OTECSA continue to support clients across industry on DSEAR including DSEAR Risk Assessment for Battery Rooms. Here we explain some of the complexities around DSEAR RA and Hazardous Area Classification for battery charging and battery room installations. If you are interested in how much a DSEAR Risk Assessment might cost, we explain this here.
The types of batteries covered include a whole range including Li-Ion, Sealed Lead Acid (SLA), Vented Lead Acid (VLA), NiCd, NiFe, NiMH and LiPo, each has their own characteristics for potential hydrogen release.
DSEAR hazards of battery rooms?
Although battery rooms and battery charging stations at industrial premises are primarily electrical rooms, the charging of batteries presents a flammable atmosphere risk due to hydrogen production.
During the charging process of most batteries hydrogen gas is evolved and battery rooms should have specific design features and protections to prevent the formation of a flammable atmosphere and minimise fire and explosion risks.
Guidance on DSEAR for battery rooms
There are various sources of good practice guidance for battery room safety. This includes the Health and Safety Executive guidance INDG 139 “Using electric storage batteries safely”.
This guidance outlines some key safety features of battery rooms in relation to DSEAR and ATEX including:
- Ventilation requirements to ensure any hydrogen evolved is dispersed safely
- Basic zoning requirements
- How to minimise risks through selection of less hazardous batteries (e.g. valve regulated type batteries)
As with any HSE guide, this typically provides means to ensure compliance, without going into too much detail.
Additional guidance is available through the Standard: IEC 62485-2. This design standard goes into more detail and allows more specific safety measures to be designed:
- More accurate (due to the increased science involved in calculations) zoning distances
- More accurate ventilation requirements (less onerous than INDG 139)
Typically for a single or multiple forklift or plant charging station, INDG 139 may be appropriate to provide zoning and ventilation guidance. When an installation includes banks of batteries under charge for power installations the more complex IEC 62485-2 should be used.
How we assess DSEAR for Battery Rooms
As part of our risk assessment for DSEAR we consider many factors, for battery rooms this is no different. The key considerations would be:
- Could there be flammable atmospheres present, e.g. from the charging of batteries and evolution of hydrogen gas?
- How large could a zoned area be? This will depend on the number of cells being charged and the characteristics of the battery design and materials.
- How badly could people be harmed?
- What design measures are in place to reduce risk? This could include ventilation, flammable gas detection, alarm systems.
- What emergency measures are in place?
- Do the personnel present understand the risks of the areas?
- Are there any other measures that should be taken to reduce risk?
Output from a DSEAR Risk Assessment includes the risk assessment details, including any recommendations. Hazardous Area Classification zoning information is also produced including HAC zone drawings to show where ignition sources need to be controlled.
As with any risk assessment, this should be updated throughout the life of the installation, from design to the operating life of the plant. This should include reviews on a regular basis, or whenever major changes occur.