Battery Safety and Handling

EFCOG Electrical Safety Task Group

Module 9

09/06/07 EFCOG Electrical Safety Task 1

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 Lead Acid Batteries
• Typically Lead-
Antimony.
• Made up of plates,
lead, lead oxide with
35% sulfuric acid and
65% water solution.
• The solution is called
electrolyte, which
causes a chemical
reaction that produces
electrons.

09/06/07 EFCOG Electrical Safety Task 2

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 Cell Element
Sepa ra tor

N eg a ti ve
Posit ive
Pl at e Group
Pl at e Group

09/06/07 EFCOG Electrical Safety Task 3

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 Hazards Associated With
Industrial Batteries
Hydrogen Gas

Sulfuric Acid

Shock

Weight of the Battery

09/06/07 EFCOG Electrical Safety Task 4

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 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.

09/06/07 EFCOG Electrical Safety Task 5

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 Acid Hazards

Ph <2 (Typically Sulfuric Acid)

Corrosive material
Burns to skin
Burns to eyes
Never open the battery caps with your
face directly over the battery.

09/06/07 EFCOG Electrical Safety Task 6

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 Electrical Hazard
• Exposed terminals, even on disconnected
batteries, present an electrical shock hazard.
• Some battery systems are capable of discharging
at extremely high rates of current. Accidental
shorting of terminals or cables can result in
severe electrical arcing, causing burns and
electric shock to nearby personnel

09/06/07 EFCOG Electrical Safety Task 7

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 Electrical Safety Precautions
 Never touch both battery terminals with your
bare hands at the same time!
 Remove rings, watches and dangling jewelry
when working with or near batteries. The metal
in the jewelry can cause a shock or burn if they
contact the battery terminals.
 Only use insulated/non-conducting tools to
remove cell caps. Never lay tools or other metal
parts on top of a battery.

09/06/07 EFCOG Electrical Safety Task 8

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 Electrical Safety Precautions
 Consider covering battery terminals and
connectors if possible with an insulating blanket
before overhead inspections or repairs

 Ensure charger is turned off before connecting or

disconnecting a battery to prevent arcing

09/06/07 EFCOG Electrical Safety Task 9

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 Electrical Hazard
• DOE Event-Worker lost
control of a jumper wire
while working above
battery bank
• Ends of jumper were not
insulated and blanket
was not installed over
battery terminals
• Event resulted in severe
arcing and potential for
injury to worker

09/06/07 EFCOG Electrical Safety Task 10

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Fire and Explosion Precautions
 Do not smoke in battery charging areas.
 Prevent open flames, sparks or electric arcs in battery
charging areas.
 Do not strike the sides of the battery with any spark
producing item.
 Keep tools and other metallic objects away from
uncovered batteries.
 Have an ABC dry chemical fire extinguisher in charging
areas or readily available.

09/06/07 EFCOG Electrical Safety Task 11

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Fire and Explosion Precautions
 Neutralize static buildup just before working on battery
by contacting nearest grounded surface

 Ensure battery area ventilation is operating prior to

working on

09/06/07 EFCOG Electrical Safety Task 12

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 Battery Explosions
• DOE Event-This
starting battery
exploded during a
load test for a diesel
generator
• Explosion can expel
debris and battery
acid resulting in
burns and injury to
nearby personnel
09/06/07 EFCOG Electrical Safety Task 13
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 Handling Battery Acid
• Use extreme caution when handling electrolyte and keep an acid
neutralizing solution—such as baking soda readily available

• Always wear proper eye, face and hand protection.

• Use non-metallic containers to handle liquid

• If the electrolyte is splashed into an eye, immediately force the eye

open and flood it with clean, cool water for at least 15 minutes. Get
prompt medical attention.

09/06/07 EFCOG Electrical Safety Task 14

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 Handling Battery Acid
• If electrolyte is taken internally, drink large quantities of water or
milk. DO NOT induce vomiting. Call a physician immediately.

• Neutralize with baking soda any electrolyte that spills on a vehicle

or in the work area. After neutralizing, rinse contaminated area
clean with water.

• To prepare electrolyte of a desired specific gravity, always pour the

concentrated acid slowly into the water; DO NOT pour water into
the acid. Always stir the water while adding small amounts of acid.
If noticeable heat develops, allow the solution to cool before
continuing to add acid.

09/06/07 EFCOG Electrical Safety Task 15

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 Changing Batteries
 Industrial batteries used to power mobile
equipment can weight upwards of 1,500 lbs.

 Ensure the battery is securely locked in place prior

to pulling away from the battery changing area.

 Do not attempt to stop a battery if it slides out of

the equipment.

09/06/07 EFCOG Electrical Safety Task 16

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 Changing Batteries
 Work on Batteries requires Non-Sparking and
Insulated tools.
 Insulation must be listed for the voltage present
 Taped wrenches are not listed

 Batteries should never be lifted by the post.

09/06/07 EFCOG Electrical Safety Task 17

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 Safe Handling of Batteries

 Use appropriate equipment to load/unload batteries

from mobile equipment.
 Ensure you are trained in using the loading equipment.
 Keep tools and other metallic objects away from
uncovered batteries.
 Use Baking Soda or cleaning agent specified in AHA to
neutralize spilled acid.

09/06/07 EFCOG Electrical Safety Task 18

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 Jumping a Discharged Vehicle
Battery
• When jump starting a vehicle, always wear proper eye
protection and never lean over battery.

• Inspect both batteries before connecting booster cables.

Do not jump start a damaged battery.
• Be sure vent caps are tight and level.

• Make certain that the vehicles are not touching and both
ignition switches are turned to the OFF position.
• Refer to the vehicle owners' manual for other specific
information.

09/06/07 EFCOG Electrical Safety Task 19

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 Jumping a Battery

09/06/07 EFCOG Electrical Safety Task 20

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 Battery Jumping Sequence
• Connect positive (+) booster cable to positive (+) terminal of
discharged battery.

• Connect other end of positive (+) cable to positive (+) terminal of

assisting battery.
• Connect negative (-) cable to negative (-) terminal of assisting
battery.
• MAKE FINAL CONNECTION OF NEGATIVE (-) CABLE TO
ENGINE BLOCK OF STALLED VEHICLE, AWAY FROM
BATTERY.
• Start vehicle and remove cables in REVERSE order of connections.

09/06/07 EFCOG Electrical Safety Task 21

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 PROTECTIVE CLOTHING
General Requirements for Handling

For general handling of

batteries with terminal
post taped

PPE Requirements:
• As specified in local
AHA or procedure

09/06/07 EFCOG Electrical Safety Task 22

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PROTECTIVE CLOTHING Requirements
for Electrolyte Handling
PPE Requirements:
• Safety Glasses/goggles
• Rubber Gloves
• Face Shield
• Chemical Apron
• Boots

09/06/07 EFCOG Electrical Safety Task 23

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 Safety Eye Wash & Shower
Requirements
•An eyewash facility should be capable of
flushing both eyes simultaneously for fifteen
minutes and a water hose or safety shower
that, if portable, is capable of drenching the
body.
•Eyewash and drenching facilities are to be
located as close to the point of exposure as
possible of battery handling areas (not to
exceed 25 ft.) (OSHA)

•If Acid comes in contact with eyes, flush for 15

minutes and report to medical immediately.
• If acid comes in contact with skin or clothing,
rinse off for several minutes and try not to spread
the electrolyte. Report to medical after rinsing.

Note: Eyewash and drenching facilities are not required for non-vented
batteries.
09/06/07 EFCOG Electrical Safety Task 24
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 Battery Safety

Know the Hazards

Use the required PPE
No Open Flame

09/06/07 EFCOG Electrical Safety Task 25

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