eTool : Lead: Battery Manufacturing - Battery Assembly - Formation | Occupational Safety and Health Administration

Text Version

Typical System Layout Low Volume/High Velocity with Chart

Typical system shown with piping sizes of 2 1/8" for 7" - 72,000 rpm Disc sander(2 1/8"), 2 1/8" for chipping hammer (2 1/2"), 2 1/8" for 6" - 10,000 rpm Cup stone grinder (3"), 2 1/8" piping for 6" X 1", 10,000 rpm Wheel grinder (3 1/2"), and 2 1/8" piping for Swing Frame grinder( 2 1/2"). Fittings are in parentheses following each machine type. All lines flow into 4" piping connected to primary separator, dust collector, with recommended automatic bag cleaner, and exhauster to atmosphere.

	cfm	I.D. Plastic Hose Size
Disk sanders 3-9 inch diameter	60-175	1 - 1.5
Vibratory Pad Sander - 4" X 9"	100	1.25
Router, 1/8" to 1"	80-100	1 - 1.25
Belt Sander, 3" - 4000 cfm	70	1
Pneumatic chisel	60	1
Radial Wheel Grinder	70	1
Surface Dye Grinder, 1/4"	60	1
Cone Wheel Grinder	90	1.25
Cup Stone Grinder, 4"	100	1.25
Cup Type Brush, 6"	150	1.5
Radial Wire Brush, 6"	90	1.25
Hand Wire Brush 3" X 7"	60	1
Rip Out Knife	175	1.5
Rip Out Cast Cutter	150	1.5
Saber Saw	120	1.5
Swing Frame Grinder	380	2.25
Saw Abrasive 3"	100	1.25

System Notes:

Bell and socket, smooth - flow type tubing and fittings should be used throughout the system. When system is used for vacuum cleaning of abrasive materials, schedule Nol40 pipe and cast iron drainage fittings, or heavier, should be used in place of tubing.

From American Conference of Governmental Industrial Hygienists (ACGIH®), Figure VS-40-20, Industrial Ventilation : A Manual of Recommended Practice, 23^rd Edition. Copyright 1988. Reprinted with permission.

Text Version

Hygiene Facility

Hygiene facility floor plan:

Street
Side
Entry

(A)

Street Side Locker Room

(B)

Storage Lockers

Hand Washing Stations

(J)

Lunchroom
(K)

Vending Machines

Work Clothes Vacuum Station(I)

Plant side Entry (E)

Clean Issue

Dirty Turn-in

Restroom
(F)

Cloak Room (G)

Shoe Cleaning Machines
(H)

Laundry

Showers

(C)

Plant side Locker Room (D)

Autoshower (N)

Facility Function/Description:

The facility can be entered from the street at only one point. (A)
Street clothes are removed and clean work clothes, hardhat, and respirator are issued and donned in the street side locker room. (B)
The employee passes through a one-way turnstile in order to get to the plant-side locker room. (C)
The employee dons work boots and other safety gear in the plant-side locker room where they are stored. (D)
There is only one entry to the plant. (E)
The restroom just inside the cloak room is readily accessible during working hours. (F)
The cloak room provides a place to store coats, hardhats, gloves and respirators during break periods. (G)
During lunch break the employee first cleans his boots at the shoe cleaning machines (H), leaves coat and equipment in the cloak room (G), vacuums off his clothes at the vacuum stations (I), proceeds to the hand washing station where he thoroughly washes his hands (J), and finally enters the lunch room. (K)
At the end of the shift the procedure is as follows: the employee cleans shoes (H), removes contaminated clothing in the plant side locker room (D), stores boots, etc. in plant-side lockers, turns in dirty work clothes, hardhat and respirator to laundry (L), and proceeds to the showers. (M) He then must pass through an automatic shower (N) to return to the street-side locker room (B), where he dresses and leaves the facility. (A)

Battery Assembly » Formation

In the dry charge (plate) formation process, the first step, called tacking consists of plates being placed in a tank and lead bars being welded, or "tacked" on. Battery plates are then formed (or charged) in tanks. The major source of lead exposure in the formation process comes from lead fumes. Wet (case) formation does not include any associated lead exposures during formation because batteries are assembled and filled with acid prior to charging.

Formation

View larger image of exhaust ventilated torch

Potential Sources of Exposure

Lead fumes are emitted from using a torch to weld lead.
High exposure to lead may occur from moving plates in and out of acid tanks, drying ovens, and racks.
Exposure to acid splash or mist may occur when placing the plates in the acid tanks.
Lead dust may become airborne during the cleaning of panel lugs using brushes.

Possible Engineering Controls

Use local exhaust ventilation on the torch.
- Ventilated Torch
Cover and ventilate tanks while tacking.
Use the "tackless formation" process.
Provide adequate PPE, a change of clothes, and shower rooms (see OSHA Lead Requirements for PPE, Housekeeping, and Hygiene Facilities).

Possible Work Practice Controls

Ensure ventilation is working properly.
Wet down plates before they are put into the system.
Use fork lifts to move groups in and out of drying ovens.
Use instruments to move plates in and out of tanks.
Vacuum racks and ovens before moving plates.
Keep floors around ovens, racks, and storage areas clean.

Lead: Battery Manufacturing eTool

Battery Assembly » Formation

Formation