Safety Guide for Lithium Ion Battery_Final_12-29-2015

Facility Safety Guidelines for the Manufacture of Lithium Ion Battery Power Banks Page 1
FACILITY SAFETY GUIDELINES
FOR THE
MANUFACTURE OF LITHIUM ION
BATTERY POWER BANKS
Improve the Life of the everyday worker
Reduce Risks to the environment, local communities and people
Enhance the industry on a global scale

1
Global Experience. GLOBAL PERSPECTIVE.
© Sumerra. www.sumerra.com
INTRODUCTION
The purpose of this guideline is to identify safety hazards associated with the manufacture of lithium ion battery power
banks. The guideline contains recommendations for the elimination and control of hazards associated with the
production of lithium ion power banks and also identifies general work practices that, if implemented, can reduce
occupational health and safety risks and protect workers.
This guideline must not be substituted for local regulations or government requirements with respect to the
manufacturing of lithium ion batteries or general production safety, but can be used as a tool to supplement local
requirements and implement additional safety controls to protect employees and organizations. Recommendations are
divided into:
Basic Requirements: Considered by Sumerra to be basic requirements for the protection of worker health and safety
and are likely either required by local law or international standards of practice.
Best Practices: Above and beyond the basic requirements and although not likely to be legally required, represent a
higher level of protection of worker health & safety and are recommended to be applied.
The storage handling and use of lithium ion battery cells presents specific risks that can result in a fire or explosion if
precautions are not taken. Fire or explosions can be the result of:
• A short-circuit;
• over charge/discharge;
• excessive heat; or
• physical damage (crushing or punctures)
The following guideline provides a summary of specific work tasks/processes
and their associated hazards however, due to the nature of facility operations
and environmental conditions, some hazards may be present throughout the
entire facility or parts thereof. Each facility should conduct a formal risk
assessment of its operations to identify and evaluate site-specific risks to
ensure appropriate safety controls and emergency response procedures are in
place to protect the health and safety of all employees.
Each facility should also have an appropriate training program for all employees
that provides information on the specific hazards associated with lithium ion
battery cells, the facility’s safety controls and emergency response procedures.

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RECEIVING & STORAGE
SUMMARY OF HAZARDS
The most common hazards associated with the receiving and storage of
battery cells are physical damage and inadvertent short circuiting. Cells may be
damaged from dropping, over or improper stacking, exposure to high
temperatures and accidental contact with conductive surfaces (i.e. metal
storage racks, employee jewelry) or other battery cells.
Receiving and storage areas may not be regularly occupied and have the
potential to contain large amounts of combustible materials including wood
pallets and packing material (paper, cardboard) that can contribute to the
spread of fire in emergency situations.
BASIC REQUIREMENTS
The following are the most basic requirements that should be followed by
manufacturers with regard to receiving and storage:
 Prior to use in the production process, store cells in their original
containers or similar packaging. Once cells are needed for
production, it is recommended to use non-combustible containers
(such as plastic bins, etc.) with dividers for each battery cell for
transporting or storing cells.
Cells Stored Outside of Original Container
 Store cells in a dry, well ventilated area
 Do not store cells with other combustible or flammable materials
 Isolate new cells from damaged or defective cells
 Properly stack boxes of battery cells to prevent crushing of cells in
lower boxes
 Require removal of any jewelry or conductive materials from workers
that handle cells
Single station smoke alarms, often
required in residential occupancies,
are not meant for protection of
property or protecting unoccupied
areas (such as storage areas) as the
smoke alarm will likely only be
heard by those in the immediate
area. For example, if no one is in
the room, it is unlikely to be heard,
especially if the area is closed off
or people are away on breaks.
Smoke detectors that are
interconnected to the alarm
system are recommended in these
areas.
Storage Area with Single Station Smoke
Alarm
NOTE ON SMOKE
ALARMS
Cells Properly Stored in Original
Containers

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 Move cells in trays with insulated padding or using insulated pushcarts to reduce the chance of dropping or
short circuit
 Cover all conductive or metal surfaces such as storage racking with insulating material to prevent accidental
short circuits
BEST PRACTICES
Beyond the above requirements it is recommended that manufacturers implement the following best practices:
 Only purchase grade A battery cells from suppliers that have appropriate testing programs and test records to
demonstrate compliance with recommended safety testing. An example would be UN/DOT 38.3
Transportation Testing Required for Lithium Battery Safety During Shipping.
 Work with battery cell suppliers and customers to implement purchasing and shipment procedures that
minimize the amount of battery cells stored onsite.
 Where possible, store cells in a temperature controlled environment at 25°C or below
PRODUCTION & ASSEMBLY
SUMMARY OF HAZARDS
During the production and assembly process batteries may be subject to physical damage, inadvertent short circuiting
or over charge/discharge. Cells may be damaged from dropping, being forced into improperly sized casings, exposure to
high temperatures or ignition sources such as soldering guns.
Connecting printed circuit boards (PCB) and batteries, battery testing such as function tests (i.e. impedance, output
voltage), aging tests, short-circuit and over discharge protection tests may cause inadvertent short circuits or
overheating.
BASIC REQUIREMENTS
The following are the most basic requirements that should be followed by manufacturers with regard to production and
assembly:
 Cover all conductive (metal) work surfaces with insulating material
 Ensure work areas are generally free of sharp objects that could puncture or damage cells
Metal rack covered with insulating materialsCells transferred in cart with insulated padding

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 Require removal of any jewelry or conductive material for workers
handling cells.
 Require workers on assembly lines to be connected to a grounding
system/wire to dissipate any built up electric charges. The grounding
wire should be continuous in length and be appropriately connected to
ground.
Wired Grounding System
 Move cells in trays (or their original containers) using insulated pushcarts to reduce the chance of dropping or
short circuit
 Ensure all inspection tools are non-conductive, or covered with a non-conductive material
 When tinning (soldering) leads, only tin one at a time to prevent short circuiting
 If connection leads or tabs need to be cut, cut only one at a time to avoid shorting the circuit
 Do not force cells into housings as this can damage the cells protective casing and/or deform the cell
 Continuously inspect cells for signs of physical damage during the production/assembly process
Tongs without Insulation
Wireless anti-static wrist strap
systems are currently available on
the market and may be considered
by some manufactures. These are
widely regarded as ineffective and
testing supports that they do not
work as advertised.
Wireless grounding systems should
not be used as they do not have
the capability to effectively
dissipate built up electrical
charges.
NOTE ON WIRELESS
GROUNDING SYSTEMS
Insulated Tongs

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BEST PRACTICES
Beyond the above requirements it is recommended that manufacturers
implement the following best practices:
• Written work instructions and specific training should be provided for
each production/assembly step. Training and instructions should include
procedures for identifying and responding to emergency situations.
BATTERY TESTING & INSPECTION
SUMMARY OF HAZARDS
During the production process, batteries are subjected to a variety of tests to ensure proper operation and safeguards
are in place. During this the tests the batteries are vulnerable to overcharging, forced discharges, simulated short
circuits that can result in battery failure leading to fire, venting or rupture (explosion)
BASIC REQUIREMENTS
The following are the most basic requirements that should be followed by manufacturers with regard to battery testing
and inspection:
 When loading cells and/or packs during short duration electrical tests (e.g. voltage checks, impedance testing),
use caution not to exceed the current rating
 When loading cells during long duration performance tests (e.g. burn-in, aging, etc.), use caution not to exceed
the maximum continuous current rating of the cells
 Continuously monitor testing areas for any signs of cell failure while testing is in progress
 Use testing racks constructed of non-combustible material and cover/coat with non-conductive insulating
material.
 Use individual battery slots whenever possible to separate individual cells and avoid accidental contact
Appropriate Racking System Constructed
of Non-Combustible Materials
Combustible Material (wood) Used for
Aging Test Rack
Combustible Material (cardboard) Used
for Padding on Test Rack

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BEST PRACTICES
implement the following practices:
 Consider using an infrared thermometer for safety checks or for quality
control. Infrared thermometers can be used for periodic checking of
individual cells for hot spots or overheating.
 Consider using a thermographic cameras (aka Infrared camera, thermal
imaging camera) to monitor cells for potential overheating. Cameras
can be handheld for periodic checking or permanently installed for
continuous monitoring of racking or storage areas.
Thermal Image
Smoke detectors should not be
installed on ends of rack
systems as they are unlikely to
quickly sense smoke from areas
not immediately adjacent
(Smoke, heat and other
combustion products with rise
to the ceiling and spread
horizontally).
Smoke Detector Improperly Installed on
Rack
In general, smoke detectors:
• Should be located on the
ceiling not less than 100 mm
from a sidewall to the near
edge; or,
• if on a sidewall, between 100
mm and 300 mm down from
the ceiling to the top of the
detector.
Smoke detectors should be
installed in compliance with
local codes or NFPA standards.
NOTE OF PLACEMENT
OF SMOKE DETECTORS
Example Thermographic ImageHandheld thermographic camera
Handheld infrared thermometers used for periodic checking of surface temperature

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EMERGENCY PREPAREDNESS & RESPONSE
SUMMARY OF HAZARDS
In the event of a fire, venting, explosion or other emergency there is a significant
risk of damage and injury to personnel and facility equipment. Appropriate
emergency response procedures must be in place. As each facility environment
(design and layout) will vary, manufactures must establish site/area-specific
emergency response procedures to handle all potential emergency situations. It
is important that only trained and equipped personnel respond to emergency
situations. The main priority in any emergency situation should be the personal
safety of all employees.
BASIC REQUIREMENTS
manufacturers with regard to emergency preparedness and response:
• All means of egress must be kept clear at all times and all exits must
remain unlocked when the facility is occupied.
• Conduct regular detailed inspection/testing of the emergency (fire)
alarm system
• Establish procedures for handling hot cells/short circuits.
Potential hot cells should never
be handled directly by hand,
insulated tongs or other means
should be used to pick up/move
the cell. Personal protective
equipment including impact
resistance safety glasses and
face shield, hand, arm and body
protection must also be worn
when handling and monitoring
suspected hot cells.
Face Shield
Heat/Flame Resistant Apron
Heat/Flame Resistant Gloves
Insulated Tongs
Closed Toed Shoes
NOTE ON HANDLING
HOT CELLS
Recommended Procedure When a Short Circuit or Hot Cell is Detected or
Suspected:
1. If possible, cut the cell leads/connections (one at a time)
2. People should be evacuated from the immediate area
3. If safe to do so, isolate the cell by moving it to a secure area (free of
combustible materials) and placed in a non-flammable non-conductive
container that contains a neutralizing material (i.e. sand)
4. Monitor the temperature of the cell should be from a safe distance using a
non-contact means of temperature monitoring (i.e. Infrared thermometer or
imager) If the cell cools, continue to monitor until it reaches ambient
temperature
5. Preparations for firefighting or forced water cooling should be on standby
alert
6. If the cell continues heating, it should be isolated as best as possible and be
allowed to burn-out. Ensure no people or combustible materials are nearby
that could be impacted by the burning cell.
7. Once cooled, the cell should be disposed of in accordance with local waste
management regulations (lithium ion batteries should not be disposed of with
regular non-hazardous wastes). Connecting terminals should be protected to
prevent any further short circuiting

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 In areas where water flooding may be used to suppress fires establish
procedures to first de-energize (shut down) all electrical systems in the
affected area.
BEST PRACTICES
implement the following practices:
 Even when not required by local fire or building code, equip storage
areas, test areas, and other high risk areas with a smoke/heat
detection system. The detection system should be interconnected with
the alarm system (detection results in general evacuation signal)
and/or monitored in a manned central location (e.g. security station)
FIRE SAFETY EQUIPMENT & RESPONSE
SUMMARY OF HAZARDS
In the event of a fire or explosion, the primary concern is personal safety and an
evacuation should be performed immediately and all staff should be accounted
for. The secondary concern in a fire event should be the cooling of the cell(s)
and surrounding material to prevent the spread of fire.
ABC-type dry chemical extinguishers are typically preferred for most types of
small fires, and some studies have shown that the dry chemical extinguishers
may work in some cases of small fires involving lithium ion batteries. However,
this may not fully extinguish burning lithium ion batteries, does not cool the
cells, and may insulate the batteries preventing additional cooling and therefore
these type of extinguishers will not provide the highest level of protection in
case of a fire in these areas. Flooding the area with a large amount of water will
be most effective in cooling the cells.
BASIC REQUIREMENTS
manufacturers with regard to fire safety equipment and response:
 All areas of the building must have the appropriate fire rated
construction as required by local codes/laws. Additionally, all openings
(doors and windows) must be protected with fire rated assemblies (aka
fire doors, fire windows) as required.
 Place portable fire extinguishers in conspicuous locations along the
regular path or escape paths in all work areas. The maximum travel
distance to a portable fire extinguisher should not exceed 75 feet (23
meters)
Each facility should have clearly
communicated training and
procedures that describe when to
and when not to fight a fire. For
example, if the fire involves a
limited number of batteries (less
than a few cells) and is in a
contained environment with no
significant risk of spreading to
other batteries or materials,
fighting the fire may be safe and
effective; however if the fire has
already spread or is spreading to
other areas /battery cells or poses
a risk to human life, a full
evacuation should be performed
and the local fire authority should
be notified.
It is recommended that
procedures for fire response
include instructions to:
1. Raise the alarm
2. Clear the area of people
3. Turn off any electrical power
systems.
4. Use a fire extinguisher (Halon
or Water) and sand to smother
the fire.
5. If necessary, cool the cells by
flooding the area with water.
Each role and responsibility should
be clear and practiced through
regular drills.
NOTE ON FIREFIGHTING

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 In addition ABC-type dry chemical extinguishers, make Halon or
Halon replacement (e.g. Halotron®, HFC-227ea) fire extinguishers
available in areas where lithium ion battery cells are stored or
handled (e.g. production, testing and storage areas)
 Ensure extra reserves of water (i.e. standpipe and hose reel
installations, secured water buckets) are available to aid in
suppressing fires and the spread of heat in testing and storage
areas
 Post detailed instructions on fire response in all lithium ion battery
storage and testing areas.
 Maintain all firefighting equipment and installations in accordance
with manufacturer’s specifications, local law requirements and
internationally recognized standards.
BEST PRACTICES
Beyond the above requirements it is recommended that manufacturers implement the following practices:
 Even when not required by local fire or building code, equip storage areas, test areas, and other high risk areas
with automated sprinkler/fire suppression systems
openings (doors and windows) with fire rated assemblies (aka fire doors, fire windows).
with emergency smoke/heat ventilation systems to vent hazardous smoke and vapors in the event of a fire or
cell venting/rupture
ACKNOWLEDGEMENTS
Publication Date: October 14, 2015
The primary authors of the report are:
Lead Author: Joe Dakin, Sumerra
Reviewer and Editor: Michael S. Andrew, MS, CIH, CSP, LEED AP, Sumerra
About Sumerra
Sumerra was created to meet the needs of Brands, Factories, Licensees, and other Associations who are striving to
improve working conditions and reduce risks throughout the world. Sumerra’s foundation is the belief that every
worker in a factory should be treated fairly while working in safe conditions. In addition, the surrounding environment
and communities should be kept clean and healthy. We strongly believe that this can, and should be accomplished,
while increasing profitability and production. It is Sumerra’s goal to increase the management systems and programs
that promote the fair treatment of workers, worker health & safety and environmental stewardship through education,
accountability and collaboration. Visit www.sumerra.com to learn more about Sumerra’s services and experience.
© Copyright 2015
HFC-227ea Fire Extinguishers

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APPENDIX A: GLOSSARY OF TERMS
Halon Fire Extinguisher: This is a fire extinguisher that contains Halon. Halon is a liquefied, compressed gas that stops
the spread of fire by chemically disrupting combustion. Halon is identified by Halon 1211 (a liquid streaming agent) and
Halon 1301 (a gaseous flooding agent).
Halon Replacement Fire Extinguisher: This is a fire extinguisher that contains a chemical with similar extinguishing
characteristics as Halon and is used as a replacement for Halon. Halon is detrimental to the environment and its use is
restricted or banned in many areas, and therefore, several replacements have been established in the market. Common
halon alternatives include:
• HCFC-123 (Trade Names: FE-232)
• [HCFC Blend] B (Trade Names: Halotron 1)
• HFC-227ea (Trade Names: FM-200, MH-227)
• HFC-236fa (Trade Names: FE-36)
Smoke Alarm: A stand-alone device with a built-in audible sounder, a control component such as a power supply
(typically battery or electric with battery backup), and a sensor
Smoke Detector: A detector typically has only a built-in sensor and is interconnected as part of a system. A detector
requires an external sounding audible device (such as a horn/strobe unit) and a control component such as a power
source, typically found at the fire alarm panel.
Thermographic Camera: A thermographic camera (also called an infrared camera or thermal imaging camera) is a
device that forms an image using infrared radiation. This can be used to identify areas of high surface temperature
which may be indicative of an overheating issue.

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APPENDIX B: ADDITIONAL RESOURCES
[1] NFPA 203, Standard for the Fire Protection of storage, National Fire Protection Association (NFPA).
[2] NFPA 13, Standard for Installation of Sprinkler Systems, National Fire Protection Association (NFPA).
[3] NFPA 80, Standard for Fire Doors and other Openings Protectives, National Fire Protection Association (NFPA).
[4] NFPA 72, National Fire Alarm and signaling Code, National Fire Protection Association (NFPA) .
[5] NFPA 101, Life Safety Code - Chapter 7: Means of Egress, National Fire Protection Association (NFPA).
[6] NFPA 10, Standard for Portable Fire Extinguishers, National Fire Protection Association (NFPA).
[7] NFPA 14, Standard for Installation of Standpipe and Hose Systems, National Fire Protection Association (NFPA).
[8] NFPA 204, Standard for Smoke and Heat Venting, National Fire Protection Association (NFPA).
[9] B. Ditch and J. de Vries, "Flammability Characterization of Lithium-ion Batteries in Bulk Storage," FM Global,
Norwood, MA, 2013.
[10] R. T. Long Jr., J. A. Sutula and M. J. Kahn, "Li-ion Batteries Hazard and Use Assessment Phase IIB: Flammability
Characterization of Li-ion Batteries for Storage Protection," Exponent, Inc. (Prepared for Fire Protection Research
Foundation), Bowie, MD, 2013.
[11] C. Mikolajczak, M. Kahn, K. White and R. T. Long, "Lithium-Ion Batteries Hazard and Use Assessment," Exponent
Failure Analysis Associates, Inc. (Prepared for Fire Protection Research Foundation), Menlo Park, CA, 2011.

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