Training Your Staff to Avoid Hydrogen Hazards in the Battery room

In 2001, a commercial building in Rancho Cordova, California suddenly exploded, destroying a 50-foot section of roof and causing massive property damage, but no injuries.

The accident could have been avoided; hydrogen had gradually built up in a computer battery charging area, eventually reaching dangerous concentrations despite the presence of a fully functioning hydrogen detector, which was sounding when firefighters arrived. Further investigation showed that the alarm had sounded for three days and had been noticed by the staff of several other businesses.

The staff of the company had neglected to remove batteries from chargers when leaving the facility, and the ventilation system was either insufficient or it had failed shortly after the staff had left. In either case, staff training would have eliminated the threat and prevented the accident from occurring.

Hydrogen Hazards in the Warehouse Battery Room

While the 2001 event occurred in a computer battery room, hydrogen explosions are an even more significant issue in warehouses and storage facilities. Forklift batteries can generate a large amount of hydrogen over time, and many facilities have high ambient noise levels, which can limit the effectiveness of hydrogen alarms.

If workers don’t understand the threat, they can’t prepare for it. To run a safe operation, every facility manager should take a few essential steps:

• Make Sure That Alarms Are Clear and Distinct

  A properly equipped battery charging area should have hydrogen monitors as well as carbon monoxide and smoke detectors. Some also have flame detectors, since hydrogen flames are difficult to see. 

  Make sure that workers understand the different auditory and visual signals associated with each unit so that they can take proper actions when an alarm is triggered. Also, if a certain alarm isn’t loud or bright enough to attract attention, replace it immediately.

• Set Up a System for Reporting Hazards

  Your staff should know how to inspect batteries and cables, and should understand your process for reporting cracked casings, frayed wires and other potential hazards. Likewise, they should understand the process for notifying supervisors of alarms — including LED warnings that precede audible alarms on hydrogen monitors.

• Post Adequate Signage to Reinforce Training

  Every battery room should have “no smoking” signs along with posted warnings regarding forklift traffic, electrical hazards and corrosive hazards. You should also invest in signage that explains the procedures for checking equipment and reporting potential hazards. Signage reinforces good work habits and aids in compliance.

• Implement Better Battery Handling Practices

  Batteries can produce excessive hydrogen when they’re overcharged, and overcharging has a host of other consequences — none of them good. Invest in a forklift fleet tracking system and make sure that your staff rotates batteries properly. This will extend the operative life of your lift truck battery fleet while improving safety.

  Make sure that battery covers are always open during charging to ensure better venting. Every worker should know where battery vents are located and why they’re important.

Finally, make sure that your staff understands that all batteries produce hydrogen gas and that adequate ventilation is in place in order to prevent a major disaster. In many forklift battery charging areas, productivity is extremely important, but safety should always be paramount.

References:

Taylor, Bob. “Broadcast Message From The Sacramento Fire Marshall.” Fort Belvoir. United States Army, 2015. Web. 30 July 2015.

“Powered Industrial Trucks Etool: Types & Fundamentals - Power Sources: Electric.” Occupational Safety and Health Administration. United States Department of Labor, 2015. Web. 30 July 2015.