PAS 7061-2021 Masterclass

Facilitated by James Gaade

BSI Programme Team

PAS 7061-2021Masterclass

<< DATE >>Copyright © 2020 BSI. All rights reserved

Batteries for vehicle propulsion electrification – Safe and environmentally conscious handling of battery packs and modules –Code of practice

Copyright © 2020 BSI. All rights reserved

Welcome

• A Publicly Available Specification (PAS) is a fast-track standardization document – the result of an expert consulting service from BSI.

• It defines good practice for a product, service or process.

• It's a powerful way to establish the integrity of an innovation or approach.


Workshop Aim

To broaden the understanding of the impact of the growth of the Faraday Battery usage and to raise awareness of PAS 7061-2021


Workshop Objectives

By the end of this workshop, you will be able to:

• Recognise the key elements of PAS7061-2021

• Discuss how the PAS relates to your own environment

• Identify areas of best practice yet to be implemented

• Take steps to further prepare your organizations

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Copyright © 2020 BSI. All rights reservedCopyright © 2020 BSI. All rights reserved

Workshop Agenda

1. Battery Propulsion Journey

2. The PAS and its reach

3. Safety Systems

4. Competence & Training

5. Controls

6. Environmental Management

This is highly participative session, designed to engage and inspire participants to embrace the content and apply the principles of PAS 7061-2021 and recoup the benefits


The UK’s Position

• £330 million UK government support for the development

• Funding research, innovation and scale-up facilities

• Lowering carbon and helping to tackle air pollution

• Moving the UK to full electrification and zero emissions vehicles.


Implications – Chat BoxConsidering the points raised in the video and polls, use the Chat Box to respond to the question:

• What are the “headline” implications to your business of the growth of battery propulsion?


What does the PAS cover?This PAS covers batteries for electrically propelled vehicles, including electric vehicles, hybrid electric vehicles, plug-in hybrid electric vehicles and fuel cell hybrid electric vehicles.

a) Failureb) Detectionc) Ventingd) Fumese) Disposalf) Hazards

g) Fire managementh) Handlingi) Liftingj) Storagek) Servicel) Competency levels.

It provides a specific focus on:


The Structure of the PASIntroduction

1. Scope

2. Normative References

3. Terms, definitions and abbreviations

4. Quality

5. Environmental management

6. Safety systems

7. Transport of batteries

8. Competency levels and training

Annexes

List of Figures

List of Tables


The Reach of the PAS

• Every stakeholder is involved

• Supply chain systems and standards

• Customer expectations

• Commercial impact


Breakout Activity 1

Working with your assigned colleagues, with the case study allocated

1. Identify the practices which have created the outcome described in your case study

2. Highlight actions which are need of attention to achieve best practice recommendations and what would be the challenges of implementing changes.

• Enable cameras and mics • Assign a group spokesperson to feedback


7061-2021 Activity Scenario• A company designing and producing battery modules and packs, using supplier sourced

cells had been in production for 3 years.• As part of the initial planning for the facility and monitoring, only production focused

systems were installed within the process to mitigate battery cell thermal runaway events, including fire suppression systems within the production areas and wider building.

• After 3 years of operation, a fire took hold overnight on the production line, spreading to completed battery packs stored in the end of line area. Internal fire suppression systems were triggered and automatically called a national control centre to alert a monitoring company of the incident. No staff were physically in the building and security staff were located at the entry to the industrial estate on which the facility was located. Local residents first alerted the emergency services due to visible smoke.

• As the local fire emergency services arrived, it became apparent they were not aware of the nature of the business.

7060-2021 Activity One


Group One:

From a product, production system quality and cell supplier perspective, discuss:

1. What may have caused the initial failure?2. What could have mitigated it?3. What may need to be considered for product in the field?

Summarise your output for the debrief discussion

7061-2021 Activity One


Activity 1 Feedback

1. Product, production system quality and cell supplier perspective

2. Cell supplier perspective

3. Production operations perspective

4. Business perspective

5. Product, production system quality perspective

Group/Topics


Safety Systems

6.1 Safety policy & systems6.2 Product safety6.3 Hazard & Risk Assessment6.4 Handling, lifting and

storage6.5 Incident management

within manufacturing and recycling facilities


Breakout Activity 2

Working with your assigned colleagues:• Consider the range of risks and hazards

present within the battery module and pack manufacturing processes, storage and transportation.

• Discus the impact of expansion due to growth, referring to Clause 6 of the PAS

• Enable cameras and mics • Appoint a spokesperson for group feedback• Make notes of the outstanding issues for

remedial action


Group Two: Product safety – Extracts from PAS 7061-2021 6.2.1 The product should be developed and tested in accordance with relevant standards to support the manufacturing, service, re-purposing and re-cycling processes. NOTE Standards that might be useful are BS ISO 6469, BS ISO 12405-4, SAE J2464 and UL 2580. 6.2.2 The battery control unit (BCU) should be developed in accordance with: a) For safety-related systems in electrical, electronic and programmable electronic safety systems, irrespective of where and how they are used, IEC 61508. b) For safety-related systems that include one or more electrical and/or electronic (E/E) systems and that are installed in series production road vehicles, excluding mopeds, ISO 26262 (but including motorcycles in ISO 26262-12). NOTE Developing and testing in this way will support the manufacturing, service re-purposing and re-cycling processes. Attention is also drawn to EC Directive 2001/95 [25] (“the General Product Safety Directive” [GPSD]), UNECE Recommendations on the Transport of Dangerous Goods Part III, Classification Procedures, Tests Methods and Criteria [1], section 38.3 and UNECE Regulation 100 [2]

7061-2021 Activity Two


Activity 2 Feedback

When called upon by group, respond to the question posed regarding the risks and hazards and proposed best Practice included in PAS7061-2021


Competence Levels & Training

8.1 General

8.2 Safety Training

(8 subclauses)


Breakout Activity 3

The competency of staff is critical to the safe management of an environment and therefore any training and education should be based on courses and information used in the automotive industry. • Electricity at Work Regulations 1989 [20]; in particular in the

context of battery systems, Regulations 4, 7, 8, 12, 13, 14 and 16. • HSE has produced guidance to the Electricity at Work Regulations:

HSR25, 2015 and HSE’s publication “Electricity at work – Safe working practices” (HSG85)

• NFPA-70E also provides useful information relating to batteries, e.g. at Table 130.5(C), for arc flash PPE.


Breakout Activity 3

Working with your assigned colleagues, with the specific subsections from the PAS allocated

1. What do your organizations do which would meet the PAS7061 Subclause Recommendations?

2. What improvements are required to mirror the recommendations of PAS7061?

• Enable cameras and mics • Assign a group spokesperson to feedback


Group One: Safety Training

8.2.1 The organization should have a documented process to continually manage training for safe work on modules and battery packs.

8.2.2 The process should be structured to take account of the organization’s overall operation within batteries for vehicle propulsion electrification.

NOTE 1 This might be for the manufacture of modules and packs only or for whole life-cycle through to vehicle manufacture, sales, service and ultimate disposal.

7061-2021 Activity Three


Activity 3 Feedback

• Group One: Subclause 8.2.1 & 8.2.2

• Group Two: Subclause 8.2.3

• Group Three: Subclause 8.2.4 & 8.2.5

• Group Four: Subclause 8.2.6 and 8.2.7

• Group Five: Subclause 8.2.8


Controls

2 Normative References

4.1 Quality Systems

4.2 Product Quality

5.1 Waste & Emissions

7.4 Transportation of Batteries


Breakout Activity 4

Working with your assigned colleagues, consider: • What updates and considerations would

be needed to bring existing accreditations in line with the recommendations of the PAS

• Enable cameras and mics • Make notes of the outstanding issues

for remedial action


Activity 4 Feedback

When called upon by name, provide one point which was identified in your group


Environmental Management

5.1 Environmental policy & systems

5.2 Operational emissions and defective material control


Subclause StructuresClause 5.1: Environmental policy & systems

Clause 5.2: Operational emissions and defective material control

5.1.1 Documented Policy 5.2.1 Emission control measures

5.1.2 Quantified targets 5.2.2 Product quality & environmental management

5.1.3 Regular target review 5.2.3 Functional checks

5.1.4 Recovery actions 5.2.4 Documented processes

5.1.5 Waste hierarchy principles 5.2.5 Monitoring & Assessment

5.1.6 Life Cycle Assessment studies


Summary Activity – Chat Box

Respond to the following two questions in the Chat Box:1. How would you rate your organization’s

preparedness? (10 = Excellent)2. Following today’s session – what would be the

priority actions that you will you be taking back to work in order to build in best practice?


Next steps

• Familiarise yourself with the remainder of PAS7061-2021

• Review the contents of the Annexes

• Visit the PAS webpage

• Share your insights with colleagues

• Adopt best practices from PAS7061-2021 in bespoke way


Workshop Outcomes

Now at the end of this workshop, you will be able to:

• Recognise the key elements of PAS7061-2021

• Discuss how the PAS relates to your own environment

• Identify areas of best practice yet to be implemented

• Take steps to further prepare your organizations

31

BSI Programme Team

PAS 7061-2021Masterclass


Batteries for vehicle propulsion electrification – Safe and environmentally conscious handling of battery packs and modules –Code of practice

Documents

PAS 7061-2021 Masterclass