Safe t y Considerations - PowerPoint Presentation

Safe t y Considerations for Elect r ic Vehicles Wh at Safety Professionals, Electric Vehicle (EV) Drivers, Emergency Responders, EV Maintenance Personnel, and Other Affected People Need to Know*IMPORTANT USER NOTE: This document was created in 2014 by the DoD Electrical Safety Working Group (ESWG) and is based on Codes and Standards in force in 2014. To use this document properly, the user must refer to the code in force at the date of use. 1 Appendix D-4 Electrical Safety in Design Final Report July 2014 ; Version 1.0

D o D V eh icl e-To- Grid (V2G) Pilot Program 2 Objective is to replace general purpose fleet vehicles with plug-in electric vehicles (PEVs), including fully-electric, plug-in hybrid electric, and extended-range electric vehicles. The PEVs will be power gri d -integ r a t ed to generate value through grid ancillary services, such as frequency regulation and peak shaving.Project ScopeInitiate large-scale testing and evaluation program for PEVs on 6installations (DOD-wide) in four regions, with the following features:100-500 PEVs with V2G capabilityLD pick-up trucksLD cargo/passenger vans MD/HD trucks and vans BusesOne V2G-capable charging station per PEVSpecialized software to manage PEV fleet with V2G capabilityTraining for multiple DOD constituenciesSustainment for PEVs, infrastructure, and softwareProgram management and systems integrationDemonstrate financial and operational benefits of a V2G fleetOption to expand up to 1,500 PEVs on up to 30 installations Appendix D-4 Electrical Safety in Design Final Report July 1, 2014; Version 1.0

D o D V eh icl e-To -Grid (V2G) Pilot Program and Southern California Edison3Southern Cal Edison is working with the DoD to perform V2G testing and safety evaluati o ns o n plug in electric vehicles and chargers before deployment to identified bases.Items in review will include but are not limited to…Vehicle and Charger PerformanceBatteryRangeEnergy consumptionGround faultTemperatureDrive away protection (vehicle disable)Grid eventsAppendix D-4 Electrical Safety in Design Final ReportJuly 1, 2014; Version 1.0

PE V – V 2 G Pilot Locations USAF, Army, Nav y, Marines, and Joint Base installationsDifferent electrical grid territoriesDifferent basesizesDifferent climatesDifferent vehicle requirements4Appendix D-4 Electrical Safety in Design Final ReportJuly 1, 2014; Version 1.0

Plug In E lectric V ehicle (PEV), Plug In Hybrid Electric Vehicle (PHEV) and Internal Combustion E ngine (ICE)A PEV is a vehicle powered by an electric battery, which is plugged into a charging station or wall socket. PHEV is veh ic l e w ith an internal combustion engine (ICE) with an electric motor which is plugged into a charging station or wall socket.7*The DoD V2G Project is focused on battery powered plug in electric vehicles.

Mediu m - and Heavy -Duty Trucks - Examples 8

About PEVs a nd PHEVs 9 Depe n da b ility and LimitationsCharging the Ve hicle Battery Packs Mainte nanceTowing

Abo u t the Ve h ic le… 8Depen dabil ity of a PEVThey're just as dependable as gas-powered vehicles. Electric motors have fewer moving parts therefore, fewer points of failure. Charge it up and go! Limitatio ns: R a n g e Limited charging stationsTime to chargeVehicle type…Car vs. truckBattery type…Lithium-IonAdded weight…None vs. freight/materialsState of charge…Full-charge vs. half-chargeEnvironment…Flat terrain vs. hills and inclinesDriver…Mindful of how the vehicle operationsIn Addition: PEVs and PHEVs are showing up in Forbes reports, Kelly Blue Book and the NHTSA reports with top ratings for safety and dependability. Appendix D-4 Electrical Safety in Design Final ReportJuly 1, 2014; Version 1.0

Abo u t the Ve hic le Continued…9 Chargi ng the vehicleJust plug it in!Each base has a designated charging site.The charging system will have a V2G software ma n a g em e nt system for grid, charger and vehicle reporting.Vehicle may be equipped with a portable charger.PEVs require a period of time for charging. It depends on the charger type i.e., commercial vs. portable and state of charge.Charge will auto cut off when either disconnected, timerset is complete or when the state of charge is completePack is in a protected casing and can with stand various terrain conditions. So don’t worry about the pot holes and water submersion. Appendix D-4 Electrical Safety in Design Final Report July 1, 2014; Version 1.0

1 2 Ma i nt e n a nceRoutine tire rotation, winds hield wiper and brake fluid fills.Software upgrades are maintained by the mfr unless otherwise instructed and other personnel are approved and have been trained by the mfr.No longer needed!! Oil changes Belt replace m en t s Various “engine” repairsFewer brake changes due to regenerative braking systemCoolants, fuel filters, etc. etcEmergency Responders (NFPA Training is Recommended)See NFPA’s Emergency Field GuideTow OperatorsFollow manufacturer guidelines for proper towing. Flat tow automatic or manual is typically required to not damage the vehicle or battery pack and tow dollies are typically never allowed.BE AWARE…. Electric vehicles are very quiet! Be conscious as a driver and as a pedestrian.About the vehicle continued…Appendix D-4 Electrical Safety in Design Final ReportJuly 1, 2014; Version 1.0

13 Ind u s t ri a l Charging Systems - Examples Charge Port Safety Poles and bump Charge PortWall MountPedestalPedestalSafety PolesSAE J1772-2009 electric vehicle connector.TypeAutomotive power connector

Ind u s t ri a l Charging Sys tems – Ins talled at LAAFB UL H a ng i n g cordsSafety poles12

Electric V ehicle S afe t y 13 EV Design Saf ety Features (Crash Worthiness, High Voltage Cables, Battery Packs and Fires)EV Charger Safety Features(Weather, Damaged, Power Surge, and Fire s ) D r i v er and Fleet MaintenanceTow Operators and Emergency Responders

EV D e si g n Sa fety Feature s(Crash Worthiness, High Voltage Cables, Battery Packs and Fires)14Electric Vehicles are built to meet all NHTSA (FMVSS) requ irements and h a ve certifi e d crash testing rating.ALL high-voltage cables are identified in a protective orange casing and meet SAE Standards. There is virtually no way for an individual to come in contact with these cables unless improperly cutting the cables.Battery packs are comprised of multiple compartments and are encased in a protective structure for pack protection from environmental leaks, individual safety and driving conditions and various road hazards. Pack “kill s w itch e s” are i n stalled o n the ve h ic l e . T he p a cks h a ve a l so been tested an d me e t SA E sta n d a rd s . Fires are h i gh l y unlike l y . T h ere are n o fu e l s i n a PE V , o t h e r th a n br a ke flu i d an d w i n ds h i e l d w i p er flu i d . R e mem b er n o e n g i n e . Note: PEVs and PHEVs may vary in battery type, kill switch location and they # they have. READthe vehicle manual for the vehicle you are in contact with, NEVER make the assumption they are all “exactly” the same. Appendix D-4 Electrical Safety in Design Final Report July 1, 2014; Version 1.0

H i g h -vo l ta g e and low-vo ltage lines are separated for electrical safety and are identified in orange.Built to attain complete electrical isolation of the battery p a ck f rom the ve h ic l e. An HVIL (High Voltage Interlock System) is used to prevent exposure of occupants to high voltagesBMS (battery management system) carries out critical safety functions such as charging and health managementOpens the contactors when voltage, current and temperature limits critical from safety points of view are violated.Protective Pack Casing Modules Located In The Packfor chemical makeup and precautions15Be sure to review the Vehicle Battery Materials Safety Data Sheet (MSDS) B a tt e ry P a ck S a fety Appendix D-4 Electrical Safety in Design Final Report July 1, 2014; Version 1.0

El e ctric V e h icl e Stand ardization efforts cover all asp ects of the charger infrastructure, battery, vehicle, safety, testing, validation, manufacturing, service, recovery and re cycling. Outd o or rat e d a nd is safe to charge in the rainGround fault protectionSafety features are in place for the charger breakers to trip if the charger is compromised i.e., hit by the vehicle or vandalismSurge ProtectionVehicle Battery Management System (BMS), no over charging/heating of the packManual Emergency Main On/OFF power switch16EV Charger Safety FeaturesAppendix D-4 Electrical Safety in Design Final ReportJuly 1, 2014; Version 1.0

“Ki l l S witc h Identifica tion, Location & Access O ne Kill Switch is located at the back of the console and requires a tool to remove a bolt for access.1 Main kill switch is located on the console for easy access to the dri ver. There are also two manual kill switches located on both sides of the truck behind the cab. 3 Total Switches17Appendix D-4 Electrical Safety in Design Final ReportJuly 1, 2014; Version 1.0

Driv e r and Flee t Maintenance 18Driv ers Approved by DoDFollow DoD vehicle usage policy and proceduresReview vehicle manual for PEV specificsKn ow w h a t type of battery pack the vehicle usesIdentify all vehicle “kill switches”Do NOT tamper with voltage cables. Electrocution is possible ifthe vehicle is powered on.Fleet Maintenance PersonalApproved by DoD and trained by the manufacturer for services orrepairs performed on a PEV.Do Not work on a PEV or HEV without approval and training.Virtually no maintenance outside of tire rotation and balancingElectrocution is possible if manufacturer procedures are not followed.Appendix D-4 Electrical Safety in Design Final ReportJuly 1, 2014; Version 1.0

T ow Operators NHTSA US Department of Transportation Interim G uide 19

23 NF P A ’ s Em e r gency Field Guide

23 In the n e w s: Expensi v e Tesla Electric Vehicle Crashes in Murfreesboro, Driver Charged with DUIThe vehicle in this crash was probably the only one of its kind in Murfr e e sb o r o and possibly in the state. It was a current 2012 Tesla Model S, all electric vehicle. The young female driver possibly survived because this car has a 5-star safety rating for front, side or rollover crashes. In checking the Tesla website, they note the high-strength steel and aluminum frame contribute to its crash performance. It appeared that possibly all 8 airbags had opened, plus this is not a lightweight car--it weighs a little less than 5,000 pounds.Before police could release the electric vehicle to be loaded onto the flatbed wrecker, they had to secure in f ormati o n on how to t u rn o f f t h e T esla M odel S. O f f ic i als recei v ed t e chnical instructio n s, and t h e all electr i c 4 - door car w as s h ut do w n.

2 4 Acci d ent Investig a tionPEV and PHEVAlwa ys assu me the high voltage battery and associated components are energized and fully charged.Exposed electrical components, wires, and batteries present potential shock ha z ards. V enting/off-gassing battery vapors are potentially toxic and flammable.Physical damage to the vehicle or battery may result in immediate or delayed release of toxic and/or flammable gases and fire.EMERGENCIESCRASH: A crash or impact significant enough to require an emergency response for conventional vehicles would also require the same response for electric or hybrid-electric vehicles.If possibleMove your car to a safe, nearby location and remain on the scene.Roll down windows before shutting the vehicle off.Place t h e v ehic l e in Park, set t h e park i ng brake, t u rn o f f t h e v ehic l e, acti v ate ha z ard l i g hts, and m o v e ke y s a t le a st 16 f eet a w ay f rom t h e v ehic l e. Al w a y s Call 9 1 1 if assistance is need e d and ad v ise t h at an electr i c or h y br i d - electr i c v ehic l e is in v ol v ed. Do not t o uch e x posed electrical components or the engine compartment, as a shock hazard may exist.Avoid contact with leaking fluids and gases, and remain out of the way of oncoming traffic until emergency responders arrive.When emergency responders arrive, tell them that the v e h i c le in v ol v ed is an EV or H E V . FIRE : As w ith a ny v ehic l e, call 9 1 1 i mm ed i at e ly if y ou s e e sparks, s m oke, or f la m es co m ing f rom t h e v ehic l e. E x it t h e v ehic l e i mm edi a t e l y . Ad v ise 9 1 1 t h at an electr i c or h y br i d - electr i c v ehic l e is in v ol v ed. As w ith a ny v ehic l e f i r e, do not in h ale s m oke, v apors, or g as f rom t h e v ehic l e, as t h ey m ay be ha z ardo u s. Re m ain a sa f e distance up w ind and uphi l l f rom t h e v ehic l e f i r e. St a y out of t h e road w ay and st a y o ut of t h e w ay of any onco m i n g tra f f ic w hi l e a w aiting t h e ar r i v al of e m er g e n cy respon d ers.

Acc i de n t Investigation Cont’d 25 POS T-INCIDENTDo not st ore a severely damaged vehicle with a lithium-ion battery inside a structure or within 50 feet of any structure or vehicle.Ensure that passenger an d cargo co m p a r t m en t remain ventilated, i.e., open a window, door or trunk.Notify an authorized service center or vehicle manufacturer representative as soon as possible as there may be other steps they can take to secure and discharge the PHV battery.Call 911 if you observe leaking fluids, sparks, smoke, flames, or hear gurgling or bubbling from the PHV battery.VEHICLE INFORMATIONKnow the make and model of your vehicle.Review the owner’s manual and become familiar with your vehicle’s safety information and recommend ed sa f ety practices. Do not atte m pt to repair da m a ge d electr i c or plug in h y br i d - electr i c v ehic l es y oursel f . Co n t a ct an aut h or i z ed ser v ice cent e r or v ehic l e m anuf a ct u r e r represe n t a ti v e f or ser v ice. Appendix D-4 Electrical Safety in Design Final Report July 1, 2014; Version 1.0

T he Natio n al High way Traffic Safety Administrati on is dedicat ed to achieving the highest standards of excellence in motor vehicle and highway safety. NHTSA provides the public with facts on v ehic l e sa fety, driving safety, and research. (www.nhtsa.gov) (www.safecar.gov) (www.ems.gov)Electric Vehicle Safety Training is a nationwide program through the National Fire Protection Association to help firefighters and other first responders effectively deal with emergency situations involving electric and hybrid-electric vehicles. The Web site hosts an EV blog, calendar of events, training videos, emergency field guides from 19 auto manufacturers, research reports, as well as an online training course for the Chevy Volt. (www.evsafetytraining.org)SAE International is a resource for vehicle safety codes and st a ndar d s. It has recently de v elo p ed and re v ised sa f ety st a ndar d s f or electr i c v ehic l es. ( ww w .s a e. o r g /standards ) T he Electr i c D r i v e T ransport a tion Association is a resource f or le a rning about di f f er e nt t y pes of h y br i d - electr i c and electr i c v ehic l es. It also has a f act sheet t h at det a i l s t h e nu m b e rs of hybrid vehicles on the road now and how many we can expect in the future. (www.electricdrive.org)The Alternative Fuels and Advanced Vehicles Data Center provides information, data, and tools to help fleets and other transportation decision - m a k e rs f ind w a y s to re d uce petroleum consu m p ti o n t h rou g h t h e use of alternati v e and rene w able f uels, ad v anced v ehic l e s, and ot h er f ue l - sa v ing m easures. ( ww w . a f dc. e ner g y . g o v / a f dc )HybridCars has detailed resources on every hybrid model on the road today. Its research section also provides studies and surveys about hybrid and electric vehicles in relation to technology, the environment, culture, and law. (www.hybridcars.com)The National Alternative Fuels Training Consortium promotes programs and activities that lead to energy independence, and encourages the greater use of cleaner transportation. (www.naftc.wvu.edu) 26 Resources Appendix D-4 Electrical Safety in Design Final Report July 1, 2014; Version 1.0