The use of electric and hybrid vehicles (E&HVs) is increasing with the growth in environmental awareness, which has led to the recovery, repair, and maintenance of these vehicles outside the manufacturers and franchised dealership networks. The Health and Safety Executive (HSE) provides guidance and the hazards associated with working with E&HVs. Here is a summary.

Types of E&HVs and their Risks
E&HVs have significantly higher voltages (up to 650V DC) than other vehicles (12/24V DC). Accidental contact with live parts above 110V DC can be fatal in dry conditions. Battery systems may contain harmful chemicals and store significant amounts of energy, leading to explosion hazards if not handled correctly. Designs of E&HVs differ between manufacturers, requiring information specific to the vehicle being worked on for safety purposes.
Electric vehicles use a large-capacity battery and electric motor(s) to drive the vehicle. Hybrid vehicles typically have two sources of energy: an internal combustion engine and a battery. Plug-in hybrid vehicles can have their batteries charged directly from the electrical supply network. E&HVs introduce additional hazards into the workplace, including high voltage components and cabling, stored electrical energy that can cause explosion or fire, components retaining a dangerous voltage, electric motors moving unexpectedly, manual handling risks, and the possibility of people being unaware of the vehicle’s movement.
Safe Working with E&HVs
Additional skills and training are necessary to work safely with E&HVs. People involved in vehicle repair and maintenance require a higher level of competence than those who undertake vehicle sales or valeting. Four categories of work have been identified, ranging from low risk to working on high voltage electrical systems, and each requires different levels of competence. Specific training and qualifications awarded by organisations like IMI Awards are available.
Guidelines for Valeting, Sales, and Other Lower-Risk Activities
To prevent accidental movement, remote operation keys should be kept away from vehicles. People who move E&HVs should be aware that they may move without warning, and pressure washing should not be used on high-voltage components and cables.
Guidelines for Incident Response, Emergency Services, and Vehicle Recovery
Vehicles should be visually checked for damage to high-voltage electrical components or cabling, and the battery system should be isolated if the vehicle is damaged or faulty. Remote operation keys should be removed before recovery onto a recovery vehicle.
Access to reliable sources of information for specific vehicle types is necessary, such as mobile data terminals used by fire and rescue services or manufacturer’s data.
Conclusion
Working with E&HVs requires additional skills, knowledge, and specialist tools to ensure safe working practices. The HSE provides guidance to people in the motor vehicle repair and roadside recovery industries and emergency services to help them identify the hazards and minimise risks. The guidelines are divided into four categories of work, with each category requiring different levels of competence and control measures.
Further Information
See the Institute of the Motor Industry Awards for further information on qualifications and training
Resources
GS38 – Electrical test equipment for use by electricians
HSR25 – Memorandum of guidance on the Electricity at Work Regulations
INDG139 – Using electric storage batteries safely (PDF)
Source www.hse.gov.uk


