The danger of lithium batteries is not while they are in use, but when they “seem fine”. Once thermal runaway starts, the time left is measured in seconds.
Thermal runaway in lithium batteries is characterised byNo warning, spreads fast, hard to extinguish.From smoke to fire can take only a few tens of seconds.
What students most underestimate isSwollen battery—— The outside looks only slightly deformed, but inside it is already at a critical state.
Another frequent mistake is fighting it with water. Water on a lithium battery fire is not only ineffective but may intensify the reaction.
| Risks | Possible consequences | Course link points |
|---|---|---|
| Continuing to use a swollen battery | Thermal runaway, fire | Visual inspection and scrapping decisions |
| Overcharge / over-discharge | Internal short circuit, fire | Charging management and understanding the BMS |
| Using the wrong charger | Overcurrent, fire | Charger matching principles |
| Short circuit (tool bridging) | Instant high heat, electric arc | Protecting battery terminals during work |
| Using water on a fire | Intensify the reaction, spread the fire | Correct extinguishing agent and isolation method |
This table is the basis for course design: a risk with no corresponding action is a risk that has not been taught properly.
These are not hypotheticals; they recur on the training floor. Each item spells out what went wrong, what the right action is and why.
The distance between the lectern and the workbench is longer than you think. This section is about how we turn knowing into doing.
Every item can be ticked; no vague wording like 'basically mastered'. A teacher can score straight from this sheet.
| Assessment items | What counts as passing | What leads to an immediate fail |
|---|---|---|
| Visual inspection | Check for swelling, damage and leakage to standard | Skipping the swelling check = fail |
| Scrap criteria | Given 5 batteries, correctly identify those that must be scrapped | One wrong judgement: points deducted |
| Charging operations | Use the matching charger, monitor temperature, do not overcharge | Wrong charger = fail |
| Firefighting drill | State and demonstrate isolation, cooling and monitoring steps | Choosing to pour water directly on it = fail |
| Storage rules | Ambient temperature, state of charge and spacing within limits | One non-compliant item in a spot check loses points |
Real sites rarely have work that belongs to only one direction. This section covers where risks compound.
| Modules | Class hours | Content |
|---|---|---|
| Principles and failure modes | 2 class hours | Charge/discharge principles, thermal runaway mechanisms, failure causes |
| Inspection and judgement | 1 class hour | Visual inspection, bulge criteria, scrapping standard |
| Storage and charging | 2 class hours | Storage conditions, state of charge, charging area requirements, BMS basics |
| Transport and packaging | 1 class hour | Transport regulations, packaging requirements, marking |
| Emergency response | 2 class hours | Response to fire, smoke and leaks; choosing an extinguishing agent; isolation distance |
Total class hours can be adjusted to the school's training schedule; when compressing, merge awareness modules first and keep hands-on and emergency content.
| Dimension | Form | What is assessed |
|---|---|---|
| Theory | Closed-book, 40 questions | Thermal runaway mechanism, choice of extinguishing agent, scrap criteria |
| Hands-on practice | Battery inspection | Given several batteries, identify which need to be scrapped and explain why |
| Emergency | Scenario drills | Simulate a smoking scenario and demonstrate isolation, alarm and firefighting procedures |
Failing theory means no hands-on practice; failing practice means retraining. We recommend putting this rule into the practical training regulations.
Send us the school's practical training equipment list and we will return course priorities based on the actual equipment.
Send the equipment list