Cox Automotive Wyton Induction Pg 7
Site Contractor Induction
Wyton
Agency Worker EV Guidance
As people become more environmentally conscious, electric and hybrid vehicles (E&HVs) are becoming more popular. More and more, these vehicles are being repaired and maintained outside of the manufacturer’s official networks. This guidance document is designed for individuals working with electric and hybrid vehicles at a Cox Automotive site.
Background
As electric and hybrid vehicles become more common, individuals need to be increasingly aware of the extra risks these vehicles pose when they’re working on them. These vehicles are also known as Battery Electric Vehicles (BEVs), Hybrid Electric Vehicles (HEVs), and Plug-In Hybrid Electric Vehicles (PHEVs). Some of the primary risks associated with E&HVs are:
Diverse Designs
E&HVs come in various designs from different manufacturers. It’s crucial to have detailed information specific to both the manufacturer and the vehicle being serviced. This knowledge helps workers identify the necessary safety measures for each vehicle.
Voltage Risks
The voltages in E&HVs are much higher than those in traditional vehicles, reaching up to 650 Volts direct current (dc) compared to the typical 12/24 Volts dc. Even accidental contact with parts carrying over 110 Volts dc can be deadly in dry conditions. In the context of E&HVs, any dc voltage above 60 VDC is considered “high voltage”.
Battery Hazards
The battery systems in these vehicles might contain chemicals that are harmful if released. They also store a lot of energy, which could lead to explosions if mishandled.
Types of Vehicles
EV or BEV: Electric Vehicles or Battery Electric Vehicle: A fully electric vehicle with no internal combustion engine. These vehicles have an electric motor and a battery that requires plugging in to charge.
PHEV: Plug-in Hybrid Electric Vehicle: A vehicle with electric propulsion as well as an internal combustion engine. These vehicles can self-charge through regenerative braking and can also be plugged in to charge them.
HYBRID or MILD HYBRID: A vehicle with electric propulsion which also has an internal combustion engine. These vehicles self-charge through regenerative braking only and cannot be plugged in
HV: High Voltage
Risks of Working with Electric & Hybrid Vehicles
Working with electric and hybrid vehicles (E&HVs) brings additional hazards to the workplace beyond those typically associated with vehicle repair, maintenance, roadside recovery, and related activities. These include:
- Unexpected Movement: Electric motors or the vehicle itself may move unexpectedly due to magnetic forces within the motors.
- Silent Operation: Electrically driven vehicles operate silently, increasing the risk of people being unaware of their movement.
- High Voltage: E&HVs contain high voltage components and wiring capable which presents risk of serious injuries, from electrocution to serious burns and fatal electric shock.
- Retained Voltage: Certain components may still carry dangerous voltage even when the vehicle is switched off.
- Potential Gas and Liquid Release: Damaged or improperly modified batteries could release flammable gases, vapour and harmful liquids. The vehicles store electrical energy, which could lead to explosions or fires if mishandled.
- Medical Device Interference: The electrical systems in these vehicles may interfere with medical devices such as pacemakers.
- Manual Handling Risks: There are risks associated with handling batteries, especially during replacement (heavy weight and potential release of explosive gases and harmful substances if batteries are damaged).
Electric Vehicles Do’s and Don’ts
Where dangers are identified on any EV vehicle, persons in the immediate area must be informed, barriers should be erected to keep people away and it must be reported to a member of management immediately.
Don’t:
- Push them.
- Tow them.
- Change wheels (incorrect jacking can pierce the battery cells).
- Remove panels.
- Touch any electrical components.
- Use ‘jump packs’ unless authorised.
- Steam clean or jet wash the charging connector or under the bonnet.
- Approach a technician working on an EV (area to be controlled by the technician).
- Move them with a forklift truck.
- Park them over drains or interceptor tanks.
- Attempt to fire fight EV/Hybrid fires.
Do:
- Ensure all training and guidance is always followed. In particular, the Cox Automotive document “How To – Electric Vehicle Charging” should be referred to when placing or removing an EV on/off charge.
- Exit the vehicle and ensure all persons are a safe distance from the vehicle if it begins to smoke or a strong smell is detected from the vehicle. Raise the fire alarm where smoke or fire is detected.
- Check for damage to cables and connectors before charging.
- Be aware of the danger of EV vehicle’s moving around site with little to no sound.
- Be aware that there are dangers of electrical shock.
- Be aware that Electric Vehicles can move themselves unexpectedly.