Coordination for the successful design of EV charging stations

EV charging insights

• Successful design and implementation of EV charging stations necessitate early and continuous collaboration between various trades.
• Coordination with local utility companies is crucial from the onset of EV charging station projects.

Designing electric vehicle (EV) charging stations requires a lot of teamwork, so it’s not suitable for those who prefer working in silos. These projects require many trades to collaborate intensively, not only among themselves but also with local utilities. Below is an overview of typical roles and responsibilities and how they intersect.

Utility companies

For new construction, discussions with the local utility must begin during the site selection process. For renovations or repurposing, load capabilities will determine a project’s feasibility. In both cases, the discussions must take place early and often.

It is typically the electrical engineer who reaches out to the utility company on the client’s behalf. Larger customers often have a dedicated account representative who can initiate the discussions and help navigate the various groups and processes within the utility company to ensure the discussions are as efficient as possible.

To prepare for these discussions, the project team needs to understand the type, quantity and estimated demand required for new chargers. For existing sites, the team also needs to understand the existing facility loads as outlined in NFPA 70: National Electrical Code (NEC), Section 220.87. If the existing loads are not readily available from the building owner, the utility company can assist in obtaining this information from the meters.

A plan to incorporate renewable energies and/or energy storage to offset some of the demand will involve additional design considerations to meet the utility’s requirements for grid-connected systems and/or energy storage. Such requirements are in place so that the utility can safely operate and maintain the grid.

Figure 1: Coordination between multiple teams and people is required for the successful implementation of EV charging stations. Courtesy: Syska Hennessy

Incentives from utility companies are another consideration. Some utilities offer rebates to help offset the costs of renewables and the installation of EV chargers. While these incentives may help to make a project financially viable, taking advantage of them requires further coordination with the utility.

Keep in mind that coordination with the utility may not involve only one person or group. In a typical utility company, one group looks at grid connections, another looks at the load and others look at rebates and incentives. Each has its own process and timeline.

Coordination with the utility can be complicated and somewhat daunting, which is why it is essential to start these discussions at a project’s outset.

Civil engineers

The civil engineer is responsible for the layout and configuration of the parking spaces at a site, including spaces that will be used for EVs. Such determinations are not only necessary to ensure safe and efficient traffic flow, but also key to the planning of the electrical infrastructure that supports the chargers.

The electrical engineer is responsible for determining how much power is required and the size and quantity of conduits for an EV installation, whereas the civil engineer is typically responsible for the routing of these conduits when they are more than 5 feet outside of the building. This can be a complicated process, particularly when dealing with an existing site, as the routing of new conduits needs to be carefully coordinated with existing utilities to avoid disruption. Some sites are easier to work with than others, but in all cases communication and coordination between the civil engineer and the electrical engineer are essential.

Architects

The architect will likely have strong feelings about what the charging stations look like and how the cords and cables are managed. Poor cable management can destroy the intended aesthetic and lead to damage, rendering the chargers useless. Indoor issues may also arise. For instance, if significant infrastructure is added to the building, electrical rooms may have to be enlarged or added.  The architect has to work with the building owner and the electrical engineer to ensure that these rooms are located, sized and built to meet the proper building code requirements.

Structural engineers

When electrical equipment is added to a building, a structural engineer has to make sure that the building can support the weight.  While this is not an issue in most cases, structural modifications or enhancements may be required, depending on the building construction type and the proposed location of new equipment.

Parking garages are another example of when to coordinate with a structural engineer. Generally, EVs tend to be heavier, due to the weight of their batteries. If a large concentration of EV spaces is planned in an existing parking garage, a structural engineer will need to assess whether the existing structure can cope with the extra weight.

Fire protection engineers

Fire protection engineers need to be consulted for two main reasons. First, if new rooms are needed or existing rooms are modified for new electrical equipment, existing fire protection systems will also likely need modification. Some electrical rooms have sprinkler pipes, but others may have non-water-based alternatives. In either case, the modification and/or expansion of these systems has to be considered.

Second, consideration needs to be given to the EVs themselves, and particularly the batteries, in the event of a battery fire. Open parking lots may not present problems, but parking garages in sites like airports or high-rise buildings may present many obstacles. People, other vehicles and the structure must be protected. Furthermore, codes vary from jurisdiction to jurisdiction and are continually evolving to keep up with the current battery technologies, so the role of the fire protection engineer is paramount.

Mechanical engineers

On some projects, mechanical engineers can also play an important role. If an electrical room is being added or expanded, they make sure that there is adequate ventilation for the chargers or equipment that supports chargers. At a minimum, the heat rejection of the electrical and/or charging equipment needs to be considered and communicated to the mechanical engineers so they can size the heating, ventilation and air conditioning (HVAC) systems appropriately for new buildings or verify the adequacy of existing HVAC systems. Depending on the type of charger and where they are located in an indoor enclosed space, the mechanical engineer may be required to provide ventilation in accordance with NEC 625.52.

Information technology consultants

Many modern EV chargers support communication for remote monitoring, control and billing purposes. These protocols enable communication between the charger, EV and other backend systems. In addition, some advanced EV chargers may support smart-grid integration features, allowing them to communicate with utility systems to optimize charging schedules, manage grid demand and participate in demand response programs. This communication often requires internet connectivity provided through Ethernet, Wi-Fi or cellular networks, especially when integrating to larger EV networks that allow users to find and use chargers. The information technology (IT) consultant is responsible for providing this connectivity through a safe, secure and reliable connection. The electrical engineer needs to coordinate closely with the IT consultant to provide the pathways for this connectivity and to power any backend systems that may be required to support it.

Coordination among trades is important for any project, but especially for the design of EV charging infrastructure. One simply can’t put blinders on and focus only on their own work. Everyone has to collaborate with one another and with the local utility.

In short: No silos allowed. When it comes to EVs, we’re all leading the charge.

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