STANDARD OPERATING

PROCEDURE
BATTERY STORAGE AND CHARGING DOC ID PRO425 VERSION 2

DOC Tom ACTIVE

19/01/2017
OWNER Foster DATE

TABLE OF CONTENTS
1. SMS DOCUMENT HIERARCHY ...............................................................................2
2. PURPOSE.................................................................................................................2
3. SCOPE ....................................................................................................................2
4. DEFINITIONS AND ACRONYMS.............................................................................2
5. ROLES AND RESPONSIBILITIES ...............................................................................3
5.1 QUU EXECUTIVE ..................................................................................3
5.2 MANAGERS .........................................................................................3
5.3 SUPERVISORS/PICOW .........................................................................3
5.4 WORKERS.............................................................................................3
5.5 CONTRACTORS ...................................................................................4
6. RELATED DOCUMENTS ...........................................................................................4
7. PROCEDURE ...........................................................................................................4
7.1 OVERVIEW ...........................................................................................4
7.2 GENERAL SAFETY PRECAUTIONS ........................................................5
7.2.1 FIRE AND EXPLOSION .........................................................................5
7.2.2 SPILLS MANAGEMENT .........................................................................5
7.2.3 MANUAL HANDLING...........................................................................5
7.2.4 PERSONAL PROTECTIVE EQUIPMENT (PPE) ........................................5
7.2.5 FIRST AID..............................................................................................6
7.3 BATTERY INSPECTION AND MAINTENANCE.......................................6
7.4 BATTERY STORAGE ..............................................................................6
7.5 BATTERY CHARGING...........................................................................6
7.6 DISPOSAL OF SEALED BATTERIES / BATTERY-RELATED WASTE ...........7
7.7 TRAINING, COMPETENCY AND SUPERVISION...................................7
8. REFERENCES ...........................................................................................................7
9. REVIEW ...................................................................................................................7
10. FURTHER INFORMATION ..................................................................................7
11. APPENDIX A – EXAMPLES OF SIGNAGE TO BE USED AT CHARGING STATIONS 8

PRO425 Battery Storage and Charging

Standard Operating Procedure
Confidential
1
1. SMS DOCUMENT HIERARCHY

2. PURPOSE
This Standard Operating Procedure (SOP) documents Queensland Urban Utilities (QUU) approach to the
management of batteries at QUU-controlled workplaces.
The overall purpose of this procedure is to ensure that risks associated with battery storage, charging and
use are adequately managed in order to minimise the risk of injury or harm to workers. This procedure
provides practical guidance on how to manage these health and safety risks.

3. SCOPE
This SOP only applies to battery storage, charging and related activities associated with plant and
equipment use. It does not apply to the recharging of mobile phones or small office appliances.
This procedure applies to all QUU staff, including contractors and other persons on QUU-controlled
worksites where lead-acid battery storage, charging and related activities occur.

4. DEFINITIONS AND ACRONYMS

Hydrogen – Hydrogen gas is formed during lead-acid battery charging. Hydrogen is very flammable and
easily ignited.
Lead-Acid Batteries – Batteries that contain lead which are used to provide high voltage current for use
in vehicles and plant. Batteries generate explosive hydrogen gas, even during normal operation, but
additional hazards during charging raise the risk to workshop personnel and other personnel.
Manager – As per QUU naming conventions, the Manager who has direct responsibility for the activity
being performed or the area the activity is occurring in.
Sulphuric Acid – Sulphuric acid is present in battery fluid. It is a corrosive chemical that causes damage
to metals, containers etc., and presents a skin irritant and health risk to workers if not handled correctly.
Supervisor – Term used for any QUU employee who acts or is appointed as a Supervisor, Coordinator or
Team Leader within QUU.
SMS – Acronym used for QUU’s Safety Management System.
WHS – Acronym used for Work Health and Safety.
Worker – Employees, contractors, subcontractors, outworkers, apprentices and trainees, work experience
students, volunteers and PCBUs who are individuals if they perform work for the business.

PRO425 Battery Storage and Charging

Standard Operating Procedure
Confidential
2
5. ROLES AND RESPONSIBILITIES
Outlined below are responsibilities specific to battery storage, charging and use at all QUU workplaces
and controlled sites.
5.1 QUU EXECUTIVE
QUU Executive and Senior Management (CEO, ELT, General Managers – Officer and Non-Officer
Appointed) are responsible for overseeing and ensuring the implementation of the requirements of this
SOP and related procedures within their respective functional areas. This includes ensuring all sites are
suitably risk assessed and have appropriate facilities, services and resources to ensure that risks
associated with lead-acid battery storage, charging and use are adequately managed to minimise the
risk of injury or harm to workers.
5.2 MANAGERS
Managers in all operational areas and QUU worksites are responsible for ensuring the review and
management of risks associated with lead-acid battery storage, charging and use. This includes:
 Provision of appropriate resources so that design and operation requirements for lead-acid
battery charging and storage areas are appropriate;
 Provision of appropriate resources to deliver training to workers who handling and charge lead-
acid batteries in:
o Related chemical hazards;
o The risks associated with recharging (i.e. fire and explosion);
o Manual handling risks associated with removing, installing and handling large lead-acid
batteries; and
o Personal Protective Equipment (PPE) requirements (refer to (PRO424) PPE Standard
Operating Procedure).
5.3 SUPERVISORS/PICOW
Supervisors and Team Leaders in all operational areas and QUU worksites are responsible for ensuring that
risks associated with lead-acid batteries are managed including:
 Completing a risk assessment in relation to lead-acid battery storage, charging and use;
 Operating and maintaining storage areas for rechargeable lead-acid batteries as per QUU
guidelines and manufacturer’s specifications;
 Providing areas suitable for rechargeable lead-acid batteries;
 Keeping lead-acid battery charging and storage areas free of ignition sources;
 Mandating that workers who handle lead-acid batteries (e.g. changing lead-acid batteries,
charging lead-acid batteries etc.) do not wear metallic jewellery and accoutrements; and
 Ensuring workers who handle lead-acid batteries or undertake lead-acid battery charging
activities are appropriately trained and use required PPE; and
 Informing all workers and contractors of requirements of this SOP and ensuring their compliance
with this SOP.
5.4 WORKERS
All workers shall ensure that they:
 Follow the guidelines of this Battery Storage and Charging SOP and related procedures and
comply with manufacturers’ recommended procedures for charging and handling rechargeable
lead-acid batteries;
 Workers wear appropriate PPE; and
 Report any incidents to their supervisor and:
o Follow the injury management procedure; and

PRO425 Battery Storage and Charging

Standard Operating Procedure
Confidential
3
o Complete a QUU WHS Incident Report Form in accordance with QUU WHS Incident
Reporting Procedures.
5.5 CONTRACTORS
At all times when performing work on a QUU site or for/on behalf of QUU, contractors must comply with
QUU’s battery management requirements detailed in this and related procedures and must report any
incidents to the relevant QUU Manager and to their employing / contracting agency in accordance
with QUU WHS Incident Reporting Procedures.

6. RELATED DOCUMENTS
 WHS Hazard and Risk Management Procedure (PRO363)
 PRO360 Training and Competence
 (PRO364) Incident Reporting, Investigation and Escalation
 (PRO377) Hazardous Chemicals Standard Operating Procedure
 (MP71) Electrical Management Safety Plan
 (PRO384) First Aid Standard Operating Procedure
 (PRO416) Manual Tasks Standard Operating Procedure
 (PRO379) Lock Out Tag Out Standard Operating Procedure
 (PRO424) PPE Standard Operating Procedure

7. PROCEDURE
7.1 OVERVIEW
QUU will take action to manage their facilities, plant, work environment and tasks as to eliminate the risks
associated with battery use and charging, and if that is not possible, QUU will minimise the risks so far as is
reasonably practicable.
The charging of lead-acid batteries can be hazardous. However, this hazard may be overlooked by
workers seeing as battery use is a common activity in many workplaces. The two primary risks are from a)
the hydrogen gas that is formed when the battery is being charged; and b) the sulphuric acid contained
in the battery fluid. To manage the risks associated with the storage, charging and use of lead-acid
batteries at their worksites, QUU will:
 Identify and assess the risk for all locations and tasks that could cause injury or damage due to
battery use;
 Supply and maintain suitable plant and equipment for workers to reduce the likelihood of a
battery-related incident;
 Provide training to workers in the safe use of equipment and plant relevant to their tasks;
 Educate workers in the risks and controls required for managing batteries; and
 Develop and test emergency response, rescue and first aid plans.
Battery storage, charging and use will vary at each QUU workplace or controlled site. QUU will determine
battery-related requirements (i.e. equipment, facilities and personnel) through a risk management
approach. This will involve:
 Identifying hazards that could result in work-related injury, illness or damage;
 Assessing the type, severity and likelihood of injuries and illnesses;
 Providing appropriate equipment, facilities, first aid and training; and
 Reviewing battery storage, charging and use requirements on a regular basis or as circumstances
change.
Refer to the WHS Hazard and Risk Management Procedure (PRO363) for further guidance on QUU’s risk
management process that must be applied.

PRO425 Battery Storage and Charging

Standard Operating Procedure
Confidential
4
7.2 GENERAL SAFETY PRECAUTIONS
7.2.1 FIRE AND EXPLOSION
 Hot works are not permitted in areas where lead-acid batteries are stored, handled or
recharged, unless appropriate controls have been implemented through a risk assessment
process;
 Lead-acid battery charging and storage areas must be designated and separated from work
areas;
 All lead-acid battery charging and storage areas must be bundled, undercover and well-
ventilated;
 Ignition sources must be removed from lead-acid charging areas;
 All lead-acid battery training must be conducted by a suitably trade qualified worker; and
 Warning signage must be displayed at charging areas (refer to Appendix A for further details).
7.2.2 SPILLS MANAGEMENT
In the event of a spill:
 Shower or wash exposed areas of skin as appropriate to size of spill and exposure;
 Stop leak if safe to do so;
 Contain the spill using spill kit materials. Do not allow to enter drains/waterways or natural
environment;
 Clean up using soda ash/spill material when containment completed or remove contaminated
soils as directed by the Environmental Team;
 Store waste in approved container;
 Complete an incident report and investigate causes; and
 Dispose of waste material in accordance with QUU’s Contaminated/Industrial Waste Procedure
(PRO420).
Hazardous chemical management is outlined in (PRO377) Hazardous Chemicals Standard Operating
Procedure).
7.2.3 MANUAL HANDLING
 Lead-acid batteries must not be carried manually where more than one battery lift is required or
where battery is large and/or awkward in size (refer to (PRO416) Manual Tasks Standard Operating
Procedure);
 Appropriate mechanical handling aides (e.g. cradles, trolleys etc.) must be used and secured for
the transportation of lead-acid batteries;
 All lead acid batteries must be stored at heights below 1.2 metres; and
 Battery electrolyte acid must be transported in or decanted from approved containers only.
7.2.4 PERSONAL PROTECTIVE EQUIPMENT (PPE)
 PPE (PRO424) PPE Standard Operating Procedure) must be worn when handling, using or
charging lead-acid batteries or the electrolyte (acid).
 As minimum, workers charging lead-acid batteries should wear:
o Overalls;
o Acid resistant aprons;
o Acid resistant gloves;
o Acid resistant face shield; and
o Suitable respiratory equipment if required (i.e. if adequate ventilation is not available).

PRO425 Battery Storage and Charging

Standard Operating Procedure
Confidential
5
7.2.5 FIRST AID
All designated lead-acid battery storage and charging facilities must provide:
 Access to emergency wash facilities to allow rapid and continuous flushing with water;
 Emergency showers must have green fluorescent lighting;
 Access to saline eye wash for minor splashes to the eyes; and
 First aid kits, stocked with appropriate electrolyte acid exposure countermeasures (e.g.
neutralising agent); and
 Access to first aid in the event of acid burn to the skin in accordance with (PRO384) First Aid
Standard Operating Procedure.
7.3 BATTERY INSPECTION AND MAINTENANCE
All batteries must be inspected for serviceability (e.g. acid leads, sweating, bulging and corrosion).
Lead-acid batteries used for emergency power supply must be subject to regular inspection and
maintenance as directed by the Electrical Management Safety Plan (MP71) and scheduled in Ellipse.
7.4 BATTERY STORAGE
Lead-acid batteries must be stored:
 In a bunded, cool, well-ventilated area;
 Away from ignition sources (e.g. welding, smoking, etc.);
 Used lead acid batteries are to be stored in well ventilated cupboard area; and
 New lead acid batteries are to be stored on wooden shelving or on other non-corrosive material.
Lead-acid batteries storage areas must:
 Be designated and indicated by appropriate signage; and
 Have appropriate emergency response equipment such as fire extinguisher, eye wash facilities
and spill kits located nearby.
Lead-acid battery terminals are to be insulated to prevent the risk of contact by metal tools/objects.
7.5 BATTERY CHARGING
To minimise the risk of danger and injury, the following precautions are to be applied when charging
lead-acid batteries:
 Manufacturer’s instructions on battery handling and charging must be followed;
 Relevant Safety Data Sheets (SDS) must be located within charging area;
 All electrical sources must be disconnected from the battery prior to any work;
 Battery must be removed from vehicle or plant for charging (where appropriate);
 Charging must be conducted in designated area;
 Charger must be located as far from battery as cabling will permit;
 Fluid level in each cell must be checked prior to charging;
 Oversharing batteries must be avoided;
 Charging area must be well-ventilated;
 Contact with battery acid must be avoided;
 Required/correct PPE must be worn;
 Appropriate emergency response equipment (such as fire extinguisher, eye wash facilities and
Spill Kits) must be located nearby;
 Spill Kits and/or soda ash must be available for spills; and

PRO425 Battery Storage and Charging

Standard Operating Procedure
Confidential
6
 If battery acid contacts with the skin, affected area must be washed immediately.
7.6 DISPOSAL OF SEALED BATTERIES / BATTERY-RELATED WASTE
Lead-acid battery material is hazardous waste and must not be disposed of in normal waste systems.
QUU work areas that store, use or recharge batteries that are not considered to be general waste
material must collect the material (battery components, cells and electrolyte liquids) in approved
containers for disposal.
All waste batteries and related battery waste material must only be disposed of in approved waste
receptacles through QUU approved hazardous/ industrial waste contractors.
7.7 TRAINING, COMPETENCY AND SUPERVISION
QUU will provide instruction to workers on:
 Chemical hazards associated with batteries;
 Battery SDSs;
 Emergency procedures related to batteries; and
 Manufacturer’s requirements for charging and changing batteries.

8. REFERENCES
The following references contain information used in the preparation and development of this SOP:
 Queensland Work Health and Safety Act 2011
 Queensland Work Health and Safety Regulations 2011

9. REVIEW
The Battery Storage and Charging SOP is to be reviewed every 2 years, or earlier if:
 There is an identified risk to business;
 A significant safety or serious injury event occurs;
 Incident investigation or audit results show that application of the standard fails to deliver the
required outcomes;
 There are changes in associated legislation; or
 There is evidence that the standard is not having a positive impact on safety-related KPIs.

10. FURTHER INFORMATION

For further information, contact your Health and Safety Representative or the QUU Safety Team.

PRO425 Battery Storage and Charging

Standard Operating Procedure
Confidential
7
11. APPENDIX A – EXAMPLES OF SIGNAGE TO BE USED AT CHARGING STATIONS

TYPE OF SIGN EXAMPLE OF SIGN

Caution Sign

Danger Sign

Danger Sign

Safety Checklist

PRO425 Battery Storage and Charging

Standard Operating Procedure
Confidential
8