Lithium-Ion Battery Storage, Handling, and Charging Procedures For Non- PoR suas

Transcription

1 VERSION 4 Lithium-Ion Battery Storage, Handling, and Charging Procedures For Non- PoR suas In Support of The United States Navy (USN) & United States Marine Corps (USMC) Approved By: Al Stumm AIRWorks Class Desk

2 Revision History Version Name Date Description Version 1 13 June 2017 Initial Draft Version 2 19 June 2017 Version 3 24 Aug 2017 Version 4 11 Sep 2017 Initial signed release. Changed title of document from USN USMC Lithium-ion Battery Safety Program to current title. Incorporated AIR-4.4 and AIRWorks Class Desk edits. Added detailed facilities, installations, and storage requirements. Clarified requirement for OEM charger; Clarified charging room temp requirements; other admin. i

3 Table of Contents 1 Purpose Facilities and Installations Requirements Receiving Transporting Charging Storage Operational Use Pre-Flight Flight Post-Flight Safety Fire Water Exposure Saltwater Exposure Crash Procedures Contact Exposure Inventory Control and History Appendix A: Battery Log... 8 ii

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5 1 Purpose The purpose of this document is to establish requirements and best practices for commercial Lithium-ion batteries associated with Non-Program of Record (non-por) Small Unmanned Aerial System (suas) operations. These safety procedures are limited to: 1. Lithium-ion batteries in group 1 & 2 (<55 lbs.) Unmanned Aircraft (UA.) 2. Lithium-ion batteries in Radio Controllers (R/C) and Ground Control Station (GCS) equipment. 3. Shore based facility operations. The requirements and best practices outlined in this document solely apply to personnel designated by a USN or USMC Aircraft Reporting Custodian (ARC). In a non-por UAS operation, the ARC is responsible for the day-to-day operations of the UAS, including its maintenance, storage, and transportation. The remainder of this document will address proper receiving, transporting, charging, storing, operational use, safety and history tracking of Lithium-ion batteries. For more information on USN/USMC battery safety policy, consult NAVSEA S9310-AQ-SAF-010 Technical Manual for Navy Lithium Battery Safety Program Responsibilities and Procedures. 2 Facilities and Installations Requirements Prior to bringing lithium-ion batteries onto installations, non- PoR UAS personal must consult with installation safety officers and fire department services. Consultation is required to establish local installation ordnance and safety procedures for Lithium-ion battery operations. Lithium battery use, maintenance, and storage shall be in accordance with (IAW) the site Hazardous Communication Plan (HAZCOM) as documented IAW 29 CFR Contact the site safety officer and/or the hazardous material representative for specific requirements. Approved locations shall be pre-established for safe Lithium-ion battery storage and charging as approved by installation and IAW this safety plan and the site HAZCOM plan. 1

6 Facilities where lithium batteries are handled and charged should consider the best practices listed below. a. Charging rooms constructed of fire proof material such as cinder block are preferred. The use of a dedicated MILVAN with adequate climate control for charging is another alternative. Charging room temperature shall be maintained IAW battery/uas manufacturer recommendations. b. Isolate charging areas from storage areas. Compartmentalization or distribution strategies may be appropriate for minimizing the hazard. c. Isolation of heating, ventilation, and air conditioning system air from adjacent work areas is preferred. Emergency ventilation to dump smoke and fumes in conjunction with fire suppression system is desirable. d. Establish a clear exit path from the work and charge stations. e. Ensure access to an emergency hand pull alarm. f. An automatic sprinkler system, actuated by smoke and/or flame is preferred. Mishap reporting procedures will be established by the ARC, and with both installation personnel and with the Navy Lithium Battery Safety Program (LBSP) Technical Agent(s). The NAVAIR LBSP Point of Contact (POC) is Mr. Reginald Fagin, reginald.fagin1@navy.mil, telephone: (301) Receiving and Periodic Inspections Upon receipt of a Lithium-ion battery, inspect the general condition of the packaging for apparent damage which includes but is not limited to leakage, damaged packaging, dented corners, discoloration, unusual odors, and swelling. If packaging or apparent damage is present, the lithium cell/batteries may be compromised. Carefully secure and store the damaged battery in a fireproof container or a fire retardant pouch to mitigate fire risk. Report the package condition to shipping originator and dispose in accordance with manufacturer and local installation shore-based ordnance instructions. 2

7 If the packaging is in acceptable condition, no further action is required and nominal operations can continue. 4 Transporting Prior to transporting Lithium-ion batteries, inspect each battery pack IAW paragraph three (3). Verify that the battery cells are nominal IAW the battery/suas user/operator manuals. Doing so ensures that the batteries are stable enough to transport. If the batteries are stable to transport, protect output terminals, pins and connectors from contact with conductive surfaces and/or personnel in such as manner as to prevent electric shock and/or short circuits. Individually secure batteries in flame retardant pouches. Transport batteries in a sealed metal container to prevent damage from a drop or puncture, and to mitigate fire risk. Specific Transportation Regulations apply depending upon the chosen means of transportation. Per NAVSEA S9310-AQ-SAF-010, the below guidance applies: TRANSPORTATION BY MILITARY AIR SHIPMENT. Transportation requirements within the DOD are covered by Air Force Interservice Manual (AFMAN) /TM /NAVSUP PUB 505/MCO P /DLAI All transportation of lithium batteries on military aircraft must be conducted in accordance with the regulations therein. NEW LITHIUM BATTERIES ON PUBLIC DOMAIN. All transportation of new lithium batteries on public highways is controlled by federal law regulating shipment of hazardous materials. The general regulations are stated in 49 Code of Federal Regulations (CFR) and Any deviations from the methods described in the CFR must be approved before shipment in the form of an exemption by the Office of Hazardous Material Safety Research and Special Programs Administration. USED LITHIUM BATTERIES ON PUBLIC DOMAIN. All transportation of used lithium batteries on public highways is controlled by federal law regulating shipment of hazardous materials. 3

8 The general regulation, as stated in 49 CFR and 49 CFR permits shipment of waste lithium batteries to a disposal site by motor vehicle only. If there is a chance for a battery to breach during transport causing electrolyte to leak, use a drum liner or lined box to contain electrolyte. TRANSPORTATION ABOARD US NAVY SURFACE SHIPS AND SUBMARINES. Lithium battery transportation aboard US Navy surface ships and submarines shall be approved by NAVSEASYSCOM (SEA- 05Z34). TRANSPORTATION ABOARD NAVY AIRCRAFT. Lithium battery transportation aboard Navy aircraft shall be approved by NAVAIRSYSCOM (AIR ). TRANSPORTATION ABOARD MILITARY SEALIFT COMMAND VESSELS. Lithium battery transportation aboard Military Sealift Command platforms shall be approved by COMSC (N7). 5 Charging Thoroughly inspect batteries IAW paragraph three (3) for apparent damage prior to charging. Batteries that appear to be compromised shall not be charged, and shall be disposed of IAW manufacturer recommendations and local installation HAZCOM plan. Contact the site hazardous material representative for specific battery disposal instructions. Lithium-ion batteries shall be charged IAW manufacturer s recommendations. Only manufacturer-approved chargers shall be used to recharge batteries. Desired features and fail-safes for chargers include polarity mismatch, current limiting and cell balancing. Chargers specifically designed for lithium batteries shall be used. Batteries shall not be left unattended during charging and will be placed in a flame retardant pouch to minimize fire risk. Battery state of charge should be reduced to a storage or longterm maintenance level when not intended to be used within 30 days. Battery and charger manufacturer instructions/recommendations for long duration storage shall be followed. 4

9 6 Storage When not in use, lithium batteries shall be removed from the UAS and stored in an approved flammable storage locker/container or pouch within a temperature-controlled environment as approved by the local installation. Batteries shall not be stacked or packed tightly together and shall not rest directly on metal surfaces. Instead, battery packs shall be placed on ceramic tiles or inside a fire retardant pouch within the established flammable storage container. While flammable storage lockers are ideal, other metal containers are acceptable. A minimum standoff distance of 36 inches is required from combustible material and an adjacent cabinet/container. Material is prohibited on top of the cabinet/locker. Individual cabinets or lockers shall be limited to an aggregate energy capacity of 2,000 Watt-hours. If the battery Watt-hour rating is not printed on the battery, it can be calculated by multiplying the nominal voltage and amp-hour capacity. Cabinets, lockers, and containers shall be marked with a hazard class 9 placards. 7 Operational Use 7.1 Pre-Flight Lithium-ion batteries shall be thoroughly inspected IAW paragraph three (3) for any damage prior to being installed on the UAS for flight. If the battery has been compromised, do not install. Dispose damaged batteries in accordance with manufacturer s recommendation(s) and local installation HAZCOM plan procedures. Lithium batteries shall be installed in the UAS IAW the UAS manufacturer s instructions. Batteries shall be kept isolated from heat sources and operated IAW manufacturer s limitations. Operating the battery at temperatures greater than manufacturer s limits may cause cells to become unstable and present an increased risk of ignition. Batteries shall not be located/stored near moving components that may cause physical damage. 5

10 7.2 Flight Operating lithium-ion batteries in environments exceeding manufacturer s specified limits shall be avoided. 7.3 Post-Flight After a flight has concluded, Lithium-ion batteries shall be removed and placed in the established location IAW paragraph six (6) and away from direct sunlight. Carefully inspect the battery IAW paragraph three (3) for damage, overheating, swelling, or leakage before transporting. Charging and storage procedures shall be followed after transporting. 8 Safety 8.1 Fire In the event of a fire, water or other aqueous agents should be used to effectively suppress the fire. Report mishaps IAW local installation ordnance procedures, and non-por UAS ARC requirements. Contact NAVAIR LBSP Point of Contact (POC) as required by paragraph two (2). 8.2 Water Exposure If the Lithium-ion battery comes in contact with water, immediately dry the battery using a clean towel. Store the battery in a fire resistant container, away from flammable substances, for a minimum of 24 hours as a safety precaution. Perform a thorough inspection of the battery for any apparent damage IAW paragraph three (3). Dispose in accordance with local installation HAZCOM procedures if damage is apparent. 8.3 Saltwater Exposure Saltwater exposure must be handled differently than fresh water exposure. Conservatively, Lithium-ion batteries that come in contact with saltwater should be disposed of. Saltwater has the potential to form an electrical path and may ignite when not handled properly. This unsafe condition may result in a delayed response, and therefore can result in an unexpected fire at the disposal site. If a Lithium-ion battery comes into contact with saltwater, rinse the battery with distilled or deionized water followed by a wipe down with a clean towel. Store the battery in a fire 6

11 resistant container, away from flammable substances, for a minimum of 24 hours as a safety precaution. Dispose in accordance with local installation HAZCOM procedures. 8.4 Crash Procedures Lithium-ion batteries involved in a crash shall be handled with extreme caution. Although it may appear that no physical damage has occurred during a crash, Lithium-ion batteries can have a delayed chemical reaction. Lithium-ion batteries shall be placed in a fire proof location IAW paragraph six (6) and observed for safety reasons. When practical, the battery shall be left in the safe location for a minimum of 24 hours. Perform a thorough inspection of the battery for any apparent damage IAW paragraph three (3). Dispose in accordance with local installation HAZCOM procedures if damage has occurred. 8.5 Contact Exposure If electrolytes in the cells should come in contact with skin or eyes, follow the exposure instructions located in the battery s Material Safety Data Sheet (MSDS). Immediately seek medical attention. Report exposure/mishap in accordance with local installation procedures and non-por UAS ARC guidance. 9 Inventory Control and History All batteries shall be designated with a unique identifier (ARC/site-specific) and dated with the original purchase date. A battery log shall be kept IAW appendix A (or equivalent) of the pack s history which includes at a minimum: date of each cycle, start voltage/end voltage (if available), charged voltage (if available), and documentation of events such as crashes, or charging anomalies. NO REPAIRS or MODIFICATIONS shall be made to the battery or battery pack(s). Tracking of such data is intended to help users determine if the particular battery is suitable for the application. Refer to manufacturer s specifications for battery lifecycle recommendations and Appendix A of this document for a sample battery log. Periodically (every six months) check the Consumer Product Safety Commission (CPSC) website (SaferProducts.gov) to identify batteries with reported problems, remove batteries listed on the CPSC website from service, and contact the LBSP technical agent 7

12 for further instructions. To avoid procuring defective batteries, check the CPSC website prior to purchase. Only Original Equipment Manufacturer (OEM) replacement batteries shall be procured for use in the subject UAS. Non-OEM batteries shall be approved by a LBSP technical agent. 8

13 10 Appendix A: Battery Log BATTERY ID/SERIAL: # 1 CYCLE DATE DISCHARGE START VOLTAGE DISCHARGE END VOLTAGE DATE OF PURCHASE: POST ANOMALIES CHARGE (*IF APPLICABLE) VOLTAGE