Revision #: / 1
Implementation Date: / 2012/01/23
Page #: / 1 of 4 / Last Reviewed/Update Date: / 2012/01/23
SOP Owner: / HWD Executive Management / Approval: / HWD Executive Management
Standard Operating Procedure – Battery Maintenance
1. Purpose
The common thread throughout the SOP and HWD Policies and Procedures in general is the identification of responsibilities. This manual is intended to clearly and concisely identify the steps required by employees to complete any given operation in a manner that is consistent with Horizontal Well Drillers standards. It will document progressive steps required in sequence that are to be followed, an authorizing company department or position, and an author that is to be consulted if there are questions in any portion of the SOP standards.
2. Scope
ALL RIG PERSONNEL
3. Prerequisites
Personnel are required to wear proper personal protective equipment, follow job safety rules, and have the appropriate experience and certifications to carry out their job functions satisfactorily.
4. Responsibilities
Tool pusher will have ultimate accountability that driller and crews are completing the procedure to standard. Driller and crews will be responsible for implementation and actions to complete this task as described in the procedure steps.
5. Procedure
1. Notify the Rig Manager and Driller that the batteries need to be serviced.
· Hold a brief safety meeting to discuss safeguards and emergency procedures in case of an explosion.
· Make sure that the battery boxes have been drilled and vented properly for cooling.
· The person performing the maintenance must put on a full face respirator or goggles and a full face shield with hardhat, three-quarter-length rain jacket from the mixing shack, and long chemical-resistant gloves.
2. Assess the area where the battery is stored and the battery to diagnose any existing battery problems.
· If batteries are hot, let them cool before servicing.
· Never lean over the battery while testing or inspecting it.
· If you smell an acrid chemical smell, the batteries could be boiling, especially if they are overcharged. Proceed with extreme caution. Allow the battery to cool before trying to remove the caps.
· If it is a very hot day or the building that the batteries are stored in is very hot, a hazardous condition is more likely.
3. Shut off the motor.
· Before shutting off the motor, check the charge on the volt meter. Over-charged batteries are more likely to explode. If they are over-charged, proceed with extreme caution.
· Shut off the floor motor and make sure that the battery is isolated from the engine.
· Make sure there is no secondary battery charger hooked up to the battery. If there is a charger, unplug the charger and then disconnect the battery clamps.
4. Disconnect the leads.
· One person must be assigned to disconnect leads and check electrolyte levels in the battery cells.
· The designated person must put on a full face respirator or goggles and a full face shield with hardhat, three-quarter-length rain jacket from the mixing shack, and long chemical-resistant gloves.
· Keep non-essential personnel out of the area while disconnecting and removing the battery.
· If there is no permanent eyewash station nearby, an eyewash bottle must be brought to the area for immediate use in case someone gets electrolyte in their eyes.
· Make sure that the area is well ventilated before removing battery leads.
· Remove the negative leads first, then the positive leads. Do not let the negative leads ground out after removal.
5. Inspect the battery and battery storage.
· If testing must be done to a battery, a hydrometer must be used to determine the specific gravity in each cell.
· Never attempt to open a maintenance-free wet cell battery to check fluid levels.
· Never attempt to add new electrolyte (acid) to a battery. Add distilled water only.
· Make sure of the following for all battery boxes:
w they must be vented,
w they must have rubber on the bottom to help absorb the vibration, and
w the rubber must also be secured to the inside of the lid on the metal boxes to prevent arcing against the terminals on the battery.
6. Remove the cell caps and check electrolyte levels.
· Make sure that the area is well ventilated before removing cell caps.
· Follow manufacturer’s instructions regarding electrolyte level.
7. Add electrolyte to the batteries.
· Dilute any electrolyte that comes out of the battery with water.
· Wipe up with a rag and dispose of the rag.
· Make sure chemical-resistant gloves are worn while cleaning up the fluid.
8. Follow the proper practices and procedures if battery requires charging.
· Determine if the batteries are on a 12 or 24 volt system.
· Never attempt to charge a battery without first reviewing the instructions for the charger.
· If using a battery charger, make sure that its settings are appropriate and compatible with the battery. Incorrect charging levels and settings can lead to sulfation and over-charging/boiling the battery.
· Always charge batteries in a well-ventilated area. Keep all vents tight and level.
· Never attempt to charge a visually damaged or frozen battery.
· Turn the charger off before attempting to connect leads to the battery to avoid dangerous sparks.
· Make sure that the charger leads are not broken, frayed, or loose.
· Connect the leads to the battery in the following sequence:
1. Red positive (+) lead to the positive (+) terminal, then
2. Black negative (-) lead to the negative (-) terminal.
· Set the timer, turn the charger on, and slowly increase the charging rate until the required ampere value is reached.
· If the battery becomes hot or if violent gassing or spewing of electrolyte occurs, reduce the charging rate or turn off the charger temporarily.
· Always turn off the charger before removing the leads.
9. Follow the proper practices and procedures if the battery needs to be replaced.
· Disconnect the leads in the following sequence:
1. Negative first, then positive. Do not let the negatives ground out on anything when they are removed. Only one person should be in the area when disconnecting the leads.
2. If batteries are in an awkward location and must be tipped on an angle to be removed, watch out for spilled electrolyte. Any spilled electrolyte must be diluted with water and cleaned up as soon as possible.
· Batteries are awkward to carry and often heavy. Use enough manpower when handling batteries to avoid excessive tipping or splashing of electrolyte inside cells
6. References
HWD Employee Handbook
7. Definitions
NA