Company Alleviates OSHA Concerns, Increases Efficiency with Battery Watering System

A fleet of 18 to 20 forklift trucks takes the wood on to a variety of equipment. A total of 45 drivers operate the trucks in three eight-hour shifts -- 24 hours a day -- except Sunday.

Dillard Plywood, located in Dillard OR, is a division of Roseburg Forest Products, an integrated manufacturer of lumber, plywood, particleboard and engineered wood products. Water is critical to the wood processing needs of both Dillard and Roseburg.

And, ironically, water also was at the core of a problem that had the potential to bring significant fines from the Occupational Safety and Health Administration (OSHA).

With operations in Oregon, California and Montana, Roseburg Forest Products employs more than 3700 people. Approximately 500 of those employees work in Dillard Plywood's two plants, one measuring 274,650 square feet and the other 153,500 square feet. Dillard manufactures pre-finished hardwood plywood, medium density overlay, sanded wood, industrial grade paneling, real wood siding and concrete forming panels. As logs come into the Dillard mills, they go through an array of lathes, chippers, stackers, dryers, spreaders, presses, skinners, sanders and banders before the finished product is ready to be shipped to customers. Between many steps in the process, a fleet of 18 to 20 forklift trucks takes the wood on to the next piece of equipment. A total of 45 drivers operate the trucks in three eight-hour shifts, 24 hours a day except Sunday. Twelve electricians perform plant maintenance tasks throughout the day -- everything from programming computers to changing light bulbs. Among their responsibilities is maintaining the fleet of forklift trucks, including keeping their batteries watered. This is a task that is performed approximately every week. "We watered our batteries pretty much like everybody else -- cell by cell, battery by battery," said Rick Pruitt, lead electrician for Dillard. "Each truck runs on a 24-cell battery. With a total of 50 batteries to water every week or so, that's time-consuming work."

An even bigger issue than time-efficiency for Pruitt was meeting OSHA standards for workplace safety. "Over watering batteries caused electrolyte spills and the acid was eating away the wooden slats supporting the batteries in our battery room as well as the concrete floor. When acid spilled on the floor we would have to sprinkle soda ash on it to neutralize it. Of course, the acid also poses a risk to our crew. So safety and environmental impact were big issues using the traditional method of watering."

The watering system features Water Injectors that snap on to each battery cell and are connected to one another with corrosion-resistant plastic tubing with a water input fitting. To fill the batteries, the technician attaches a hose to the input fitting and turns a ball valve. Water flows through the plastic tubing and, simultaneously, into each of the cells.

Pruitt had tried an automatic battery watering system, but wasn't pleased with its performance. "The floats -- the components designed to keep acid from spilling out of the battery -- malfunctioned." Pruitt said.

In early 2004 Pruitt heard about a single point watering system from Philadelphia Scientific, Montgomeryville, PA. The watering system features Water Injectors that snap on to each battery cell and are connected to one another with rugged, corrosion-resistant plastic tubing with a water input fitting. To fill the batteries, the technician attaches a hose to the input fitting and turns a ball valve. The water flows through the plastic tubing and, simultaneously, into each of the cells. Within 15 seconds, the battery is filled -- without any spillage. Looking into the cells to determine whether the level is correct is no longer necessary. The Water Injectors fill each cell to the required level so the batteries cannot be overfilled and electrolyte doesn't boil over. And the operator no longer has to remove and replace individual vent plugs. These features save time and improve safety.

"It's incredible how fast the watering system works," said Pruitt. "When we saw how well the watering system works, we put one on every battery in each plant."

Each Injector has its own level-sensing valve, which is powered by water pressure, enclosed in a protective housing. There are no floats or delicate exposed parts to stick or to break, so the Injectors are unaffected by oil and tar in the cells and can function in extreme cold or hot, dry and abusive conditions.

Philadelphia Scientific's remote electrolyte monitor is also utilized at the plant. The monitor is an LED indicator light that can be mounted on the outer edge of a battery. The flashing green light indicates the battery is working correctly and the electrolyte level is acceptable. When the light stops flashing, it's time to add water. The monitor is easily visible from a distance, so technicians don't have to check water levels up close. Pruitt notes that maintenance time has been significantly reduced. Dillard has also alleviated the acid spillage that was the basis of OSHA concerns.

Philadelphia Scientific,

207 Progress Dr., Montgomeryville, PA 18936

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