High Voltage Risk Management

Developing a comprehensive risk management document for high-voltage vehicle work is an essential part of any business owner or leader’s responsibility; the approach to risk management can indeed have dual interpretations—either seen as bureaucratic, or as a constructive framework to enhance knowledge and safety. 

 

Here’s a structured outline for a risk assessment based on the context of Salvage Wire’s level 3 electric and hybrid vehicle training:

 

1. Identifying Risks

Begin by listing all potential hazards, such as:

• High Voltage Energy: e.g. Risk of electric shock or arc flash.
• Component Weight: Potential for muscular or skeletal injuries.
• Movement of Components or Vehicles: Risks related to shifting, lifting, or manoeuvring large, heavy objects.
• Others: Any environmental hazards, such as fire or chemical exposure.

 

2. Who Could Be Harmed

Consider all personnel who could be impacted, for example:

• Technicians: Risk from handling components or electrical shock.
• Other employees: who may be in the vicinity of these vehicles.
• Visitors/Contractors: Exposure to ongoing operations.
• Public: Potential exposure if incidents occur outside controlled areas.

 

3. Current Mitigations

Document the current safety protocols in place, which could be:

• Training and Certification: Ensure that employees have level 3 HV vehicle training and are certification.
• Tools and PPE: Availability and proper use of insulated tools, gloves, visors, and other required PPE.
  
• Standard Operating Procedures (SOPs): Follow either manufacturer SOPs or company-developed guidelines for handling or working on HV components and vehicles.

 

4. Risk Matrix: Likelihood vs. Consequence

Use a grid to assess the:

• Likelihood of Occurrence: From unlikely to highly probable.
• Consequence of Incident: Ranges from minor to catastrophic.

Example:

• Risk: Working on HV vehicle without training or PPE.
• Likelihood = High
• Consequence = Catastrophic
• Overall Risk = Unacceptable

 

5. Action Plan for Improvement

After identifying unacceptable risks, list steps to mitigate them which may include:

• Action: Train employees, enforce SOPs, provide necessary PPE.
• Responsible Person: Assign a team member or manager to oversee implementation.
• Deadline: Set a clear date for completion.

Then go back to the risk matrix and determine the overall risk – is it acceptable?

 

6. Review and Update Process

The document is dynamic and should be revisited periodically:

• Incident-based Review: Following any accidents or near misses.
• Scheduled Review: Quarterly, bi-annually, or annually depending on the nature of the risks.
• Component Changes: Reassess when new technology or components are introduced.

 

7. Document Archive

Retain older versions for reference to track progress and changes:

• File Versions: Save previous and current versions to maintain a clear historical record.

 

This framework allows organisations to proactively manage risks while fostering a positive culture of continuous learning and safety. 

 

For more details about certified High Voltage training from Salvage Wire  then please check out the training pages on the Salvage Wire website - https://www.salvagewire.com/training-courses and if you would like help to complete risk assessment documents then arrange your free 1 hour consultation at https://www.salvageinsight.co.uk

 

 

 

Electric Landmines

Landmines are designed to injure or kill, they are placed to trap the unaware and could be detonated by presence, proximity or direct contact.

 

Electric vehicles may not have landmines fitted, but they can harm if you are in the presence or proximity of the vehicle or by direct contact.

 

There are four main risks to take account of:

Chemical

Electrical

Fire 

Electromagnetic

 

All batteries are chemical devices that include an electrolyte, this electrolyte can cause serious personal damage if it leaks from the battery, the battery module or battery cell. 

A Lead Acid (12v) battery will lose all of its electrolyte if damaged, the risk of this acid is well known by vehicle technicians as we have been working with these for well over 120 years.

High voltage batteries have an alkaline electrolyte that can be very harmful to health if the battery is damaged and electrolyte is leaking. It may only be a small amount of electrolyte as only the damaged cells will leak, but even in very small quantities the electrolyte can be very harmful.

 

The biggest risk is electric shock – this occurs when a person touches the vehicle and creates a circuit through their body – this could be between two points on the vehicle or between the vehicle and an earth point. The heart is very vulnerable to electric shock and a small amount of voltage and current is needed to put the heart into ventricular fibrillation, which means that the heart is not pumping blood around the body. Almost all hybrid vehicles and every plug-in vehicle (hybrid or full EV) carry lethal amounts of voltage and current.

 

Fire can happen in any vehicle, it doesn’t matter what type of power source; the risk is that with high voltage vehicles the consequences could be much more severe.

An arc flash is where the electricity jumps an air gap – this superheats the air and can seriously burn a technician if they are close to the arc flash. Equally the arc could ignite substances nearby (fuel vapour from depollution for example) which may cause an explosion.

Batteries do catch fire (although far less than the press reports would have you believe) and they could burn for 3-5 hours, need large volumes of high pressure water (over 10,000 litres or 2,500 gallons) that will require the fire services to establish a pump connection to a fire hydrant. 

 

Electromagnetic fields in a high voltage system can impact heart pacemakers, so anyone that has one of these fitted should not work on one of these vehicles. These vehicles are perfectly
safe to drive, plug in and operate if you have a pacemaker – just do not work on them when they are live.

 

How do you protect yourself from these electrical landmines? -Easy, be trained, have the right HV tools, HV Personal Protective Equipment and follow the manufacturer processes.

 

Training is absolutely essential, vehicle technicians need to use a training provider that is offering accredited and certificated training courses that include awareness of risks, how to work safely and practical assessments. Without these the technicians will not have the right awareness, knowledge of how to complete the work and the confidence to complete high voltage operations.

HV tools range from insulated hand tools, through cat 3, 1000 volt multimeters or voltage detectors and vehicle scan kit.

HV personal protective equipment (PPE) includes class 0, 1000v rated electricians safety gloves, 1000v rated safety footwear or rubber mat, face or eye protection, full length overalls, safety rescue hook, and warning signs and barriers.

Eintac can supply all HV tools and PPE required, have a look at https://eintac.com/shop/ and use Discount Code ES10 for 10% off

Correct processes can be obtained from the vehicle manufacturer and many other sources – see the end of this article for some of those that are available.

 

If the technician has been trained, they have the tools, the PPE and they follow the process then they will be able to avoid the electrical landmines and get home to their families at the end of each working day.

 

Salvage Wire has developed specific and accredited Electric Vehicle dismantling training that is available at 4 levels which equips every person in every recycler with the knowledge, understanding and confidence to work on these vehicles, for more details email training@salvagewire.com

 

 

Resources

Some are free of charge, others do carry a cost.

Training

ARA University has on-line training https://arauniversity.org

Salvage Wire complete accredited training at 4 levels, taking technicians through the process and keeping them safe find out more at https://www.salvagewire.com

 

Education

The ARA Hybrid Vehicle Technology book is available as a free download from ARA University https://arauniversity.org/electric-hybrid-vehicle-technology-guide/

Electric and Hybrid Technology book https://www.tomdenton.org

 

Disconnection and Dismantling Processes

International Dismantling Information Service https://www.idis2.com

Rescue Sheets http://rescuesheet.info/seite_3.html

EV Fire Safe https://www.evfiresafe.com

 

Phone and Tablet Apps

Euro Rescue

You Have To Get Your Feet Wet

 ‘When the priests got to the Jordan and their feet touched the water at the edge, the flow of water stopped…The river went dry…..and the people crossed.” (Joshua 3 14-16)

There is so much leadership wisdom in this short passage - especially when you understand what preceded this.

The Israelites were moving from Egypt to the promised land, they had spent 40 years in the wilderness and had to cross the Jordan River to take control of the land flowing with milk and honey. They didn’t wait for the river to stop flowing or for a bridge to be built. No, they started out and got their feet wet before the river stopped flowing and they could cross into the promised land on dry ground.

In our business lives we should be looking at how to move forward into new pastures or new opportunities and as we do this we see the barriers ahead of us. It could be knowledge, registration or licensing, resource, equipment or much more, so we research, prepare, register, practice but we cannot move forward until we have put our feet into the water. 

The Israelites spent 40 years in the wilderness preparing, they didn’t wait for a miracle to occur before they moved across the Jordan River, they put their feet in and the river stopped flowing. 

Your may want to move your business forward or instigate change in the way it operates, but all you can see is that river in front of you that is stopping you from moving forward. It is time to take action; spend a few months preparing the changes or preparing for that forward movement, but the river doesn’t open up and welcome you in, you have to take a step or a leap of faith, get your feet wet and step into the change, or into that opportunity and watch it open up as you move forward.

You may just get your feet wet, you may go a little deeper and push forward, but there comes a time where the water starts to drop and you are through to the other side, or you may have to retreat, review, change and then put your feet in the water again. There is no fear of failure, if what you are doing doesn’t work then retreat and adapt, and there are two absolute rules here - never go so far that you are in danger of drowning and never retreat and go back in again without reviewing, changing and adapting the plan - a sign of insanity is doing the same thing each time and expecting a different result.

Over the last two years Salvage Wire have developed a number of new programmes for various clients, and in all cases we planned, prepared, and practiced before we took the plunge and made the changes, and as the changes or the new programmes were implemented we reviewed regularly, changed and adapted what we were doing so we could reach the other side. Yes, we got our feet wet, but only our feet and our clients are now on dry ground looking back at what they used to be whilst marching forward towards their new goals.

If you have an idea, and you are seeing a river blocking your way to that new idea, then contact Salvage Insight, enter your details and join us for a free 1-hour consultation where one of our consultants can discuss your idea in more detail and formulate an action plan for you. Find out more at  https://www.salvageinsight.co.uk/

New High Voltage training for vehicle dismantlers and recyclers

Very soon after starting Salvage Wire we identified a need for high voltage vehicle training

specific to vehicle dismantlers and recyclers, so we wrote training and got it accredited. Over the last couple of years we have seen vehicle technology change very rapidly and we have just completed a review and re-write of the training.

Previously there was one training level, now due to the changes we have seen in high voltage technology there will be four training levels for vehicle dismantlers that reflects the increased level of technology in the vehicles and the changing needs in the vehicle salvage and dismantling industry. This new training provides a tiered approach to training that helps develop vehicle dismantling and recycling technicians, raises their knowledge, understanding and competence with these vehicles and the technology, and increases professional standards across the industry.

The training is specifically designed for vehicle dismantlers, it is accredited by the Chartered Institute of Waste Management, and will soon be certified by TUV Rheinland - an organisation that will give global certification for the training; 

The training is at four levels and certification is valid for three years. Level 1 is awareness for leaders and managers. Level 2 is the lower level of technical training for technicians working on the vehicle that has already been made safe. Level 3 is higher level technical training for ‘live’ vehicles and Level 4 is battery strip. 

Level 1 - informs leaders, owners and senior managers about High voltage vehicles, what they need to do to keep their staff, their customers and their business safe; the processes and procedures required along with the risks of these vehicles and the need to invest in training, tools and PPE.

4 hours duration including theory training, practical demonstration, and assessment and this training can be face-2-face or on-line/remote

Level 2 is for vehicle technicians, parts storage and shipping, and drivers collecting vehicles and gives them the knowledge and confidence to work on high voltage vehicles after the vehicle has been made safe; to remove, store, sell and ship high voltage components.

Technicians, parts team and drivers can start at Level 2 - they do not need to complete level 1 first, but they must be working in the vehicle salvage and recycling industry.

8 hours duration including theory training, practical training, and assessment. Training must be face-2-face

Level 3 for vehicle dismantling technicians and drivers collecting vehicles and enables them to safely assess and work on high voltage vehicles that are ‘live’; make them safe and confirm disconnection before continuing to dismantle the vehicle themselves or handing the vehicle to a Level 2 person for further dismantling; they also become the point of reference for technical queries and processes. Candidates for Level 3 MUST have completed Level 2 training within the previous 12 months

8 hours duration including theory training, practical training, and assessment. Training must be face-2-face

Note: A fast track level 2 and 3 training can be completed over a two-day period.

Level 4 – technicians will be able to assess and dismantle high voltage battery packs, store modules correctly and prepare for shipping. They will also understand the process to re-manufacture, balance, and test batteries.

There are 2 entry options for Level 4:

1. Vehicle Dismantlers for Level 4 MUST have completed Level 3 training within the previous 12 months 
2. Battery Dismantlers for Level 4 must have completed Level 1 within the previous 3 months Note: Core product businesses do not dismantle vehicles; they just deal with components that have already been removed so levels 2 and 3 are not appropriate - hence the option for battery dismantlers to jump straight into level 4

8 hours duration including theory training, practical training, and assessment.

So much of the work that Salvage Wire complete is dedicated to helping vehicle recyclers become leaders in their industry and this is another example of how Salvage Wire are raising professional standards, keeping people and businesses safe, helping them to become better, train and retain staff, and grasp the new opportunities that high voltage vehicles bring.

10 years of Salvage Wire, 10 things we have learnt from our experience with clients, partners and friends.

10 years of Salvage Wire, 10 things we have learnt from our experience with clients, partners and friends.

1 - Reluctance to change

‘We have always done it like this’ are the seven worst words anyone can hear. This indicates that the speaker has no ambition to look at things differently, find ways to improve, become more efficient, safer or cleaner. A willingness to change means the business could be looking forward, finding that competitive advantage, reducing cost, being more efficient and improving profitability. Change does not have to be dramatic, it can be many little changes over a period of time, so much so that the changes are only really seen when the business looks back over a 12, 18 or 24 months and notices how much has changed for the better. 

2 - Resistance to learning from management 

One comment we do get is ‘why should I train my staff, it will cost me and they will either demand more money or leave and join the competition.’ I despair sometimes at the negative comments from some senior managers and owners, but it then gets me wondering why they are like this and how I can change their attitude by outlining the benefits of training.

• Safer working conditions - reduce risk, reduce insurance costs, less time off due to accidents
• Increased efficiency - more product per day, reduction in costs, increased profit
• Quality Improvements - more satisfied customers, potential increase in repeat business 
• Satisfied staff - more likely to stay because they feel valued and respected

Yes, it could mean a wage increase, however this will be more than covered by increased efficiency, safer working conditions, more repeat business, and better staff satisfaction. What would you rather have, employees who are trained, safe, efficient and respected or employees who are not trained?

3 - Rapid changes in vehicle technology

For many years vehicle technology hardly changed. Over the last 10 years vehicle technology is on a very steep trajectory - electric vehicles, advanced driver assistance systems, vehicle structural changes, emissions regulation and more. Vehicles are now computers on wheels and the best technicians need to understand all of this so they can correctly diagnose faults and work on the vehicles. Repairing vehicles cannot be a process where you chuck new components at it until the fault goes away, you have to analyse, diagnose and correctly repair the vehicle, and then make certain all the systems are correctly calibrated and functioning before the vehicle is released to the customer - training and experience is vital. 

4 - Do not want to fail

Failure is part of life, without failure we do not learn, grow and develop. Too many are afraid of what could happen if they fail so they do not take any risks. Smart people try, if it doesn’t work they review, change and try again, and again, and again if necessary. A description of stupidity could be doing the same thing and expecting a different outcome each time. Thomas Edison found over 500 ways how not to make the light bulb - he kept going until he had perfected the light bulb. 

Years ago I was part of a panel interviewing candidates for a project manager role, I deliberately asked the candidates about projects that had gone wrong because I wanted to see how they reacted to failure and what they learnt. One of the candidates said that he had never had a project fail because he was so good - he didn’t get the role!

Failure is essential to learn, get better, stronger, smarter and succeed - do not be afraid of failure! 

5 - Happy with the status quo

The vehicle recycling and dismantling industry occasionally falls into this trap - we are doing ok so why change? As an industry we should be looking upwards and challenging not just everything we do, but the perceptions of the industry. 

We need to shout about how environmentally friendly the industry is, the benefits to the planet alongside the cost benefits of re-using vehicle parts. But we can do more.

Public, professional and governmental perceptions are that vehicle recyclers are just ‘scrapyards’ - dirty, smelly, poor quality, low standards, unsafe, I could go on… As an industry we need to change this through professionalism, working with politicians and government agencies to influence legislation, increase enforcement of illegals and combat the unscrupulous elements of the industry; but before we do this we need to get our own house in order, this includes our environmental performance, professional standards, training, association membership, certified recycler status and more, and use this to show that we are a professional industry and not ‘scrapyards’. All of which will improve the perception of the industry, increase sales of parts, bring the industry to the table in talks with government, legislators, enforcement agencies, vehicle manufacturers and more.  

6 - The larger the company, the slower they pay their bills

As a small business our cash flow is important, and the vast majority of our clients pay their bills quickly and without fuss, but bigger organisation can take months to pay - why is this? They have vast reserves, lots of cash flow but insist on taking 60 or 90 days to pay. We know who these are and price our work accordingly to allow for the delay in payment - they can do better and should.

7 - Who you know is sometimes worth more than what you know

Particularly when Salvage Wire first started I relied on people I knew from the industry who gave me tips, connected me to others, or gave me work - I will be forever grateful to them all. Over the last few years I have been able to do the same for a variety of others, connecting them, helping and supporting, giving them work or just being there to talk. It all helps.

8 - Preparation gives the ‘luck’ required to capitalise on opportunities

I have been called lucky for being in the right place at the right time for the EV boom - it has taken me 40 years to get here. My EV journey started before Salvage Wire came into being and has grown because I have invested in training for myself, been open to learn, worked on these vehicles, worked with others and taught many more. All of this ‘preparation’ has given me the chance to capitalise on the many opportunities that are out there.

9 - Never turn down the opportunity to learn

Every day is a learning day - a quote I often use. Rarely does a day go past without me learning something, and I get very annoyed with those people who have no ambition and look upon learning, training, or development as a waste of their time - our learning doesn’t stop the day we leave school, we have to continue that learning and I see so many wasted opportunities. In many cases this could stem from how people were treated at school, or at home, but many employers have had the opportunity to change that and failed to mentor their staff, improve them, develop them and allow them to soar. Look at the people in your teams, if they had been helped, mentored, and allowed to learn, grow and develop how good would they (and potentially your company) be now?

10 - Some conferences are worth the investment - but only because of the people you meet!

Conferences can be expensive, time away from the business, travel, accommodation and the conference costs can often run into the many thousands of £’s. Yes, I do learn from the speeches and presentations, but I learn more from the people I meet and interact with, and all of them are an opportunity to earn revenue. I spent over £2000 attending a conference in Vienna a few years ago that has turned into a contract worth over £10,000 a year from meeting one person at that conference. Now that is a great return on investment.

You have to be selective, I get so many conference invitations I could become a professional conference attendee - but pick the right conferences and your revenue will increase!

As I look back at 10 years of Salvage Wire there is one piece of advice I would give to everyone. 

Start each day with a little bit of quiet reflection - no phones, no music, no kids (I know, sometimes not possible), and think about the day ahead. Write down up to three things that if completed (or significantly moved forward) would make your day amazing - this is not a to-do list (keep that separate), it could be 1, 2 or 3 things, but no more than 3, that at the end of they day leave you with immense satisfaction and a feeling of a job well done. I have done this for years and kept all the records and occasionally will look back over them to see how far I have moved forward in that time - truly inspirational!