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Standard Operating Procedure (SOP): Lithium Polymer (LiPo) Battery Safety

1.0 PURPOSE

This SOP provides comprehensive safety guidelines for handling, charging, storing, and disposing of Lithium Polymer (LiPo) and Lithium-ion (Li-ion) batteries. Due to high energy density and volatile chemistry, strict adherence is required to prevent thermal runaway, fire, and injury.

2.0 PPE AND PREPARATION

2.1 Personal Protective Equipment (PPE)

When handling novel, damaged, or malfunctioning batteries: * Eye Protection: Safety glasses. * Hand Protection: Flame-retardant (FR) glove liners with a chemical-resistant outer glove (e.g., Nitrile) to protect against electrolyte leakage and flash fire.

2.2 Lithium Battery "Crash-Bins"

The lab maintains metallic containment bins for damaged/defective units. * Contents: Non-combustible metallic container, inert bead lining (e.g., CellBlock or sand), and a Ziploc bag of additional beads. * Deployment: Place the battery inside, cover with additional beads if the battery is hot, and place the lid loosely over the top. * Pressure Relief: Do not re-attach latching rings or press-fit lids; pressure must be allowed to vent safely.

3.0 RESPONSIBILITIES

3.1 Researchers and Students

  • Follow all charging and storage protocols without exception.
  • Report any "puffy", dropped, or damaged batteries to the Lab Safety Manager immediately.

3.2 Environmental Health & Safety (EHS)

  • Manage hazardous waste pickup and disposal.
  • Provide plastic buckets and specialized containment for battery waste.

4.0 INSPECTION

  • Regular Checks: Inspect batteries before every use for swelling, punctures, or discoloration.
  • Signs of Failure:
    • Swelling/Puffing: Indicative of internal outgassing.
    • Heat: Temperature >45°C (113°F) during rest or use.
    • Noise/Odor: Hissing, cracking, or "sweet" chemical odors.

5.0 CHARGING AND DISCHARGING

5.1 Charging Protocol

  • Unattended Charging: Never leave batteries charging unattended.
  • Surfaces: Charge on flat, non-conductive, and non-combustible surfaces (e.g., stone or metal) away from flammable materials.
  • Chargers: Use only the manufacturer-approved charger. Never use a charger just because the connector fits.
  • Environment: Charge at room temperature. Never charge below 0°C (32°F) or above 40°C (105°F).
  • Power: Plug chargers directly into wall outlets; avoid extension cords or power strips.

5.2 Voltage Limits

  • Max Voltage: Never exceed 4.2V per cell.
  • Min Voltage: Never drop below 3.0V per cell (3.3V recommended for longevity).
  • Irreversible Damage: Any cell exceeding 4.2V or dropping below 3.0V is permanently damaged and must be retired.

6.0 STORAGE AND TRANSPORT

6.1 Storage Conditions

  • Storage Charge: For long-term storage, maintain cells at 3.80V - 3.85V (approx. 40-50% SOC) (where possible).
  • Maintenance: Check voltages every 30-90 days. If a cell drops below 3.7V, recharge to storage voltage (where possible).
  • Environment: Store in a dry, well-ventilated area between 15°C and 35°C (59°F - 95°F) out of direct sunlight.

6.2 Transport

  • Protect terminals with electrical tape or caps to prevent short circuits.
  • Use padded cases to prevent mechanical shock or punctures.
  • Never carry a battery by its terminals.

7.0 EMERGENCY PROCEDURES

7.1 Handling Failing Batteries

  1. Disconnect: Immediately unplug the device or charger, if safe.
  2. Isolate: Move the battery to a "Crash-Bin."
  3. Monitor: Observe from a safe distance. If it remains stable, contact EHS for disposal.

7.2 Fire or Smoking Battery Response

  • Immediate Action: Pull the fire alarm, evacuate, and call 911 to report the incident.
  • Containment: Do not attempt to contain a battery that is smoking, puffing and growing, or on fire.
  • Extinguishers: Class A, B, and C extinguishers are generally ineffective. Do not use water, as it may cause a violent reaction with molten lithium and creates an electrocution risk for multi-cell packs.
  • First Aid: If exposed to electrolyte, rinse the area with water for 15 minutes and seek medical attention.

8.0 WASTE MANAGEMENT

8.1 Disposal

  • Never throw LiPo batteries in regular trash.
  • Preparation: Tape any exposed terminals. Place into a EHS waste pickup bin and seal.
  • Pickup: Schedule a hazardous waste pickup via the UF EHS Portal.
  • Supplies: Email [email protected] if the lab is out of designated waste buckets.