Voltage – See Loaded Circuit Voltage.

Derate – The calculation for an individual battery pack used to subtract a certain amount of
capacity from the standard value limit of the battery packs. Usually performed by the QC
department when it determines the amount of energy available during incoming inspection.
Electrolyte – A chemical compound which provides the reaction base for the lithium anode
and the cathode. Sulfur chloride and thionyl chloride are some of the more common
electrolytes.

Thionyl Chloride Electrolyte

Figure 9

D00030124 Rev. C Sheet 46 of 49

End of Life – The end of usable energy from a lithium cell. Usually defined as 2 V for a
loaded cell.
External Short Circuit – A short circuit applied to a stave, pack, cell or battery from an
outside source such as salt water, a wire, or any electrically conductive path connecting the
positive and negative terminals.
Hazardous Good – Lithium cells containing more than 0.5 g of lithium per cell, or a battery
containing more than 1 g of lithium. This classification places restrictions on how batteries,
staves, packs, or cells can be shipped, where they can be shipped, and what containers can
ship them. All hazardous goods must be approved for shipment by completing the UN/DOT
transportation testing regime on the device being transported. This includes cell level,
battery, or pack level. Transport is defined as anything leaving the premises, even if it is
being carried across the street or flown out of the country. (See Form, Environmental Safety
Data Sheet Lithium Thionyl Chloride Batteries.)
High-Rate Cell – A lithium cell that has been constructed for a maximum amount of surface
area interaction between the lithium and the electrolyte. This configuration is also called a
“Spirally Wound” cell. This type of cell is capable of providing higher levels of current at
higher voltage levels, and it has a higher capacity than other cell types. This type of cell will
have a much more violent reaction to being mishandled than other cell types. It contains the
largest amount of lithium of all cell types. See also Low Rate and Moderate-Rate Cells.
Internal Short Circuit – A short caused inside of the cell, usually the result of a
manufacturing problem. It can also be induced by severe vibration or shock (outside of the
specification limits). This type of short is not possible to stop and can cause a vent or even a
violent vent.
Lithium – The third element on the periodic table. Extremely reactive in water and melts at
180.5°C. It is the power source for a lithium cell.
Lithium Alloy – A chemical compound that can be used to increase the melting point of the
lithium, allowing lithium cells to reach temperatures above 180.5°C without causing a
violent vent. Examples include lithium-magnesium which is used in the BEI 200°C cells.
Loaded-Circuit Voltage – The voltage reading obtained from a cell while providing power to
a load. The load can include electronics, resistors, or other devices requiring energy to
operate.

D00030124 Rev. C Sheet 47 of 49

Low-Rate Cell – This type of lithium cell is the most common configuration used at HES
(as of 6/23/97). It has the lowest capacity rating and contains the least amount of lithium of
all cell types. It does not contain as much lithium, and its explosive force (violent vent) is
not as great as the others. This cell is also called a “bobbin cell” (Figure 10). See also
Moderate-Rate and High-Rate Cells.

A Bobbin or Low-Rate Cell

Figure 10

Moderate-Rate Cell – The cell lies between the Low-Rate and High-Rate lithium cells in
power, amount of lithium, capacity, and explosive force. It can be designed in three different
ways: the split bobbin (or S configuration), the double bobbin (two concentric cylinders of
lithium connected via a wire), or as a partially spirally wound configuration (just a few
winds, rather than a large number). See also Low-Rate and High-Rate Cells.

A Double-Anode Low-Rate Cell

Figure 11

D00030124 Rev. C Sheet 48 of 49

Open-Circuit Voltage – For a cell, it is the measured potential difference between the lithium
(or lithium alloy) and the electrolyte. For a battery, stave, or pack, it is the measured
difference between the positive and negative terminals. The open-circuit voltage is only
accurate when there is no load attached.
Pack – Similar to a stave, but it comes preassembled from the manufacturer. Usually, it is
self-contained and sealed, preventing access to the individual cells. Sometimes a battery is
referred to as a battery pack because it contains staves or packs that have been assembled at
another location.
Shelf Life – Lithium cells lose energy over time, even while sitting on a shelf. Although it is
largely a function of temperature, lithium cells lose only 2% of their capacity per year
(at 25°C).
Stave – A collection of lithium cells placed in series to increase the amount of usable voltage
without increasing the current levels. Usually, a stave can be disassembled, which allows
access to the individual cells, and can be used with different cells.
Toxic Fumes – When a lithium cell vents, it releases several gasses. These gasses are a result
of the chemical reactions in the cell during discharge which allow it to provide energy to a
load. These gasses include HCL, SO, SO2, and others. These are all deadly and corrosive
fumes which can rust metal and cause severe lung damage if inhaled. See the safety
documentation page regarding how to respond to these fumes.
Vent – A break in a lithium cell container allowing the thionyl chloride and some toxic
fumes to be extruded. This causes a strong odor (like paint thinner) and can lead to a violent
vent. The corrosive properties can damage other nearby cells, causing them to vent as well.
Violent Vent – An explosive release of the internal components of a lithium cell. Usually
accompanied by a fireball, toxic fumes, lithium fires, molten lithium, and shrapnel. This is
usually a result of over temperature exposure or an external short, both cause the cell to heat
up internally and exceed the melting point of the lithium or the lithium alloy (Figure 12).

Cells after a Violent Vent in the FE Lithium Battery Lab

Figure 12

D00030124 Rev. C Sheet 49 of 49