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Industrial Battery Safety |
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Lead acid batteries are the most popular source of power for moving
materials and personnel. They power equipment in manufacturing,
warehousing, transportation and mining applications. Unlike many other power sources, batteries produce power without noise or hazardous emissions. They perform so quietly that it is easy to overlook their safety hazards. It is easy to deal with these hazards when they are recognized and when trained and properly equipped personnel operate and service them. All power sources (gasoline, propane, natural gas, electricity, storage batteries) represent potential safety and health hazards to those that operate them. The major risk with any power source is the sudden and unanticipated release of power outside the intended power flow path. This unplanned and sudden release can cause damage to equipment and injury to operators. Properly operated and serviced industrial batteries are a very safe stored power source. They provide reliable and affordable power, and offer a long service life. Typically, industrial motive batteries can provide as much as six years of service and hundreds of use cycles. When replacement of a battery is finally necessary, 97 percent of the materials in the battery can be recycled for additional productive use. Batteries are a cost-effective and environmentally responsible power choice. Combustible energy sources cannot make claims of environmental responsibility, and introduce some serious safety and health hazards. Large batteries are electro-chemical power generating devices. Batteries represent both chemical and electrical exposure hazards to those that service and operate them. Most batteries in use today are lead acid batteries. Dilute sulfuric acid is the electrolyte. Dilute sulfuric acid is a corrosive that can cause skin and eye injuries. Material handling batteries range in voltage from 24 volts for a pallet-jack to 72 volts or more for heavy-duty material handling equipment. Battery chargers are usually 220 volts. The amperage associated with these voltages is more than enough to cause electric shock. The lead exposure hazard is limited because most of the lead and lead compounds are inside the battery cells. Exposure to lead occurs when doing service work inside the battery cells. A battery service specialist is equipped to safely work inside a battery cell. Battery Fires and Explosions Batteries can and do explode and catch fire. While battery fires and explosions are not usual, they are possible. There are simple safety steps that dramatically reduce these risks. The most obvious of these would be the elimination of combustion causing and combustion supporting hazards on or around the batteries. Open flames or sparks can cause an explosion if the hydrogen level around the batteries exceeds the lower explosive limit of hydrogen gas. That limit is four percent. Batteries generate most hydrogen in the final stages of recharging. By design, in order to avoid pressurizing the battery cell, some hydrogen escapes the battery through the vent holes in the cell cap. Electric Shock In the operation of high voltage batteries and chargers, there is a risk of electric shock. Both AC in the charger and DC in the batteries can cause shock injury. There are simple steps to take to minimize the risk. Immediately remove and replace frayed cables and damaged cable plug connectors. Employ the industry standard for cable sizing and connector plug color-coding to avoid voltage mismatching and electric arcing. Color-code the connector plug housings and use of red positive and black negative cables. Replace damaged or missing plastic insulators. Exposed lead inter-cell connectors conduct current and are a shock hazard. The snap-on plastic insulators (called shrouds) provide real protection to the battery and to personnel. Batteries are stored power devices. Even an apparently fully discharged battery retains enough amperage to cause injury. OSHA requires the use of certified, insulated tools where 50 volts or more may be present. Avoid the use of conductive tools by using only tested and certified insulated service tools. It is also advised when operating batteries, do not wear metal finger rings and other jewelry. These are a few measures to prevent electric shock. Electrolyte Exposure Avoid exposure to battery electrolyte, usually dilute sulfuric acid. Sulfuric acid is an aggressive corrosive chemical. Avoid breathing an acid mist or having it contact eyes or skin. It is an extreme irritant and it can do permanent damage. Splash-proof goggles and full-face shields along with chemically resistant aprons, gloves and boots are the best defense. Exposure to acid is most likely when moving batteries into or out of the battery stands or when they are being rewatered or re-charged. Be sure to replace damaged or missing cell caps to eliminate acid splashing out of the cells. OSHA requires an eyewash station with 15-minute capacity be located within ten seconds of unimpeded travel from where the exposure risk is greatest, the battery transfer and charging area. If acid is splashed in the eyes or on skin, there is no time to go searching for an eyewash unit. Large acid spills are most likely to occur when moving or re-watering your batteries. As is true with any spill of a hazardous chemical, only those trained in spill clean up should perform this task. Keep a spill kit specifically designed for acid spills in the battery area. Use an acid spill absorber and neutralizer and the required personal protective equipment. Avoid the use of baking soda or soda ash. Both of these produce a vigorous reaction that can produce an asphyxiating cloud of carbon dioxide. Neither is able to absorb the spill. We find another exposure risk in the acid that can contaminate the top of the battery. That acid also produces acid shorts that slowly drain the battery and produce disruptive shorts when the battery is in the vehicle. Use a special purpose battery cleaner/neutralizer periodically to eliminate this hazard. Do not use baking soda, it has no cleaning power and when it accumulates between the cells, it causes shorts, performance and service problems. Moving and Dropping Moving batteries between the vehicle and the recharge location can result in dropping or tipping a battery. Big batteries can weigh hundreds of pounds. If dropped, a big battery can easily cause a crushing, bone breaking injury. Proper and affordable battery handling equipment is available for every size and type of battery, and its use dramatically reduces the risks. Inadequate battery handling equipment can cause serious damage to the batteries. Battery handling equipment also improves the ease of battery changing and can reduce the number of batteries required to support equipment operation. Procedures Help Do not overlook the battery area when making a facility wide effort to improve safety. Here are some steps to take. 1.) Inspect the area with an expert. The company that provides your batteries can provide the required expertise. 2.) Train employees in the safe operation of batteries and chargers. Forklift driver training often does not adequately cover battery safety. 3.) Establish procedures and monitor for compliance. Post them on the wall if necessary. Be sure to have material safety data (MSDS) in the area for the batteries, acid, and any chemical cleaners and neutralizers used there. Post safety signs appropriate to a battery and charger area. 4.) Provide personal protective equipment and monitor its condition and use. 5.) Equip the battery area with fire extinguisher, eyewash station, acid spill kit, and plug or connector lockout with lock and key. It is smart to operate batteries and chargers safely. There is additional good news. When your battery program keeps the operators safe, the batteries perform better and last longer. What is good for the operator is good for the battery too. FSM Bill Ramsey is president of Battery Protectors. The company offers battery care chemicals, neutralizers, acid mats, spill kits, personal protective equipment, service tools, battery replacement cables and repair parts. Learn more at www.batteryprotectors.com. FSM |
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