Even a small spark can lead to the battery explosion. The remedy is to ensure the battery vent plugs are not blocked. Always remove the vent plugs in a flooded battery during battery charging. Always ensure the cables connected to the battery terminals are good without any frayed wire ends at the crimped ends of the terminal connectors. Frayed ends are a source of sparks and can easily cause the battery to explode if the battery is housed inside a closed battery container.
Brushed motors near the battery spark every time they kick in. SO ensure the brushed motors are separated from the battery well. Sometimes the battery cable may be frayed at the point where it enters into the battery box at the point of contact of the metal container.
Check to see that the cable is not at a sharp angle at the entry point. Tracking across wet battery lids during charging It is inevitable that some amount of battery acid bubbles out during battery charging. Leaving cables tracking over such spills is not a good thing as it causes earth leakage voltage.
Always wipe clean any acid droplets after the charging is complete. Hydrogen gas will accumulate inside the room when ventilation is poor. This is an explosive mixture and is triggered by even a tiny spark. When gas accumulates inside a cell during charge and is not vented out promptly, hydrogen can build up inside the room.
Hydrogen gas becomes explosive at a concentration of 4 per cent. What to do if a battery explodes? At what temperature do batteries explode? Can batteries explode if they get too hot? What happens if a battery gets hot? What happens if a car battery gets too hot? Why does my battery smoke when I jump it? Does a car battery get hot while driving? Can a dying car battery cause overheating?
Why do batteries get hot when not in use? What causes batteries to overheat? How do I cool down my battery? Can hot batteries cause a fire? PPE Batteries used in forklifts are heavy—some weighing more than a ton.
For handling electrolytes, provide a carboy tilter or siphon. Smoking should be completely forbidden in the charging area. Open flames, sparks, or electric arcs should be avoided in the charging area. Anything metallic e. Moisture on top of the battery can lead to corrosion and cause the battery to become electrically conductive; it is a sign of a problem overfilling, excessive out-gassing, or leaky seals that needs to be corrected immediately. Have neutralizing agents on hand at all times in case of an acid spill.
Takeaway Battery-charged forklifts offer many advantages, but steps must be taken to ensure safety while servicing them, such as using PPE, ensuring the charging station is suitably set up, and using checklists.
Image courtesy of U. Air Force, Master Sgt. Make sure that all electrical connections are tight and mechanically sound to prevent any arcing or loss of power. Wear a face shield or goggles, rubber gloves, apron and boots when checking, filling, charging or repairing forklift batteries during periods of possible exposure to acid or electrolyte.
When forklift batteries are charged on racks, the racks should be insulated to prevent any possibility of shorting. When charging an enclosed or covered forklift battery, always keep the battery tray cover, or compartment cover, open during the charging period.
This will help to keep the forklift battery cool and disperse the gases. Keep vent caps in place at all times except while servicing or repairing cells. This minimizes the loss of electrolyte and prevents foreign matter from entering the cells.
Shut off and disconnect both input and output connections to the charger before repairing charging equipment. When taking specific gravity readings, use a face shield or goggles and read the hydrometer with eye at about the same level as the electrolyte. Return all electrolyte to the cell. The splashing of acid into the eyes is the most dangerous condition which can be encountered while handling sulfuric acid or electrolyte.
If this should happen, the eyes should immediately be gently flooded with clean, fresh, running water for at least 15 minutes followed as quickly as possible with a physicians examination. If the person is wearing contact lenses they should be removed before rinsing the eyes.
Acid or electrolyte splashed onto the skin should be washed off under running water. Battery electrolyte will usually only cause irritation of the skin; but if a bum develops, it should be treated medically. When electrolyte is splashed on clothing, use a weak solution of bicarbonate of soda, as soon as possible, to neutralize the acid. A carboy tilter or safety siphon should be provided for handling acid from a carboy container.
Use the protective box when moving a carboy. Store acid in a cool place out of the direct rays of the sun. When mixing acid, to prepare electrolyte, always pour the acid slowly into the water and stir constantly to mix well.
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