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Interview William S. Lerner
Following the electric vehicle fire in Incheon (Cheongna) and the ongoing reports of fires around the world, we have been in continuous discussions with William S. Lerner, an EV infrastructure specialist and risk mitigation consultant in the United States, regarding safety measures for battery-related vehicles, on-site fire response, charging and infrastructure, and considerations for building sites during September and October. Here’s what we discussed.
Written by han _ han@autoelectronics.co.kr
William S. Lerner _ wslerner@gmail.com
He is an EV infrastructure specialist and risk mitigation consultant, focusing on safety issues in the transportation sector, including fuel cell vehicles, hydrogen refueling stations, battery electric vehicles, electric vehicle charging, and fuel supply and infrastructure. Additionally, he is an independent inventor and a Fellow of the Royal Society of Arts (F.R.S.A. Manufactures and Commerce) in the UK. He holds numerous patents in the United States and currently has additional applications pending to expand his portfolio in the fields of transportation and safety.
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The response to electric vehicle fires is a much more complex issue than people realize, and there is a lot to learn. There is no single approach to address all potential problems.
EV Battery fire incidents continue to occur, and the situation in the United States is no different. What do you think about this?
William Unfortunately what I predicted years ago is happening in real time. Three years ago, I had to look for e-mobility, EV, and lithium-ion events, and gather global data, which did not exist. Why? Lab data, and real world data are very different. I spent eight years in the standards world with ISO and other organizations, so I have an understanding of standards. They are written in five year cycles for the minimum performance and safety. And, they are data driven. That is a short explanation of why there are no fundamental guidelines, on a global scale. Everyone is charting their own course, including the fire service. It is a patchwork of “suppression methods” concerning how to handle these events. I educate first responders and police in two states, and I know this from interviewing them.
I focus on what is happening to the public, the infrastructure, the first responders and awareness for organizations, to be prepared for any potential issues. You can’t negate all of them, but you can prepare and have a plan of action. For example, a multi-story parking lot can have every safety feature in the world, and the best action plans, but you don’t control what cars customers bring into a garage, on a bridge or in a tunnel.
We are seeing more and more significant fires, and events related to electric vehicles and lithium-ion batteries. Since our last interview, we have had two events at ports. Montreal saw a large fire, with a white out condition of smoke from the burning batteries in a container. There were over one hundred first responders (photo). What is shocking is to see the first responders in SCBA talking to a woman on the street. They should have directed her to move as far away from what could have been the toxic white cloud of “HF.” The other incident at the Port of Los Angeles was handled in a completely different way. A truck with lithium-ion batteries overturned, and the decision was to let it burn, and not use water. Why? They didn’t want the toxins that would mix with the fire water to pollute the area. Two countries, two methods, two ports, same week.
This week also brought the aftermath of Hurricane Helene which affected many US states. Florida once again learned EVs and salt water can be a toxic situation. Much to the Governer’s credit, he announced this and told residents to move them away from areas that could be flooded. Why is salt water a problem? For two reasons. One is logical and based in science, and the other is, in my opinion, a foolish choice by some battery manufacturers. Salt water, simply put, can bridge the gap between the negative and positive terminals of a battery which can cause it to short circuit. This can happen when the vehicle is submerged, partially submerged, moved after submersion and post event, if the water, salt and corrosion remain in the pack. Remember many EV batteries are composed of individual cells and believe it or not are fragile, like e-bike packs. The reason that I can’t seem to get an answer to is why manufacturers do not have IPX68 vents. They usually opt for IP68 which allows water ingress. Maybe the second salt water flooding event will change things.
Montreal Port Battery Fire, Late September.
A new plan for permeable pavements is being implemented in New York and surrounding areas, with elevated crosswalks being promoted.
Yesterday, NHTSA and Stellantis used a “do not drive, charge or use vehicle” recall for its plug-in hybrids Grand Cherokees and Wranglers.. A total of 154,000 vehicles, not including the previous recall of the plug in Wranglers. The recall notice said a software fix may be needed. Sounds simple, right? If you really read the documents from NHTSA you will see the issue: “some may have been built with a battery pack that contains cells which are susceptible to separator damage.” Software fix? Not a chance. It is a battery issue, not a battery management issue. Software can not modify the physical aspects of a sealed battery pack, no more than software fixes can fix flat tires or leaking sunroofs. We have seen this before. There was a recall of plug in hybrid vans. Post fix, more vehicles caught fire post “software” fix. Yes, software is a vital component of battery management, but it will not be able to repair defective hardware.
And this week also brought the plans for the continued deployment of “Permeable Pavement.”
This is a new deployment in New York City and the surrounding areas. What is it? Basically a road that allows the water to seep through the pavement for ‘’improved drainage.” To quote a NYC official: “ we have to take every opportunity to try to soften our landscape and allow for storm water to infiltrate into the ground.” Interesting right? Well think about the water used when an EV or e-bike catches fire. The firewater and the subsequent contaminated water from rainwater will take those forever chemicals directly under the street, and into the soil. And, even if you could remediate with a “cleaner” or think you can hose it down the sewer drains, you can’t. And, the same day, the raised crosswalks were also promoted. What are they, and what do they do? Speed humps that slow down traffic, and make pedestrian crossings “safer”. The idea is to slow down the traffic, and have a dedicated area for crossing that is safer, has better drainage, and the hope is that drivers will learn to slow down before crossing the pedestrian area on a street. Sounds ideal, right? Maybe, but certainly not ideal for EVs, in a city that is pushing for EV adoption. Why? Those same safety speed bumps are exactly what can cause battery packs to fail. Why and how? Batteries are like brains, they get concussions, are fragile, and the packs can be damaged from the bottom.
I also felt that driving an electric vehicle in Jeju Island over potholes and bumps caused significant impacts on the EV.
William If you are constantly scraping the bottom of the car, especially a smaller EV, it is a repetitive insult to the battery. Even a common plug-in hybrid's Minivan is only 12 inches from the ground. Think about EV performance cars with nominal ground clearance of 4.12 inches. Incheon and the Mercedes EQE fire? First the blame was on the “Chinese battery” which I found to be an absurd instant point of blame. Now it is being reported that it may not be the ‘’Chinese battery” which I never suspected as the issue, but a physical damage to the battery pack itself by the owner of the vehicle. We all hit curbs, however when you do that in a gasoline vehicle or battery vehicle, you may not notice it or have an immediate issue. However if you damage the pack, the fire can start immediately or 60 hours after the vehicle is parked, which is what happened at Incheon. When I educate, I actually have a mobile phone battery, which I set on toy wheels that move the battery (insert photo) to demonstrate that an EV is really just a large battery on wheels. And, the battery is at the bottom of the vehicle. You certainly would not put your mobile phone battery under your car and drive through rough streets, rain, salt, snow and hit curbs, and have car accidents and expect the battery to be perfect, right? I am making a point, that damage to the undersides of vehicles does occur, and that is where the battery pack is.
Well, you certainly had an eventful week! So, the question is how did we get here, and why are so many incorrect presumptions surfacing? And, why are the dangers increasing? And wasn’t the e-mobility and EV movement supposed to help the environment?
William The short answer is that there was no master plan. The Nissan Leaf in 2010 started the EV movement. It was an ideal vision. A small, low power, low cost vehicle that replaced a large gasoline vehicle, which may have contributed to polluting the environment if it was old, or it’s size did not match the driver’s current needs. If Nissan got a driver of an old SUV that was not needed, because the children were off to college and the car really was only used now to go to the market and for visiting friends, who needed a gas guzzler that was a polluter that may have gotten nine miles per gallon? A win/ win. Then came Tesla in 2012. That made an EV very appealing. Power, style, luxury, and speed. Then we snowballed into the hulking EVs and SUVs of today. The Cybertruck, The F-150 Lightning, the Ram Electric pickup truck.
And, Maserati and McLaren have just launched their fully electric supercars. You don’t buy a McLaren to drive slowly, you buy it for performance. That performance requires a very powerful battery, which is 4.12 inches off the ground. And the more you push a battery the more stress it incurs on the battery. Also understand the ‘’rule” is to never charge a battery past 80%. We are seeing Korea stress that now. However, if you have a McLaren or own a car rental dealership, range is a problem, so it is always charged to the upper limits. I have yet to engage with any EV owner that stops charging at 80%. In fact, most people charge their EVs and leave them plugged in, which creates even greater issues. We can mitigate many events, if owners charged to 80% and immediately unplugged the EV. Will that happen? No. What is truly terrifying is that many car service drivers are putting cold towels on the charging handle to fool the software into thinking it is not overheating, which will abort the charge. The drivers need the vehicle to be at a 100% state of charge. An idle car does not make money.
Since battery packs can bounce out and individual cells can roll far away, a burning EV cannot be thought of as a single unit.
So, car batteries are configured differently today?
William Yes. Now, batteries are not always a collection of cells within a solid case. Some batteries may be designed so that the individual cells drop out of the bottom in an emergency.
One vehicle manufacturer has encased the individual cells using a pack or module with open architecture. You can see the individual cells. The cells and modules in these cars can explode and shoot up and out of the vehicle. In a recent EV fire, three individual cells shot through the roof a vehicle reaching a height of fifty feet. This is not an isolated case- the UK fire service has documented cells shooting sixty-six feet during a e-bike fire.
There are some cars with the battery placed within the cabin, under the rear seat for example. Each battery configuration presents unique challenges.
Because battery packs can be ejected and individual fuel cells can shoot and roll great distances, we cannot think of a burning EV as a single discrete unit. We must be prepared to suppress a fire that is at a distance from the vehicle itself. Each fire has the potential to become several fires.
As a Safety and Risk Mitigation Consultant, my role is to identify risks and work with clients to implement strategies designed to decrease the number of events that jeopardize the infrastructure and cause personal injury, while protecting first responders and the public.
In photos from the Luton airport fire, the flames spread in an irregular pattern, leaving parts of the floor missing, resembling "Swiss cheese." This seems to be related to the location of electric vehicles parked there.
Let’s start with infrastructure. Can you talk about the cause and effect of the fire at Incheon?
William We may never know what caused the specific injury or insult to this battery, but we do know that in most cases like this, one or more of the cells that comprise the lithium-ion battery can be damaged and following a chemical reaction it starts to burn, igniting the other cells or modules. There may be other defects in the battery pack, specific to some battery designs, that can provoke a similar reaction. And, as the speculation swirls about, it may be the owner’s fault because something was damaged due to their error.
A battery can be damaged in many ways. In the USA, there are six million car accidents annually. Every accident is a potentially damaged battery. This statistic does not consider the number of vehicles that hit the curb, run over a pothole or experience an unreported minor “fender bender”. Anytime an electric vehicle hits the curb or a speed bump, there is potential to damage the battery pack.
These fires burn at incredibly high temperatures, causing devastating damage to the surrounding infrastructure. A gasoline powered vehicle burns at roughly 1500F, an EV fire typically burns at 4000- 5000F. This is hot enough to melt steel!
A building’s normal defenses are destroyed in the face of this incredible heat. Sprinklers can fail and cease to function and steel infrastructure can be compromised. If you’ve ever seen a photograph of an electric vehicle after a fire, there is nearly nothing left- often just a pile of ashes.
In a parking structure, cars are close together and the fire easily jumps from one vehicle to the next, creating a path of destruction it its wake. Remember, an EV fire does not have to start with the EV. If a traditional gasoline car is parked near an EV, and the gasoline powered car catches fire, it can easily spread to the EV, setting off a new cascade of events. As we know, forty vehicles were incinerated and more than eight hundred were damaged at Incheon, resulting in more than six hundred insurance claims to date.
In the Luton airport fire, photos reveal that the fire burned in irregular patterns, leaving a pattern of damage that resembles Swiss cheese. Parts of floors are missing and this appears to be related to the location of EVs that were parked there.
To be clear, the concern is not limited to parking structures. Lithium-ion battery fires can happen anywhere. There have been several serious fires in shops selling e-bikes. Many of these are small shops with apartments above the store. In New York City, we have seen several fires that started when someone brought an e-bike into an apartment.
There are parking structures underground, on the street level and above offices, shopping malls and apartments. Each location presents specific challenges. Parking structures are incorporated into apartment buildings, shopping malls, airports, office towers and schools. There are even apartment buildings, in many cities around the world, where you can drive your car right into an elevator and park in your apartment.
Businesses can't rely on the first responders to protect their property from the suppression of an EV or e-mobility event. Their job is to suppress the fire, make it safe, and allow the remediation to begin. Many think it is the end of the event. In many cases it is just the start. Why? The first responders do not remove the water they used to suppress the event which may have spread toxins throughout the structure, which is what happened in Incheon and Luton. That is why risk assessments and recommendations before an event are vital. And, for small business owners, the financial burden may be unsustainable, and may lead to a closure due to lack of income from the property or business. Larger, highly profitable business and conglomerates are not immune either. They are often "self-insured" to a degree. Having events like this can take any business and alter it's course in dramatic ways. And, the minute you hang the "Grand Reopening" sign up, it can happen again. I spoke with two vehicles dealerships about risk assessments. Both said "We make the best EVs!" I said, that may be true, but you have this area called "Service", and you have no idea what condition customers are bringing vehicles into your shop. It is for "service" which may not be a routine maintenance issue, however it may be a battery pack failure or one of the half-million battery vehicles that have been recalled to date, that have a "do not drive, park inside or charge the vehicle." governmental regulator decree. You can't diagnose every potential battery issue in the ten minutes it takes to put the car in your service lot, and get the customer into a loaner. " Their reaction? No reaction, just a blank stare off into space.
Luton Airport's fire did not close the airport. However, smaller regional airports, with garages in the middle area of the airport, could effectively shut the airport down, and many are located by the water, which becomes an environmental issue. I am not a negative person, I am a realist who hates surprises and bad outcomes that could have been prevented with awareness, education, and strategic plans in place. Those in charge of a business or real estate venture capital organizations, need to understand the property they may be buying or investing in. The insurance companies will surely raise or cancel insurance for properties who have no safety preparations. We have turned a corner concerning all things battery, and we need to be prepared for what can happen. Being inactive and waiting for the next tragic event is no longer an option.
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