working precautions for work around battery plant electrolyte

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# Forklift Trucks - Batteries (cont.) ## Why is it important to follow safety procedures when charging batteries? (cont.) NOTE: This OSH Answers document provides general guidance for industrial lead-acid batteries used to operate forklifts and is not meant to replace the requirements from the manufacturer or legislation. ## Why should you follow safety precautions when charging batteries? Lead-acid batteries contain sulfuric acid. Only trained and authorized personnel should handle them. When talking about lead-acid batteries, people usually call sulfuric acid "battery acid" or the "electrolyte". An electrolyte is a general term used to describe a non-metallic substance like sulfuric acid or salts that can conduct electricity when dissolved in water. Lead-acid batteries can produce explosive mixtures of hydrogen and oxygen gases when they are being charged. Note that in some cases, hydrogen gas has been found to interfere with carbon monoxide detectors. Check with your detector manufacturer(s) for more information. - Charge batteries only in approved, well-ventilated battery-charging areas. - Install a safety shower and an eyewash station in a battery-charging area. - Always follow the manufacturer's instructions for safely charging the battery. ## What are some precautions to use when watering a battery? During the normal operation of a forklift with a flooded lead acid battery, the water in the electrolyte evaporates and needs to be refilled (watered) to keep the battery operating effectively and safely. - Develop procedures based on the manufacturer's instructions on how and when to water the battery. - In general, a battery should be watered after it has been fully charged and cooled down. - Do not water a battery before or during charging, as the water may boil over and cause acid to leak. - Use distilled water (not tap water) to refill the electrolyte. - Never add sulfuric acid to the electrolyte. - Wear appropriate personal protective equipme…

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CCOHS CCHST Canadian Centre for Occupational Health and Safety Centre canadien d'hygiène et de sécurité au travail Safety Hazards # Battery Charging - Industrial Lead-Acid Batteries ## On this page Why is it important to follow safety. procedures when charging batteries? What are the risks of charging an industrial lead-acid battery? Why is there a risk of an explosion? What are the ventilation requirements for charging areas? Why can you get a burn from acid when handling the batteries? What should I know about watering a lead-acid battery? Are there any other hazards involved? How should industrial size batteries be handled? ## Why is it important to follow safety procedures when charging batteries? The use, handling and charging of batteries in the workplace can be hazardous. It is important to identify and assess the hazards and risks, and to have the appropriate control measures in place to protect workers. The hazards and risks associated with a battery will depend on the type of battery, how it is used, how it needs to be charged and maintained, the area where it is being charged and used, among other factors. Workplaces should always make sure that procedures and practices are developed based on the battery's manufacturer's instructions and recommendations. Requirements from occupational health and safety legislation, building codes, electrical codes, and fire codes must also be followed. Always make sure the charging stations and devices have a Canadian certification mark (such as from the Canadian Standards Association (CSA) or Intertek (cETL)), indicating it meets Canadian electrical safety standards (jurisdictions may specify which certification marks are acceptable). In all cases, workers should be trained on safe work procedures, spill response, first-aid, and other related duties. Refer to the manufacturer's instructions and safety data sheets (SDS). Battery Charging - Industrial Lead-Acid Batteries CCOHS

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# Safety Precautions ## 1.5.2 Battery Hazards - Always disconnect batteries when servicing electrical components or when performing welding on the machine. - Do not allow smoking, open flame, or sparks near battery during charging or servicing. - Do not contact tools or other metal objects across the battery terminals. - Always wear hand, eye, and face protection when servicing batteries. Ensure that battery acid does not come in contact with skin or clothing. ## CAUTION Battery fluid is highly corrosive. Avoid contact with skin and clothing at all times. Immediately rinse any contacted area with clean water and seek medical attention. - Charge batteries only in a well ventilated area. - Avoid overfilling the battery fluid level. Add distilled water to batteries only after the batteries are fully charged.

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# Forklift Trucks - Batteries (cont.) ## What are some precautions to use when watering a battery? (cont.) - Use extreme care to avoid spilling or splashing the electrolyte. It can destroy clothing and burn the eyes and skin. - Make sure spill response equipment and personal protective equipment are readily available, and that spill response procedures have been developed. - Neutralize spilled or splashed sulfuric acid (electrolyte) with an appropriate neutralizing solution (e.g., baking soda solution), clean the spill area using spill response supplies (e.g., cleaning pads, disposable bags), and rinse the area with clean water. Make sure appropriate personal protective equipment is worn. - Dispose of contaminated items safely. ## What do I do if someone gets sulfuric acid (electrolyte) on their skin? Emergency response and first-aid procedures should be developed in the case of worker exposure. An example of a first-aid procedure is: - As quickly as possible, flush the contaminated area with lukewarm, gently flowing water for at least 30 minutes using an emergency eye wash station or shower. - If irritation persists, repeat flushing. - DO NOT INTERRUPT FLUSHING. If necessary, keep the emergency vehicle waiting if advised by medical professionals. - Do not rinse contaminated water into the unaffected eye, or onto other areas such as the face or skin. - Under running water, remove contaminated clothing, shoes, and other leather goods (e.g., watchbands, belts). Discard contaminated clothing, shoes, and leather goods. - First aiders should avoid direct contact. Wear chemical protective gloves, eye and face protection and other PPE, if necessary. - Quickly transport the person to an emergency care facility or call 911. If it is safe to do so, continue flushing during transport. - Safely dispose of contaminated clothing, equipment, and materials. ## What do I do if someone gets sulfuric acid (electrolyte) in their eyes? Avoid direct contact. Wear …

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# Battery Charging - Industrial Lead-Acid Batteries (cont.) ## Why can you get a burn from acid when handling the batteries? (cont.) - Take care not to rinse contaminated water into the unaffected eye, or onto the face or skin. - First aiders should avoid direct contact. Wear chemical protective gloves, eye and face protection and other PPE, as necessary. - Quickly transport the victim to an emergency care facility or call 911. If safe to do so, continue flushing during transport. - Safely dispose of contaminated clothing, equipment, and materials. ## What should I know about watering a lead-acid battery? Flooded lead-acid batteries (e.g., used in some electric forklifts) contain an electrolyte solution of sulfuric acid and distilled water. During normal operation, the water evaporates and needs to be refilled (watered) to keep the battery operating effectively and safely. Use distilled water. Do not add sulfuric acid to the electrolyte. Batteries should be watered after it has been fully charged and has cooled down. Do not water a battery before or during charging, as the water may boil over and cause acid to leak from the battery. Develop procedures on how to safely water a battery, based on the manufacturer's instructions, and train workers. Appropriate personal protective equipment (PPE) should be worn, including eye and face protection (e.g., chemical safety goggles and face shield); chemical-resistant gloves, aprons, and boots; or other protective clothing as needed. Make sure to water the batteries in the designated charging area where there is access to spill response equipment, PPE, and emergency eyewash stations or showers. There are also sealed batteries, such as absorbed glass mat batteries, which have the electrolyte fluid sealed into the battery, and do not require distilled water to be added. Always use the type of battery that is compatible with the equipment and recommended by the manufacturer. ## Are there any other hazards involved? It…

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# To construction work, as defined in $ 1910.12, nor (cont.) ## 1910.268(b)(1)(ii) (cont.) frames. 1910.268(b)(1)(iii) Working spaces. Maintenance aisles, or wiring aisles, between equipment frame lineups are working spaces and are not an exit route for purposes of 29 CFR 1910.34. 1910.268(b)(1)(iv) Special doors. When blastproof or power actuated doors are installed in specially designed hardsite security buildings and spaces, they shall be designed and installed so that they can be used as a means of egress in emergencies. 1910.268(b)(1)(v) Equipment, machinery and machine guarding. When power plant machinery in telecommunications centers is operated with commutators and couplings uncovered, the adjacent housing shall be clearly marked to alert personnel to the rotating machinery. ## 1910.268(b)(2) ## Battery handling. 1910.268(b)(2)(i) Eye protection devices which provide side as well as frontal eye protection for employees shall be provided when measuring storage battery specific gravity or handling electrolyte, and the employer shall ensure that such devices are used by the employees. The employer shall also ensure that acid resistant gloves and aprons shall be worn for protection against spattering. Facilities for quick drenching or flushing of the eyes and body shall be provided unless the storage batteries are of the enclosed type and equipped with explosion proof vents, in which case sealed water rinse or neutralizing packs may be substituted for the quick drenching or flushing facilities. Employees assigned to work with storage batteries shall be instructed in emergency procedures such as dealing with accidental acid spills. - 1910.268(b)(2)(ii) Electrolyte (acid or base, and distilled water) for battery cells shall be mixed in a well ventilated room. Acid or base shall be poured gradually, while stirring, into the water. Water shall never be poured into concentrated (greater than 75 percent) acid solutions. Electrolyte shall never be placed …

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# Battery Charging - Industrial Lead-Acid Batteries (cont.) ## Why is it important to follow safety procedures when charging batteries? (cont.) NOTE: This OSH Answers document provides general guidance for industrial lead-acid batteries used to operate forklifts and is not meant to replace the requirements from the manufacturer or legislation. ## What are the risks of charging an industrial lead-acid battery? The charging of lead-acid batteries (e.g., forklift or industrial truck batteries) can be hazardous. The two primary risks are from hydrogen gas formed when the battery is being charged and the sulfuric acid in the battery fluid, also known as the electrolyte. Hydrogen gas can lead to fires and explosions, and worker exposure to sulfuric acid can lead to chemical burns and other adverse health effects. Improper handling of batteries can also lead to shocks and electrocution, and battery charging can also result in the release of other harmful contaminants. For general safety precautions when working with batteries, please see the OSH Answers Garages - Batteries which covers automotive vehicle sized batteries and the OSH Answers on Forklift Trucks - Lead-Acid Batteries for forklift batteries. For specific guidelines regarding large industrial batteries, check with the manufacturer for recommended safe work procedures. ## Why is there a risk of an explosion? When leac-acid batteries are being recharged, they generate hydrogen gas that is explosive in certain concentrations in air (explosive limits are 4.1 to 72 percent hydrogen in air). The ventilation system needs to be able to exchange an adequate amount of fresh air for the number of batteries being charged. This is essential to prevent an explosion. Batteries should also not be charged or handled near sources of heat, flames or sparks, such as welding activities, burning cigarettes, or other source of ignition. Charging stations for battery-powered industrial trucks, per the National Fire Code of Can…

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# Battery Charging - Industrial Lead-Acid Batteries (cont.) ## What are the ventilation requirements for charging areas? (cont.) Many standards and codes recommend a ventilation system that prevents the accumulation of hydrogen to above 25% of its lower explosive limit (LEL), or above 1% by volume. Guidelines for ventilation in battery charging areas, based on the National Fire Protection Agency Standards (NFPA 855), are provided below: Natural exhaust ventilation: designed to limit the concentration of flammable gas to 25% of the lower explosive limit (LEL) during the worst-case scenario of charging all batteries at the same time. Mechanical Ventilation: an exhaust ventilation rate that is effective at limiting the maximum concentration of hydrogen to 1% of the total volume of the room or area during a worst-case scenario when all batteries are being charged at the same time. Alternatively, having a ventilation rate based on the area of not less than 1ft3 / min / ft2 of the floor area of the room. ## Why can you get a burn from acid when handling the batteries? You can get a skin burn when handling lead-acid batteries. Sulfuric acid is the acid used in lead-acid batteries (electrolyte) and it is corrosive. Note: workers should never pour sulfuric acid into flooded lead acid batteries (included in new watering a battery section). If a worker comes in contact with sulfuric acid when watering a battery or when handling a leaky battery, it can burn and destroy the skin. It is corrosive to all other body tissues. For example, the eyes, respiratory tract, or digestive system can be harmed severely if a worker gets a splash in the eyes, inhales sulfuric acid mist or unintentionally ingests sulfuric acid. As with any corrosive chemical, appropriate handling procedures must be followed to prevent contact with the liquid. These procedures include the wearing of face and eye protection, and protective chemical- resistant clothing such as aprons and gloves that are suita…

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# Safety Precautions ## 1.5.2 Battery Hazards - Always disconnect batteries when servicing electrical components or when performing welding on the machine. - Do not allow smoking, open flame, or sparks near battery during charging or servicing. - Do not contact tools or other metal objects across the battery terminals. - Always wear hand, eye, and face protection when servicing batteries. Ensure that battery acid does not come in contact with skin or clothing. ## CAUTION Battery fluid is highly corrosive. Avoid contact with skin and clothing at all times. Immediately rinse any contacted area with clean water and seek medical attention. - Charge batteries only in a well ventilated area. - Avoid overfilling the battery fluid level. Add distilled water to batteries only after the batteries are fully charged. 24 31223023 600AJ