1、Public Lessons Learned Entry: 2876Lesson Info:a71 Lesson Number: 2876 a71 Submitting Organization: IVV a71 Submitted by: David Sheldon Subject: Battery Explosion Abstract: A lead acid battery used for emergency generator starting burst and spread surfuric acid within close proximity of the generator
2、. Diesel Generators (stand-by use) are located in a room at the facility that must be accessed by personnel for reasons other than maintenance. Personnel cannot be expected to recognize the presence and potential hazards of dangerous battery failures at undetermined times. Preventative maintenance s
3、chedules will include increased checks and ensure appropriate barriers are purchased and/or constructed to prevent personnel exposure to battery faults for all generators. Description of Driving Event: On May 17th, 2010 at approximately 10:00 am, the start-up battery on Generator #1 (not due to star
4、t-up) exploded for no apparent reason. This fault (root cause is unknown) has not been determined at this time however, something caused the battery shell to break leaving acid and fragmentation in the area around the generator. Technicians cleaned up the acid and washed all contaminated equipment.
5、The service vendor was contacted immediately to remove and replace the damaged battery. There were no injuries as a result the battery failure due to the fact that no personnel were in the generator room at that time of the incident. Lesson(s) Learned: Charging a lead-acid battery produces hydrogen
6、and oxygen gasses which creates pressure inside the battery. Battery explosions can occur and have been reported in industry. One conclusion is when one or more cells have a high concentration of hydrogen gas because the vent cap was plugged or defective and did not release the gas effectively an un
7、safe condition is created. In addition, when electrolyte levels fall below the top of the plates, a low resistive bridge can form at the top of the plates and when current starts to flow, it can cause an arc or spark in one of the cells to intensify that condition. This combination of events ignites
8、 the gas, blows the battery case cover off and spatters electrolyte with potentially injuring unaware personnel and to further damage associated equipment. Recommendation(s): 1. Remove batteries from current placement (attached to generator rail) to eliminate vibration (potential causal factor) and
9、place on floor easily accessible to technicians and vendors 2. Contact service vendor and request a formal report pertaining to any historical trends (battery faults) with like Generator equipment as used at this facility 3. Preventative maintenance schedules will include increased checks and be doc
10、umented 4. Any affiliated equipment (battery chargers) will be re-evaluated to assure that the system is operating in a efficient manner and that the startup batteries are monitored effectively to ensure adequate readings for technicians 5. Check to determine if there is any Government-Industry Data
11、 Exchange Program (GIDEP) notice out there on our batteries or chargers. 6. Continue to properly maintain batteries, ensuring that battery charge rates are set properly, electrolyte levels are correct, battery caps are properly vented and maintenance is only performed by trained professional and bat
12、tery charger should be off while performing maintenance. Place appropriate signage on the entrance way to warn personnel entering the facility of the hazard 7. Ensure appropriate barriers (recommend battery containment are purchased and/or constructed to prevent personnel exposure to battery faults
13、for all generators Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-http:/ of Recurrence Control Effectiveness: N/A Documents Related to Lesson: N/A Mission Directorate(s): N/A Additional Key Phrase(s): a71 Program Management. a71 Maintenance a71 Faci
14、lities a71 Energetic Materials - Explosive/Propellant/Pyrotechnic a71 Hazardous/Toxic Waste/Materials a71 Safety & Mission Assurance a71 Risk Management/Assessment Additional Info: a71 Project: IV&V Program Approval Info: a71 Approval Date: 2010-10-18 a71 Approval Name: mbell a71 Approval Organization: HQ Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-
