Battery Explosion and Acid Splash to Face

On 28th November 2012, a boat engineer observed sparks coming from the terminals of one of the pair of batteries used for starting the engine. He requested the Able Bodied seaman’s assistance

to start the engine while he was still holding the terminals. When the Able Bodied seaman pushed the start button, the battery exploded and splashed battery acid on the engineer’s face. He immediately ran out of the engine room and was taken to the clinic.

What Went Wrong

• Injured Person (IP) did not identify the hazards associated with working with batteries; he was not wearing any PPE while working on the batteries.
• The original manufacturer’s charging system was faulty and replaced with external charger as a temporary measure. The inbuilt safety devices in the original charging system were compromised with the introduction of the external charger.
• The external charger used was not the „smart‟ self-regulating type. Its continuous charging caused the battery to overcharge, thus producing a hydrogen cloud which was ignited by the sparks from the battery terminal.
• There was no procedure in place for battery operations, maintenance, inspection and charging.

Lessons Learned and Required Actions

• Always use the “Hazard Id tool” to identify energy sources and associated hazards around work places before commencing job tasks. Use the “hierarchy of controls” to prevent incidents.
• Do not compromise manufacturer’s recommended safety, operational and maintenance standards.
• Ensure appropriate procedures are in place to guide employees on batteries as well as other tools and equipment safety, operations and maintenance standards.