eTool : Lead: Battery Manufacturing - Battery Repair and Reclaim - Battery Repair | 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 Repair and Reclaim » Battery Repair

Defective batteries are repaired and salvaged. The plate groups are tested and reused when possible. Groups are removed by sawing or cutting the covers off the battery, breaking or burning the intercell connectors, and removing the groups.

The major source of lead exposure in the battery repair process comes from lead oxide which can become easily airborne.

Battery Repair

Potential Sources of Exposure

While removing plates, the operator, if not careful, may spill oxide out of the battery case, bang the dry plates together or against the case causing contaminants to become airborne.
High levels of lead fumes are generated when flames are put in contact with lead.
Moving groups in and out of battery cases may cause a bellows effect. The bellows effect will release lead particulates at the workstation.
Contamination may occur from improper disposal of battery parts.

Possible Engineering Controls

Provide local slot or downdraft ventilation at work stations.
Put a vacuum drop at workstations used for battery repair and salvage.
Use local exhaust ventilation on torch.
- Ventilated Torch
Provide local exhaust ventilation in areas for storage of tools, plates, and supplies.
Use air-propane or air-MAP gas instead of air-acetylene flame for torches.
Use a laminar flow (supplied-air) island.

Possible Work Practice Controls

Make sure ventilation is working properly around sawing areas.
Keep area vacuumed.
Clean up oxide spills immediately (see Figure 1).
Use a ventilated scrap barrel for disposal of elements.
- Scrap Handling Barrel/Drum Exhaust Hood
Place, do not throw, elements into the scrap barrel.
Cover barrel with plastic before moving.
Open the container and disassemble it in a ventilated work area.
Use caution while removing plates from the battery case.
Remove plates cautiously to prevent a bellows effect.
- If a bellows effect occurs, vacuum up particulates immediately with a central vacuum system or HEPA vacuum.
Do not store materials on active work surfaces; they may interfere with ventilation.
Provide adequate PPE, a change of clothes, and shower rooms (see OSHA Lead Requirements for PPE, Housekeeping, and Hygiene Facilities).

Lead: Battery Manufacturing eTool

Battery Repair and Reclaim » Battery Repair

Battery Repair