Battery Safety Course

Lesson 1 • Electrochemical Principles of Batteries

Covers oxidation-reduction reactions, ion transfer, and voltage generation inside a cell. Provides the chemical foundation needed for all subsequent safety analysis.

Lesson 2 • Battery Pack Architecture

Explains how individual cells are arranged in series and parallel configurations to form packs. Links pack design to voltage, capacity, and thermal behaviour.

Lesson 3 • Battery Cell Types and Chemistries

Surveys lead-acid, nickel-based, lithium-ion, and solid-state chemistries. Distinguishes performance and risk profiles across each type.

Lesson 1 • Electrical Hazards in Battery Systems

Covers shock, arc flash, and short-circuit risks from high-voltage and high-current sources. Connects voltage thresholds to injury severity levels.

Lesson 2 • Thermal Runaway Mechanisms

Explains the self-reinforcing heat cycle that leads to thermal runaway in lithium-ion cells. Identifies trigger events and propagation pathways within a pack.

Lesson 3 • Hazard Severity and Likelihood Assessment

Introduces risk matrices and qualitative scoring to prioritise battery hazards. Prepares students to rank risks before selecting controls.

Lesson 4 • Mechanical and Physical Hazards

Addresses crush, puncture, vibration, and drop hazards that can compromise cell integrity. Links physical damage to downstream electrical and thermal risks.

Lesson 1 • Transport and Shipping Regulations

Covers dangerous goods classifications, packaging requirements, and documentation for air, sea, and ground transport. Emphasises state-of-charge limits and labelling obligations.

Lesson 2 • International Safety Standards Overview

Surveys globally recognised battery safety standards for cells, packs, and systems. Explains how standards bodies develop and update requirements.

Lesson 3 • Workplace Safety Regulations

Addresses employer obligations for hazard communication, exposure limits, and safe work procedures. Connects regulatory duties to daily operational decisions.

Lesson 1 • Engineering Controls and Ventilation

Describes local exhaust ventilation, interlocks, and isolation barriers used in battery work areas. Connects control design to specific chemical and thermal hazards.

Lesson 2 • Electrical PPE Selection and Use

Covers insulated gloves, face shields, arc-rated clothing, and dielectric footwear for high-voltage battery tasks. Links PPE class ratings to voltage exposure levels.

Lesson 3 • Hierarchy of Controls for Battery Work

Applies elimination, substitution, engineering, administrative, and PPE controls to battery hazards. Establishes the priority order for selecting protective measures.

Lesson 4 • Chemical PPE and Respiratory Protection

Identifies appropriate gloves, aprons, goggles, and respirators for electrolyte and off-gas exposure. Explains fit testing and cartridge selection for respiratory hazards.

Lesson 1 • Battery Storage Area Requirements

Specifies temperature ranges, segregation distances, fire-rated storage, and signage for battery storage areas. Aligns physical layout with hazard control principles.

Lesson 2 • Internal Transport and Staging

Addresses cart selection, securing methods, and route planning for moving batteries within a facility. Minimises mechanical damage and electrical hazard exposure during transit.

Lesson 3 • Receiving and Incoming Inspection

Defines inspection steps for verifying packaging integrity, labelling, and visible damage upon delivery. Prevents damaged or non-compliant batteries from entering service.

Lesson 4 • State-of-Charge Management in Storage

Explains optimal storage charge levels, periodic maintenance charging, and monitoring schedules. Prevents capacity loss, lithium plating, and over-discharge damage.

Lesson 1 • Battery Management System Functions

Explains cell balancing, overvoltage, undervoltage, overcurrent, and temperature protection functions of a BMS. Connects BMS operation to hazard prevention during charge and discharge.

Lesson 2 • Recognising Charging Faults and Anomalies

Trains recognition of overcharge symptoms, abnormal heat, swelling, and error codes during charging. Enables early intervention before a fault escalates to a thermal event.

Lesson 3 • Charging Environment Safety

Specifies ventilation, fire suppression, and clearance requirements for dedicated charging areas. Reduces ignition risk from off-gassing and thermal events during charging.

Lesson 4 • Charger Selection and Compatibility

Identifies compatibility criteria between chargers and battery chemistries, voltages, and capacities. Prevents mismatched charging that causes overcharge or thermal events.

Lesson 1 • Battery Fire Suppression Techniques

Explains extinguishing agent selection, cooling water application, and suppression limitations for lithium battery fires. Addresses re-ignition risk and extended cooling requirements.

Lesson 2 • Electrolyte Spill Response

Details decontamination steps, neutralisation agents, and waste disposal for acid and lithium-salt electrolyte spills. Prevents secondary chemical exposure during cleanup.

Lesson 3 • Post-Incident Procedures and Reporting

Establishes scene preservation, incident documentation, and regulatory notification steps after a battery event. Feeds data into root-cause analysis and corrective action processes.

Lesson 4 • Electrical Injury First Aid

Covers safe victim rescue from energised sources, shock first aid, and arc burn treatment priorities. Emphasises scene safety before any contact with an injured person.

Lesson 1 • Routine Visual and Physical Inspection

Defines inspection intervals, checklist items, and pass/fail criteria for battery visual assessments. Establishes a baseline for detecting degradation before it becomes a hazard.

Lesson 2 • Thermal Imaging and Advanced Diagnostics

Applies infrared thermography and ultrasonic testing to detect hot spots and internal defects. Extends diagnostic capability beyond what visual and electrical tests reveal.

Lesson 3 • Recycling, Disposal, and Second-Life Options

Covers hazardous waste classification, approved recycling pathways, and second-life repurposing criteria for spent batteries. Ensures environmental compliance and resource recovery.

Lesson 4 • Electrical Diagnostic Testing

Covers voltage measurement, impedance spectroscopy, capacity testing, and insulation resistance checks. Links test results to actionable maintenance or replacement decisions.