Applied electrical safety for systems
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May 25, 2023 - Alternating current (AC) electrical power has been used in industrial facilities and in people’s homes since 1882. Over the years, we have come to recognize the hazards associated with AC, while safety professionals have implemented regulations and procedures for managing their risks.
However, the hazards of direct current (DC) systems from a new generation of high voltage lithium-ion batteries are not well understood. Safety Now highlights that 4,000 people every year are injured from electrical contact or arc-flash incidents, and workplace electrical incidents are significantly more serious than other types of workplace injuries. A study of data collected from 2011-2021 by The Electrical Safety Foundation International (ESFI) reveals that industrial workers bear a higher risk of electrical injury, with 44.8 percent of electrical fatalities occurring while working on or near energized conductors or parts.
The high voltage and energy density of lithium-ion batteries make them optimal for applications requiring high-power output and reliable energy storage, including electric vehicles, renewable energy systems, and serving as a source of emergency backup power. DC systems are becoming more common and more powerful, and they come with some of the same safety concerns as AC power, like electric shocks and flash burns. Lithium-ion battery systems also pose additional handling, storage, and emergency response challenges that are unique to their technology.
Sectors such as electric vehicle manufacturing and energy storage systems often see workers interacting with dangerous, high voltage DC systems in the 300-to-800-volt range, but they are unsure of how to manage the unique risks presented by lithium-ion battery technology. Alongside this is a lack of guidance on how to protect workers exposed to DC hazards, as most regulatory standards and references have been predominantly focused on AC systems and older lead-acid battery technology.
Given the increasing prevalence of high voltage DC technologies, it is crucial for industry professionals to receive appropriate training and be equipped to understand and mitigate shock and arc-flash hazards from lithium-ion batteries. Implementing safety measures becomes paramount when handling high voltage lithium-ion batteries or working on high voltage DC systems. This includes the selection and use of protective equipment such as arc-rated garments and shock-protection PPE such as electrically insulated gloves, mats, and non-sparking tools. Additionally, workers and first responders must be familiar with emergency response actions to be taken in the event of a battery thermal runaway, fire, or loss of electrolyte.
David Paoletta will be presenting this topic along with further safety tips and insights at the American Society of Safety Professionals (ASSP) Safety 2023 Conference & Expo, held from June 5 to 7 in San Antonio, and at the National Fire Protection Association (NFPA) Conference & Expo from June 19 to 23 in Las Vegas.
Register for the ASSP Safety Conference & Expo or the NFPA Conference & Expo. For more insights on environmental, health, safety and well-being, digital trust, privacy and information security, and other topics that should be at the top of your organization's list, visit BSI's Experts Corner.
