eTool : Lead: Battery Manufacturing - Battery Assembly - Intercell Welding and Post Burning | 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 » Intercell Welding and Post Burning

After workers place all the groups in the battery case, the straps are fused together using a torch or high electrical power source. This process can also be done Through The Partition (TTP), using a case that has been punched. The connections are then welded. The units are tested and the posts are attached. The major source of lead exposure in the intercell welding process comes from lead fumes.

Intercell welding and post burning

Potential Sources of Exposure

Lead fumes are emitted during the manual burn welding process. This is a minimal source of exposure for Through The Partition (TTP) welding.
Exposure to lead may occur from manual handling of burning jigs or contaminated dams.
High lead exposure may occur when repairing batteries.
Contaminated air from other areas may be exhausted into the work station as a result of exhausting too much air from other workstations.
Lead particles may become airborne if the pressure of the torch flame is too high.

Possible Engineering and Work Practice Controls

Use local exhaust ventilation around the torch or provide a portable welder exhaust hood on a monorail or other configuration connected to a suitable exhaust collection system (Figure 1).
Use a plastic or glass see-through guard between the breathing zone and the conveyer carrying the battery.
Use canopy or slot hoods if lead pots are used.
Use a down draft or slot hood ventilated workstation when performing battery assembly (Figure 1).
Install a laminar flow (supplied-air) island above workstation.
Keep torch hose lengths to a minimum to prevent employee from working outside the ventilated area.
Keep burning temperatures low by substituting air-propane or air-MAP gas for oxy-acetylene flames.
Provide adequate PPE, a change of clothes, and shower rooms (see OSHA Lead Requirements for PPE, Housekeeping, and Hygiene Facilities).

Possible Engineering and Work Practice Controls

Ensure that local exhaust ventilation is working properly.
Perform battery repair at a ventilated workstation.
Vacuum oxide spills immediately with a central vacuum system or HEPA vacuum.
Avoid pointing torch flame into battery containers whenever possible.

Lead: Battery Manufacturing eTool

Battery Assembly » Intercell Welding and Post Burning

Intercell welding and post burning