POTENTIAL ACCIDENTS AND HAZARDS

Portable Generators
Portable generators are used to provide an alternate source of AC power to equipment. These generators
may be diesel or gasoline driven. The units range in size from being relatively small to furnish power
for emergency lighting and/or control circuits or they may be very large and are capable of generating
several megawatts of power. These generators are to be considered operable at all times, unless locked

out because they may be remotely operated and could be in the standby state or running. Even small
portable generators as seen in Figure 29 easily produce enough current and voltage to kill. Also, if the
generator has just been turned off the equipment could still be hot and present the possibility of a burn if touched.
Battery Banks
DC systems on Site include banks of batteries, motor-generator (MG) sets or battery chargers, and the
necessary system wiring and controls to supply the DC power. The function of a DC electrical system is
to provide power to essential control systems and equipment, which does not depend on normal AC
power.
For safety, it is required that battery rooms have an eyewash station, in case acid from the batteries is
sprayed in the face of the operator. Ventilation fans should always be operating to prevent hydrogen gas
buildup. Due to the possibility of hydrogen gas being present there will be NO SMOKING in the
battery rooms and always make sure the ventilation fans are operating before entering. Only qualified
personnel should enter a battery room. Only necessary tools should be taken into the battery room. All
tools should be insulated tools. Rubber blankets should be utilized any time when working overhead.
This reduces the likelihood of shorting out the DC system. Batteries should be covered with suitable
insulating materials (i.e., rubber blankets) when personnel are working overhead with tools or metallic objects. Shorting the DC system is extremely dangerous because the system may not be protected by an over current device.
Battery Chargers
There are numerous styles of battery operated trucks that range from small, motorized pallet trucks to
much larger high lift trucks. No matter what kind of truck you have, there are similar hazards associated
with their batteries and their chargers. There are two styles of batteries in industrial trucks today: Lead
acid or nickel-iron. Both of these batteries pose a health threat in several ways:
• Gases emitted during changing can be highly volatile
• Corrosive chemicals within the battery
For these reasons, battery charging stations and the employees that work around them must be properly
equipped and certain safety procedures implemented.
The following procedures must be followed:
1. Eye or face protection must be worn when connecting a charger to a battery.
2. Chargers must be turned off when leads are being connected or disconnected.
3. All leads and cables must be checked and in good condition.
4. When charging batteries and when moving batteries, vent caps must be kept firmly in place to
avoid electrolyte splashing
5. If charging is to be conducted on a battery in a mobile piece of equipment, the battery
compartment cover must be left open to vent heat and explosive gases.
6. There must be adequate ventilation in the charging area.
7. The battery charger must be protected from damage. This usually means a physically protected
area.
8. Facilities for quick drenching or flushing of the eyes and body must be provided at or near the
charging area (approved emergency eyewash and safety shower).
9. Smoking and other ignition sources must be prohibited in the charging area. “No Smoking”
signs must be posted.