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BLRs Safety Training Presentations

Battery Safety
29 CFR 1910.178(g) 29 CFR 1910.305(j)(7) 29 CFR 1917.157

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Goals
Battery hazards, storage, and charging Battery maintenance, PPE, and emergencies Quiz

11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Battery Hazards
Battery acid Flammable gases Electrical shock Heavy weight

11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Typical Battery Cell


Positive (+) and negative (-) plates Electrolytesolution of sulfuric acid and water 2 volts of power Vent cap

11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Battery Discharges
Acid becomes weak and cannot produce a current Connect battery to AC source for charging Acidity of electrolyte is restored
11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Battery Cycle
One discharge and one charge Limited cycles Maximize battery life with a full discharge and full charge

11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Charging and Storage Locations


Designated area Adequate ventilation Equipment for spilled electrolyte Fire protection Emergency shower and eyewash Protection for charging apparatus
11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Battery Handling
Handling heavy batteries Vent caps in place Conveyor Overhead hoist Insulated equipment

11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Lift Trucks
Position trucks properly Apply parking brake Turn off ignition Turn off lights and accessories Disconnect battery from lift truck

11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Battery Charger
Match charger to battery Verify voltage and capacity Check that charger is grounded or double insulated Be sure vent caps are in place Turn charger off before connecting to battery Open battery compartment cover
11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Reinstall Batteries
Avoid battery contact with walls or components Position properly in the lift truck Secure in the lift truck Battery restraint system

11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Goals
Battery hazards, storage, and charging Battery maintenance, PPE, and emergencies Quiz

11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Battery Maintenance
Inspect connectors Keep the battery clean Keep the battery cool Do not overcharge

11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Vent Caps
Allow gases to escape Hold electrolyte in Keep foreign material out Should be kept in place at all times

11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Hydrometer
Measures density of electrolyte Fully charged will read 1.290 Discharged will indicate 1.120 Measure 2 or 3 cells after charging
11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Adding Electrolyte or Water


Add water or electrolyte only after charging Charging increases electrolyte level Handle electrolyte with a carbon filter or a siphon Slowly add water to electrolyte Wear correct PPE

11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

PPE
Goggles Face shield Rubber gloves Rubber apron

11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

No Smoking
Do not smoke in charging areas Hydrogen gas is produced Prevent open flames, sparks, welding Utilize ventilation

11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Metal Tools
Keep metal tools away from batteries Dont lay metallic objects on top of batteries Short circuits could cause sparks
11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Emergencies
Acid spill kit Neutralizing solution Emergency shower and eyewash station First aid

11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Battery Installation
Ventilation Grounding

11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Goals
Battery hazards, storage, and charging Battery maintenance, PPE, and emergencies Quiz

11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Summary
Hydrogen gas is given off during charging Vent caps release gas and contain electrolyte Batteries should be inspected regularly PPE should be worn Electrolyte spills should be cleaned up immediately

11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Quiz
1. What kind of flammable gas is given off during recharging? 2. Electrolyte expands during the charging process. True or False 3. Name two reasons for making sure vent caps are in place. 4. What PPE should be worn when cleaning the battery or checking electrolyte? 5. Before disconnecting the battery from the forklift, turn off the ignition and all accessories. True or False
11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Quiz (cont.)
6. What can be used to neutralize an electrolyte spill? 7. What could happen if metal objects are placed on top of a battery? 8. What should you do if you get electrolyte on your skin? 9. What does OSHA require a battery installation to have? 10. Smoking is OK when batteries are not being charged. True or False

11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Quiz Answers
1. Hydrogen gas 2. True 3. Vent gases, contain electrolyte, keep dust and dirt out of cells 4. Goggles, face shield, rubber gloves, rubber apron 5. True

11006134/0212 Copyright 2002 Business and Legal Reports, Inc.

Quiz Answers (cont.)


6. Baking soda 7. Short circuit and cause a spark or other damage 8. Wash your skin with soap and water for at least 10 minutes 9. Ventilation 10. False, smoking is never allowed in battery storage and charging areas.

11006134/0212 Copyright 2002 Business and Legal Reports, Inc.