Batteries are used everywhere—farm equipment, vehicles, forklifts, and a multitude of other applications which make our lives easier. However, they come with hazards that can cause serious property damage, injuries, or even death. Your safety program should include training and procedures on battery maintenance, jump-starting, installation or removal, and charging.
Ignoring the potential hazards of batteries can have severe consequences like explosions or fires. This may release acid, which can burn and scar the skin. Additionally, toxic fumes can also be produced which may cause lung damage if inhaled and blindness upon contact with the eyes. The use of Personal Protective Equipment (PPE) is mandatory when working with batteries and should be part of your safety program.
Here are some best practices to consider while practicing battery safety:
Maintenance procedures
Batteries vent hydrogen gas, which can accumulate around the battery compartment. Make sure that you always ventilate the battery compartment prior to performing any maintenance, repairs, or tightening of terminal connections.
It is important that you keep your batteries clean and dust-free to protect against shorting. Spilled electrolyte mixed with dust on a battery can create a low resistance electrical path, which may cause a short in the battery.
Maintenance and inspection programs should be tailored to the particular battery. Flooded non-maintenance free lead acid storage batteries require the most maintenance. However, even so-called “maintenance free batteries” may still require some upkeep such as cleaning. Consult the manufacturer’s recommendations for specific maintenance details.
Installing or removing batteries
Before installing or removing any batteries, ensure that you power down all related electrical loads. When removing the battery, remember to always disconnect the negative (black) terminal connector before connecting or removing the positive (red) terminal connector. This will prevent an electrical arc from occurring should a wrench touch a grounded surface.
Charging batteries
Before connecting the charger connectors to the battery, make sure the charging circuit isn’t energized. An energized battery can create short circuits, overcharging or other battery and charger malfunctions, which in turn, can produce heat buildup and even a fire.
Charging batteries produces explosive and highly flammable gasses. As a result, batteries should be charged away from ignition sources such as hot work activities, open flames, or other electrical equipment.
Chargers should be monitored and used only during business hours. Always make sure to follow the manufacturer’s operating instructions. The charger should be unplugged from the power supply and more importantly from the battery at the end of the day. Not disconnecting the battery from the charger may cause a reverse flow of current which has been known to cause the charger to overheat resulting in explosions, fires, and significant property loss.
Disconnecting the power supply
Disconnecting the battery in equipment being stored inside the shop is a good risk management practice. This becomes even more important if the vehicle or equipment is brought in for servicing because of electrical issues.
Devices called battery cut-off switches can be installed to make disconnecting a battery’s power supply quick and easy. After installing a battery cut-off switch on the negative post, the battery cable is then attached to the cut-off switch. A mechanism on the cut-off switch tightens and loosens it, which engages or disconnects the power supply from the battery.
Cut-off switches are also an effective loss prevention tool for deterring theft. The mechanism on many of these cut-off switches can be totally removed, making it impossible to start the vehicle. This helps prevent theft while the vehicle or equipment is parked overnight or being stored, in addition to preventing battery drainage.
Preventing injuries
Serious injuries and fires caused by battery charging are often preventable. So, be sure to review your battery charging equipment, replace it if necessary, and adopt safe battery charging and handling procedures in writing to share with your employees.
Protect your business with insurance
Despite your best efforts and preparation, accidents happen, especially when working with batteries. That’s why it’s important to invest in comprehensive coverage to ensure that your business is protected. Learn more by visiting our Business Insurance page today!
This blog is provided for information only and is not a substitute for professional advice. We make no representations or warranties regarding the accuracy or completeness of the information and will not be responsible for any loss arising out of reliance on the information.
