Manage unstable high voltage systems in an electric vehicle
Overview
This standard is designed for those who provide a first response to an accident damaged electric vehicle, for example, those working in the fire service or roadside recovery operators; the standard would also be appropriate for those involved in the dismantling and disposal of electric vehicles. It covers the working practices and knowledge needed to continually monitor and work safely around an electric vehicle that has damage to its high voltage system and is showing signs of being unstable or potentially becoming unstable and requiring emergency response.
For the purposes of this standard, an electric vehicle is any vehicle that is in part or wholly electrically propelled. This would include:
- Hybrid (HEV) - to include mild/micro hybrid vehicles where the voltage is considered dangerous.
- Plug-in Hybrid (PHEV)
- Extended Range Electric Vehicle (ER-EV) or Range Extended Electric Vehicle (RE-EV)
- Battery Electric Vehicle (BEV) or Pure Electric Vehicle (PEV)
- Fuel Cell Electric Vehicle (FCEV).
This standard does not deem someone competent to maintain, service or repair an electric vehicle’s high voltage systems and their components.
Performance criteria
You must be able to:
P1 Identify the electric vehicle type and the location of the high voltage battery
P2 Wear personal protective equipment (PPE) and use safety equipment in line with your working procedures and appropriate to the work activities you are carrying out
P3 Carry out a dynamic risk assessment to identify the hazards presented by the unstable electric vehicle high voltage system, assess the risks and formulate an agile mitigation plan
P4 Follow the correct procedures to make the vehicle safe prior to starting any work activities, including where necessary and safe to do so, isolating high voltage electrical systems, within your level of training, competence and authority
P5 Recognise and continually monitor the indicators of instability within an electric vehicle's high voltage system
P6 Apply control measures appropriate to the indicators presented by the vehicle
P7 Quickly respond to changes/escalation within the emergency situation
P8 Carry out work activities in a way that minimises risks to yourself, other people and the environment
P9 Refer any problems with the vehicle that you cannot deal with yourself to a relevant person and follow their instructions
P10 Record and report the detail of work activities you have carried out on or near the vehicle to relevant personnel.
P11 Follow a robust, documented/logged handover procedure
Knowledge and Understanding
You need to know and understand:
Use of technical information
K1 How to identify an electric vehicle and the location of its high voltage battery
K2 How to find, interpret and use sources of information applicable to unstable electric vehicle high voltage systems
K3 The importance of using up-to-date data and emergency response and recovery guidance
Legislative and organisational requirements and procedures
K4 The health and safety legislation, industry codes of practice or guidelines and workplace procedures relevant to working on, near or with unstable electric vehicles, including the appropriate personal protective equipment and its use, and the safety of the working environment
K5 How to carry out a dynamic risk assessment on unstable electric vehicles and formulate an agile plan to mitigate escalating risks
K6 The manufacturer’s and your workplace procedures for:
K6.1 assessing and managing the risks associated with unstable electric vehicle high voltage systems
K6.2 identifying the indicators associated with unstable electric vehicles
K6.3 ensuring that the vehicle condition is monitored for signs of deterioration or escalation in severity
K6.4 referring/reporting problems when working with unstable electric vehicles
K6.5 recording and reporting work carried out on unstable electric vehicles
K7 The workplace specified information that must be included in an incident handover record for an unstable electric vehicle
K8 The importance of adhering to a robust, documented handover procedure
Hazard indicators and control measures
K9 The standard operating temperature of an electric vehicle high voltage battery
K10 The indicators, causes and consequences of thermal runaway
K11 Why actively smelling for indicators of an unstable EV system must be avoided
K12 How emergency response actions (relocation of the vehicle, extrication etc.) may initiate thermal runaway
K13 The control measures available to deal with thermal runaway and the benefits and implications of their use
K14 How to use different control measures and when it is appropriate for them to be applied
K15 How to determine the hot zone and safe working zone around an EV incident
K16 The actions to take where electrolyte leakage has occurred
K17 The considerations to be made regarding the recovery of an unstable electric vehicle
K18 The importance of keeping up to date with new electric vehicle technologies and control measures
Scope/range
Vehicle - any vehicle that is in part or wholly electrically propelled. This would include
1.1. Hybrid (HEV) - to include mild/micro hybrid vehicles where the voltage is considered dangerous.
1.2. Plug-in Hybrid (PHEV)
1.3. Extended Range Electric Vehicle (ER-EV) or Range Extended Electric Vehicle (RE-EV)
1.4. Battery Electric Vehicle (BEV) or Pure Electric Vehicle (PEV)
1.5. Fuel Cell Electric Vehicle (FCEV)PPE and safety equipment may include:
2.1. High voltage gloves
2.2. Full face protection
2.3. Respiratory protective equipment
2.4. Protective clothing
2.5. PPE as specified by workplace
2.6. Electrolyte neutraliser
2.7. Safety equipment as specified by workplace
2.8. Casualty respiratory protectionHazards may include:
3.1. High voltage
3.2. Unpredictable vehicle movements
3.3. Gases
3.4. High-voltage system residual charge
3.5. Highly magnetic components
3.6. Fuel explosion
3.7. Hazardous materials
3.8. Leaking electrolytes
3.9. Pressurised systemsIndicators may include:
4.1. Visual vehicle warning alerts
4.2. Audible vehicle warning alerts
4.3. Smoke or vapour emission
4.4. ‘Popping’, ‘crackling’ or ‘hissing’ sound
4.5. Burning smell
4.6. Strong odour
4.7. Physical impact damageMonitoring equipment may include:
5.1. Thermal imaging/monitoring equipment
5.2. Gas detector/monitorControl measures may include:
6.1. Water
6.2. Chemicals
6.3. Extinguishers
6.4. Extinguishing devices e.g. lance
6.5. Leave to burn out
6.6. EV fire blanket
6.7. Water tank/pool
6.8. Electrolyte neutraliser
Scope Performance
Scope Knowledge
Values
Behaviours
Skills
Glossary
Additional Information
This section contains examples and explanations of some of the terms used but does not form part of the standard.
Dynamic risk assessment - the practice of continually mentally observing, assessing and analysing an environment while working, to identify and remove risk. The process allows individuals to identify a hazard on the spot and make quick decisions in regard to their own safety.
Handover procedure – to include mark up of vehicle and detailed incident record, including hazards encountered and actions taken
Hazards associated with high voltage electrical vehicle components - exist not only during work on high voltage systems, as specified above, but also on all other high-power electrical drive systems and high-pressure storage systems. Vehicle and equipment manufacturers’ guidance should be followed at all times.
High voltage – Regulation No 100 of the Economic Commission for Europe of the United Nations (UNECE) — Uniform provisions concerning the approval of vehicles with regard to specific requirements for the electric power train, states that: ‘High Voltage’ means the classification of an electric component or circuit, if its working voltage is > 60 V and ≤ 1 500 V DC or > 30 V and ≤ 1 000 V AC root mean square (rms). Electricity at Work Regulations (1989), and associated HSE guidance should be followed at all times.
N.B. Some electric vehicles may operate at voltages below or above industry recognised standards.
Recovery considerations - to include safe transportation route, whether a chaperone would be advisable and the suitability of the final destination.
Relevant person - May be someone within your organisation, or other authority.
Sources of information applicable to unstable electric vehicles - Examples include rescue response guides (RRG), manufacturer guidance, hard copy manuals, online data and data obtained from on- board diagnostic displays. It may also include control room or other personnel, the vehicle driver or passengers.
Unstable - being unstable or potential to become unstable.
Work activities – recovering, collecting or dealing with unstable electric vehicles as part of a first response.