SAFETY PRECAUTIONS FOR HANDLING BATTERIES

H S SEHGAL
 What is a Battery?
• A device that stores electrical energy in the
form of chemicals and by means of
electrochemical reaction,
• Converts stored chemical energy into direct
current (DC) electric energy.
• Alessandro Volta, an Italian Physicist,
invented the first battery in 1800.
• Batteries have become a very important
source of energy in the last decade or so.
 Cell and Battery
• Basic electrochemical unit responsible for the actual
storage of energy is called a Cell.
• A battery often consists of one or more “cells” that are
electrically connected in either a series or parallel
configuration to provide the necessary voltage and
current levels
A cell typically contains three main components:
• Two electrodes
• Electrolyte
• Terminals, separator and a container.
• Two types of electrodes called the Anode and the
Cathode
• Anode is the negative electrode
• Cathode is the positive electrode
 Types of Batteries
Two types:
• Primary (non-rechargeable)
• Secondary (rechargeable)
Primary Batteries
• Source of power for several portable
electronic and electrical devices like lights,
cameras, watches, toys, radios etc.
• Cannot be recharged electrically,
• “use it and when discharged, discard it”
 Types of Batteries
Battery Type Characteristics Applications
Zinc – Carbon Common, low cost, variety of Radios, toys, instruments
sizes

Magnesium (Mg/MnO2) High capacity, long shelf life Military and aircraft Radios

Mercury (Zn/HgO) Very high capacity, long shelf life Medical (hearing aids,
pacemakers), photography

Alkaline (Zn/Alkaline/MnO2) Very popular, moderate cost, high Most popular primary batteries
performance

Silver/Zinc (Zn/Ag2O) Highest capacity, costly, flat Hearing aids, photography, pagers
discharge

Lithium/Soluble Cathode High energy density, good Wide range of applications with
performance, wide temp range capacity between 1 – 10,000 Ah

Lithium/Solid Cathode High energy density, low temp Replacement for button and
performance, long shelf life cylindrical cells

Lithium/Solid Electrolyte Low power, extremely long shelf Memory circuits, medical
life electronics
 Secondary Batteries
• Called Rechargeable Battery
Secondary batteries used in two ways.
• First category - Energy storage devices where they are
electrically connected to a main energy source and also charged
by it and also supplying energy when required.
• Examples - Hybrid Electric Vehicles (HEV), Uninterrupted Power
Supplies (UPS), etc.
• Second category - Those applications where the battery is used
and discharged as a primary battery.
• Once it is completely discharged (or almost completely
discharged), instead of discarding it, the battery is recharged with
an appropriate charging mechanism.
• Examples - Modern portable electronics like mobiles, laptops,
electric vehicles, etc.
• Energy Density of secondary batteries are lower than that of
primary batteries
• Good characteristics like high power density, flat discharge
curves, high discharge rate, low temperature performance.
 Common Secondary Battery Types
Four major types are:
• Lead – Acid Batteries
• Nickel – Cadmium Batteries
• Nickel – Metal Hydride Batteries
• Lithium – Ion Batteries
 BATTERIES HAZARDS
• Handling, transporting and installing pose
different threats to personnel and property.
Hazards associated :
• Caustic and/or acid burns
• Hydrogen gas accumulation and explosion
• Electric shock
• Potential high currents, arcing, burns, and
fire
• Battery charging installations located in areas
designated for that purpose.
 Hydrogen Gas
• A by-product of the battery’s 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
 RISK OF EXPLOSION
• The gases released from all lead acid batteries have the
potential to be explosive.
• Ignites battery - Sparks, cigarettes or open flames.
• To minimize risk of potential injury, wear protective gear
such as goggles, gloves and face shields when working
around a battery.
• Never lean over a battery while in use whether you are
charging, jumping or connecting/disconnecting the battery.
• Circuit terminals on the battery are always conducting
currents.
• Never try to create a spark by breaking or tampering with
the battery terminals.
• Make sure the cables are in good working condition
• Poor connection could result in an electrical arc
 Sulfuric Acid
Hazards
• Ph <7
• Corrosive material
• Burns to skin
• Burns to eyes
• Never open the battery caps with your
face directly over the battery.
 Handling Battery Acid
• Battery acid, or electrolyte, is a solution of sulphuric acid and water that can
destroy clothing and burn the skin.
• USE EXTREME CAUTION WHEN HANDLING BATTERY ACID
• Keep an acid-neutralizing solution — such as baking soda or household ammonia
mixed with water — readily available. When handling batteries:
• Always wear proper eye, face and hand protection.
• 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.
• If electrolyte is taken internally, drink large quantities of water or milk.
• DO NOT induce vomiting.
• Get prompt medical attention.
• 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 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.
 Battery Use and Storage
• Enclosure of lead-acid batteries MUST be adequately
ventilated.
• Ventilation depends on the size and type of the
batteries, temperature, and the amount of current
used to charge them.
• Follow manufacturer’s recommendations for handling
and venting.
• Do not install any spark producing components
(relays, switches, etc) in the same enclosures or in
close proximity to the lead-acid batteries.
• Guarantee that there is minimal chance of accidental
shorting during routine maintenance and use.
• Insulated tools be used to reduce the risk of a short.
• Remove rings, necklaces or other metal that could
accidentally contact the battery terminals.
 Battery Use and Storage
• To insure a safe work area.
• Over current devices such as fuses or circuit
breakers should be place as close to the batteries
as possible and the wire size used should be large
enough to handle any over current surges.
• Do not place electrolyte or gel containing batteries
where they may freeze and subsequently crack
releasing hazardous materials to the environment.
• Use secondary containment for any battery other
than a non-spill able type.
 Battery Charging
• Battery charging produce explosive gases and an
electrolyte film may form on top of the batteries.
• Adequate ventilation required for all lead-acid and gel
battery charging operations to avoid build up of
flammable gas.
• No smoking or open flames or ignition sources should
be present in a battery charging area.
• Presence of an electrolyte film can cause an acid burn
and also act as a conductor to transmit a charge to any
grounded source.
• This film be removed using a neutralizer.
• Always check wet battery electrolyte levels before and
after charging to guarantee it is at a safe level.
• “Dry” charging can cause a fire or explosion.
 Lithium Battery Powered Devices
• Lithium cells provide sustained power and often
have the capability to recharge .
• Lithium batteries are normally safe .
• Cause injury if they have design defects.
• Made of low quality materials.
• Assembled incorrectly.
• Used or recharged improperly, or are damaged
• Workers who wear or frequently handle lithium-
powered devices or batteries are particularly at
risk if a lithium battery catches fire or explodes
since the device or battery is close to the body.
 Damage to lithium batteries
• Physical impacts that can damage lithium batteries include
dropping, crushing, and puncturing.
• Damage to all types of lithium batteries can occur when
temperatures are too high (e.g., above130°F).
• External heat sources (e.g., open flames, heaters, etc.) can
also accelerate failure in cells with defects or damage from
other causes.
• Damage to lithium-ion batteries can occur when the
batteries themselves or the environment around the
batteries is below freezing (32°F) during charging.
• Charging in temperatures below freezing can lead to
permanent metallic lithium buildup (i.e., plating) on the
anode, increasing the risk for failure.
• Charging a device or battery without following
manufacturer’s instructions may cause damage to
rechargeable lithium-ion batteries.
 Prevention
• Ensure lithium batteries, chargers, and associated
equipment are tested in accordance with an appropriate
test standard (e.g., UL 2054)
• Certified by a Nationally Recognized Testing Laboratory
(NRTL).
• Follow manufacturer’s instructions for storage, use,
charging, and maintenance.
• When replacing batteries and chargers for an electronic
device, ensure they are specifically designed and approved
for use with the device and they are purchased from the
device’s manufacturer or a manufacturer authorized
reseller.
• Remove lithium-powered devices and batteries from the
charger once they are fully charged.
• Store lithium batteries and devices in dry, cool locations.
 Prevention
• Avoid damaging lithium batteries and devices.
• Inspect them for signs of damage, such as bulging/cracking,
hissing, leaking, rising temperature, and smoking before
use, especially if they are wearable.
• Immediately remove a device or battery from service and
place it in an area away from flammable materials if any of
these signs are present.
• If batteries are damaged, remove them from service, place
in fire resistant container (e.g., metal drum) with sand or
other extinguishing agent, and dispose in accordance with
local, state, and federal regulations.
• Contact a local battery recycling center for disposal
instructions.
• Follow manufacturer’s guidance on how to extinguish small
battery fires, which could include using ABC dry chemical
extinguishers, Class D fire extinguishers (for lithium-metal),
dirt, or sand.
 PRECAUTIONS IN HANDLING
• Avoid bringing metal into contact with batteries. Metals like--
Metal tools , Hoist chain , Jewelry, Watches etc Belts.
• Metal conducts electricity. Anyone touching a metal object as it
comes into contact with the battery runs the risk of electrocution.
• Never allow both terminals to make contact with an item
(particularly yourself) simultaneously.
• When both terminals are engaged, an electrical current will pass
through anything touching them.
• Do not hand-guide batteries during lifting/moving process.
• Puts in danger if the battery were to drop or shift.
• Touching the battery proves a danger due to electrical shock or
bring into contact with corrosive battery acid.
 PRECAUTIONS IN HANDLING
• Practice safe and appropriate lifting procedures.
• Do not bring unprotected hands into contact with the
battery throughout the moving process.
• Use only specified lifting equipment designed for this
purpose and approved for the battery’s weight.
• Risk of damaging the battery or lifting equipment.
• Wear protective equipment when handling batteries
including gloves, eyewear and hardhat.
• Gloves and protective eye gear are to guard against
battery acid while a hard hat is important during the
lifting process in case a battery swings or falls.
 PRECAUTIONS IN HANDLING
• Batteries can be dangerous when mishandled.
• Not only are these batteries large and heavy objects
that can cause severe injury and damage if dropped.
• Battery acid is extremely corrosive and can cause
severe burns to the skin or corrode equipment that it
comes into contact with.
• Touching batteries without proper equipment and
preparation can result in high-voltage electric shocks.
• All personnel working with batteries should first be
trained in the proper lifting and handling procedures.
• Good practice to regularly remind workers of
appropriate battery handling procedures in order to
maintain a safe working environment.
 BUTTON BATTERIES
• Button batteries are commonly used today
• Dangerous to children.
• Button batteries are round small batteries that are used in a
variety of devices such as:
• Remote controls
• Games
• Toys
• Hearing aids
• Calculators
• Bathroom scales
• Musical greeting cards
• Key fobs
• Ornaments
• Electronic jewelry.
 HAZARDS WITH BUTTON BATTERIES
• If these small batteries are swallowed or are
placed in the nose or ear, serious injury can occur.
• Once placed in the body, these little batteries
send out a current that begins to burn the body.
• If your child swallows a button battery, watch for:
• Fever
• Irritability
• No interest in eating or drinking
• Throat pain
• Vomiting.
 Battery Safety Tips
1. Adhere to manufacturer’s instructions and
recommendations.
2. Periodically check toys for leaking batteries or
corrosion around the battery posts.
3. Don’t mix and match batteries. Replace all
batteries in a device at the same time with like
batteries.
4. Don’t do what my brother and I tried when we
were kids. Don’t crush batteries with a hammer or
try and light them on fire.
5 . Store batteries out of reach from small children.
 Rechargeable battery safety tips
Don’t overcharge.
• Read the instruction on how long batteries should
charge.
• An automatic shutoff when the batteries reach full
charge.
Charge nearby.
• Plug in the charger near you.
• Keep an eye on them.
• A battery fire could occur very quickly if for some
reason the batteries overheat.
Good ventilation.
• Appropriate airflow around the charger.
• Keep the charger out of direct sunlight.
 Rechargeable battery safety tips
Don’t mix and match.
• Don’t use different rechargeable batteries in your
devices or charger.
• When it is time to change the batteries, replace them
all at once with new batteries of the same type.
• Don’t put a variety of batteries in the charger.
• Each charger is made for a specific battery type.
Recycle.
• When your rechargeable batteries reach their end of
life, don’t just throw them in the garbage.
• Electronic stores near you may collect them and
dispose of them properly.
 Smart phone charging safety tips
Genuine Parts.
• Charge your phones with genuine parts or reputable
alternative brands.
• A cheap cord may not be the best for your phone.
Stay out of bed.
• Avoid charging your phone between your blankets.
• This can lead to a fire.
Don’t drain your phone.
• To prolong your battery life, try to keep your battery
between 50 and 80 percent.
• Don’t let your phone drain down to zero.
• Charging your phone often from 0 percent to 100
percent is hard on the battery and could reduce its life
expectancy.
 Safety Tips With Industrial Batteries

No smoking, sparks, naked flames or welding in close

proximity to battery charging
It may seem slightly obvious but having any naked flame or
spark near a battery charging station is an immense ignition
risk, which could result in a major explosion.
 Safety Tips With Industrial Batteries

Ensure battery cover is open during charging

As batteries emit hydrogen gas during charging adequate
ventilation is needed to disperse the gas otherwise it can
build up in high concentration and become an ignition risk.
Opening the battery cover will provide sufficient ventilation
 Safety Tips With Industrial Batteries

Keep vent caps on during charging

The vent caps have their own vents in them for allowing gas
to escape.
If the caps are open or removed, droplets of acid and water
will form on the top of the battery causing electrical shorts
to the case and frame of the battery.
This can lead to hard to trace problems with your lift truck.
 Safety Tips With Industrial Batteries

Always switch charger off before disconnecting battery

It is imperative that all chargers are switched off before you
disconnect a battery as live electricity can spark and become
a source of ignition.
 Safety Tips With Industrial Batteries

Never unplug battery by pulling leads, always hold plug

Pulling leads out of a battery will eventually damage the
leads
 Safety Tips With Industrial Batteries

Always allow charger to complete charge cycle

Disconnecting a battery before a charge cycle is finished
when using a standard type charger can damage battery
performance, thus reducing overall battery life.
 Safety Tips With Industrial Batteries

Ensure battery top is clean and dry at all times

Top of the battery is clean and dry at all times as
If it wet when connected to charge it becomes an
electrocution hazard.
Self-discharge due to voltage tracking.
Lead to an over discharged battery condition when return
from extended shutdown periods.
Clean charging points ensure a proper connection and that
the battery charges correctly.
 Safety Tips With Industrial Batteries

Never discharge battery below 80% of its rated capacity

•Lead acid traction battery is rated to either 1200 or 1500 cycle to 80% depth of discharge.
•When the battery is discharged beyond 80% the life cycle expectancy is significantly reduced,
instead of lasting at least 5 years (single shift, 5 day a week operation), your battery may only
last 2.
•Over discharging also causes electrical issues with your lift truck, overheating electrical
circuits, bowing fuses etc.
•Charger will not recognize the battery for a recharge
•Need expensive battery repairs.
 Safety Tips With Industrial Batteries

Always allow appropriate cooling period for battery

A proposed cooling down period should be observed as the
battery temperature increases under charging.
•Potential hazard if it overheats;
•Significantly reduces the life of the battery
 Safety Tips With Industrial Batteries

Inspect battery, leads and plugs for damage, report any

faults immediately
•A thorough inspection of all charging equipment conducted
before each charge to ensure a proper charge is completed.
•Damaged equipment lead to faults within the charging
process.
 Safety Tips With Industrial Batteries

If no auto equalize charge, ensure battery is equalized at least once a month

Battery is made up of multiple 2V cells
linked together to form a required voltage, 24, 36, 48 etc
Each of these cells are individuals, they charge and discharge at different rates.
After a period of time, you will end up with varied voltages where some cells are fly charge,
some half charged and some flat.
If this is not controlled, your battery will fail early.
This is where equalize charging comes in.
Depending on your work application, the equalize requirements will be different.
An equalize charge instigates at a timed period after a full charge has completed, usually on a
weekend.
A low current charge will occur for a set period of time.
A low current is utilized so the fully charged cells do not get overcharged too much whilst the
lower cells are catching up.
 Safety Tips With Industrial Batteries

Only top up once battery is fully charged

During discharge the electrolyte is absorbed into the plates, this effect
is reversed when the battery is charged.
If the battery is topped up at any stage other than fully charged you
risk the battery spilling acid out during the next charge/charges.
The reason we top up batteries is to replace the liquid that has
evaporated during the charge cycles, not replace the liquid that has
been absorbed into the plates during discharge.