Properly protecting integrated microgrid and EV charging infrastructure

Electric vehicles (EVs) have a big part to play in the future of transportation. From individual vehicles to fleet electrification, people should expect to see more EVs on the road in the years to come. This increase in EVs will come with a corresponding energy demand. In fact, the National Electrical Manufacturers Association (NEMA) recently released a report that predicts a 9000% growth in e-mobility power consumption through 2050.

Growing e-mobility power demand combined with increased pressure on the electrical grid from other sources means that EV fleets and charging operations need to be thinking about how to generate their own power. In short, if you are in the EV business today, you’re also in the microgrid business.

It starts with energy storage

Energy storage is the most critical microgrid technology for EV engineers to be thinking about. Energy storage unlocks the potential of onsite renewable energy and provides a way for charging station and fleet operators to manage fluctuating grid power prices and availability.

Renewable power generation is inherently variable. For instance, solar panels only generate energy when it is sunny out. However, vehicles need charging available 24/7. If charging stations are attached to onsite renewables, energy storage is essential to decouple energy production from use. Investing in renewable energy and energy storage is a good investment, as these microgrid installations can eventually pay for themselves in generated electricity. Additionally, if vehicles are not in use, or don’t need to be charged, charging station microgrids can sell excess power back into the grid, providing another income source and helping to build a greener, more sustainable energy system.

However, even without renewables integrated into fleet charging infrastructure, energy storage can change the financial math for electric vehicles through peak shaving and charging optimization. EV charging stations should, at the very least, use energy storage installations to lower energy costs by relying on stored power when grid energy is particularly expensive, and recharging energy storage units when grid power is cheaper. This kind of smart charging infrastructure makes it easier to justify investment in EV charging and can save a great deal of money over time. It also helps contribute to a more reliable and resilient electrical grid by reducing usage during times of high demand. Energy storage can also provide power resilience in the case of outages or extreme weather. For these reasons, over the next 15 years, the amount of storage connected into the U.S. electricity grid will grow by 1100%, per NEMA.

Grounding and other microgrid protection systems

Microgrids bring a lot more electric technologies into building and facility infrastructure. Because of this, it is extremely important to ensure that systems are appropriately protected and grounded. Current always flows through the path of the lowest impedance, and even the most well-designed electrical systems can be at risk of fault currents from lightning, equipment malfunctions, or surges from power sources. Good grounding and bonding systems consider soil conditions, seasonal patterns, and other unique site differences. They also require mechanical, compression, or exothermic connections between system components that can pass safety audits and be relied upon for years after being buried in the ground. This improves safety for people working with and around EV charging installations.

Enclosures also play a pivotal role in enhancing the resiliency of charging infrastructure by protecting sensitive electrical components and keeping them operational under various conditions. Enclosures protect equipment against environmental factors such as extreme temperatures, moisture, dust, and debris. Enclosures also enhance safety by preventing accidental contact with live electrical parts and offer physical security against vandalism and theft.

Enclosures equipped with advanced thermal management systems, such as liquid cooling, also help manage the heat generated by high-power components, preventing overheating and driving efficient operation. Compliance with industry standards and regulations is a critical consideration, as certified enclosures meet legal and insurance requirements, contributing to the safe operation of EV charging infrastructure.

Electrical balance

Maintaining the right electrical balance of energy systems is a basic step but one that cannot be ignored as energy systems rapidly change and evolve. This work includes choosing reliable components to connect renewable energy generation equipment to microgrids and storage installation. UL1741 Compliance is a key safety standard governing inverters, converters, and controllers used in renewable energy systems. Ensuring compliance with UL1741 is vital for grid-tied installations, as it certifies that components meet safety and performance requirements. Implementing proper design for the electrical balance of systems supports seamless energy conversion, minimizes losses, and supports compatibility with the grid.

Maintaining microgrids

As the EV charging infrastructure engineers start integrating more renewable energy and battery energy storage into their installations, it is shifting service and maintenance needs. A well-designed microgrid EV charging system must facilitate efficient serviceability and maintenance over its operational lifespan. Modular components simplify replacements and upgrades, minimizing downtime. To prevent failures, it is important to schedule maintenance plans and implement predictive maintenance protocols based on operational data. Additionally, it is important to design a layout of electrical components that facilitates access to key components for routine inspections and repairs. 

It is also key to design systems with clear labeling, accessible components, and standardized safety procedures to support trained personnel. Relatedly, training programs must be constantly refreshed to make sure they are relevant to the current conditions personnel will face in the field. 

For all technologies, both those directly related to vehicle charging and those supporting charging installations, modularity and scalability are key. Facility managers need to make sure they work with OEMs and equipment providers that offer designs that can be easily scaled up to meet future demand without costly rework and downtime.

 

About the author: Dave Kaminski is the Automotive and E-mobility Vertical Growth Leader for nVent, a global leader in electrical connection, protection and cooling solutions. Dave takes great pride in developing products and solutions for new market opportunities. He is a graduate with a B.A. in communications from the University of Mount Union in Alliance, OH. Prior to nVent he spent over 15 years in Industrial Lighting and Controls.  In his spare time, he enjoys kayak fishing, cooking BBQ and playing with his dog, Tobin. He also volunteers as the Marketing Coordinator for the Northern Ohio Chapter of the Surfrider Foundation.