1. SCOPE
2 REFERENCE DOCUMENTS
3 AUTHORITIES AND RESPONSIBILITIES
4 MATERIALS CONTROL
5 BATTERY ACID SOLUTION FILLING
6 PROTECTIVE EQUIPMENT
Procedure for Battery Acid Solution Filling
SCOPE
This procedure covers the Method Statement for Battery Acid Solution Filling. This procedure will
be applied to the work for filling of acid solution carried out by the Electrical Department.
Construction shall review the feasibility of methodology in reference to actual site condition, Project
specification and standard and approved construclion drawing.
2 REFERENCE DOCUMENTS
a) Applicable/ Approved International Standards
b) Issued For Construction Drawings
c) Manufacturer Instructions
3 AUTHORITIES AND RESPONSIBILITIES
Site Manager — Determine all requirements needed in order to comply with contractual
requirements and safety standards.
Construction Manager – Lead all construction activities and enforce strict adherence to all project
requirements.
Electrical Superintendent — Ensure that work once started is carried out as planned and that the
applicable standards are complied with. Check working methods and precautions to be taken by the
supervisors/foreman before commencing work.
Field Engineer – Ensure that all related works are carried out in accordance with approved Released
for Construction drawings, specifications, schedule, quality and safety. Report to Construction
Manager.
Safety Officer – Ensure that “Safety, Fire, Loss Prevention” program or Safety Plan was been
implemented and monitored.
Supervisor/ Foreman – Supervise all field installations Reports to Electrical Superintendent.
4 MATERIALS CONTROL
a) Ensure that materials and equipment are stored and handled in accordance with project and
vendor requirements. Battery Acid Solution and other equipment must be stored in an
environment condition required by the manufacturer.
b) Check if all supplied materials are in conformance with Purchase Order or Specifications or
Drawings. Any discrepancies to be reported
immediately to Abener Construction
Department.
c) Check all electrolyte products is accordance with !EC 993 and components as per data sheet.
d) Verify the material composition as per weight percentage of basic materials.
5 BATTERY ACID SULOTION FILLING
a) Ensure that the environmental conditions are suitable for the battery acid solution filling.
b) Use glass or plastic jugs and funnels for filling the cells, do not use metallic vessels fill the cell the cells to the level line on the cell and leave to allow the acid to soak into the separator and plates.
c) The quality of dilute acid required to fill each cell according to manufacturer’s instruction.
d) Purified water shall be added to the cell if the electrolyte level approaches the minimum mark.
e) Battery to be handled and fill each battery cell with acid.
I) The following protective procedure shall be observe.
a) Use caution when working on batteries since they present a shock hazard.
b) Prohibit smoking and open names, and avoid arcing in the immediate vicinity of the battery.
c) Avoid wearing metallic object such as jewellery
6 PROTECTIVE EQUIPMENT
1) Goggles and face shields
2) Acid-resistant gloves
3) Protective aprons
4) Portable or stationary water facilities for rinsing eyes and skin in case of contact with electrolyte
5) Class C fire extinguisher
6) Adequately insulated tools
Note: Some battery manufacturers do not recommend the use of CO2 Class C fire extinguisher due lo the potential of thermal shock as per IEEE Std. 1188-1996 Sec.4.1.
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Step by Step Guide of the work plan
Explain in detail the steps that must be taken to ensure that the task is carried out safely (include drawing and sketches where Required, include pre commencement of work activities and the work itself in _a chronological manner).
A. Verify IFC drawing and Manual instruction for Battery Installation
B. Verify Document for QC material receiving inspection
C. Transport of Materials Loading & Unloading
D. Assembly & arrangement of Equipment & Material for Battery Electrolytes filling
E. Battery Electrolytes filling
F. Installation of Batteries – Levelling, Alignment, Connection, Termination and Fixing
G. Housekeeping
A. Transport of materials loading & Unloading (Get approval to the security for access follow site speed limits follow proper traffic signs & signals, tum on hazards light. only competent and certified rigger and operator should do the lifting, ensure one flag man for traffic control during activity. Provide barricade with signage’s. Follow manual instructions for proper handling and lifting of Battery)
B. Assembly and Arrangement of Equipment & Materials for Battery Electrolyte Filling (Only qualified personnel to perform the task, ensure wearing of proper PPE. Equipment and materials checked and conditions verified. Third party calibration certificate necessary for testing equipment. Manufacturer’s instruction/ MSDS are followed during handling Battery Electrolyte.).
C. Battery Electrolytes Filling (Only qualified personnel to perform the task, ensure wearing of proper PPE. Area must be barricaded during Battery electrolyte filling. Equipment to be used during the work must be in good condition. Third party calibration certificate necessary for testing equipment. Manufacturer’s instruction/ MSDS are followed during handling of Battery Electrolyte. Environmental protection/drip tray for spillage. Operation to be stopped when leak is observed) Battery shall be handled and filled each battery cell with acid in accordance with SEC safety requirements
D. Batteries – Levelling, Alignment, Connection, Termination and Fixing (Ensure permit to work, and Conduct toolbox talk prior the start of activity. Install warning sign and barricade the area. Unauthorized person must not be allowed at the activity area. Ensure people are capable for the handling task, Proper Manual Handling Safety Awareness, Ensure that the environmental conditions are suitable for the installation of Batteries. Access ways free of excess civil materials and civil debris, Floor, walls and ceilings dry with adequate sealing to ensure no new ingress of water, All civil works completed;
area is clear and clean, All apertures closed to minimize ingress of dust,. All Personnel given and wear appropriate PPE. Material & tools is properly arranged in the work area. After Battery intercell connections are completed all covers and containers to be cleaned and ensure the battery to be protected from construction dirt and debris.)
E. Dally housekeeping (Full supervision on the area remind personnel for safe working and good housekeeping on the area should be done before and after the work Materials must be properly segregated and stacked where it will cause no obstruction or hazard to other construction activity and worker)