Sample Project Safety PlanDate: 04.14.2015Plan Completed By: Bulldogs RacingTeam Members and Contact InformationFirst NameLast NameEmailPhoneBackgroundBulldogs Racing is the Yale University chapter of the Society of Automotive Engineers (SAE). The team designs and produceshigh-performance, Formula-style race cars for the annual collegiate Formula SAE race series. For 2015-2016, Bulldogs Racingis building an entirely new car. Major projects for the year 2015 include collecting data on the BR14 car in its current state,designing a new high voltage system, and designing and fabricating an optimized chassis and new carbon fiber body. Theknowledge that the team acquires on BR14 will be used to refine the design of BR16 as well as to increase its durability andreliability. BR14 incorporates a 250 cc bike engine and an electric motor. The total sustained power output is around 60 kW, witha peak power output of about 100hp. BR16 will incorporate two electric motors, each capable of putting out a peak power of108hp.Proposed Test Description(s)We will be driving the car on the ; at no point will we be conducting any off-road tests. The course will be pre-determinedwith an emphasis on durability rather than agility or speed. Course will be marked with cones to indicate both the track and thedirection.Signs that read “BRAKE” will be placed at the end of straights longer than 25m to warn drivers about when to brake. Curbs andother fixed objects will not be used as an integral part of course markings – there will be at least 1m of distance between thecourse marked by cones and the fixed objects. Brakingo Regeneration efficiencyEnergy Consumptiono Fuelo Battery ChargeHeat generationo Internal combustion engineo Batterieso Electric motorSensor analysis and testingo GPS datao Roll, pitch, yaw datao Weight transfer calculationso Pedal travel optimizationo Center of gravity optimizationo Suspension adjustment and optimizationo Data transmission over wireless communicationWe have removed all components of testing that would constitute “competitive driving”. The purpose of the test will be to gaugethe durability and reliability of the car, as such the car will not be driven to test its agility or speed.Speed of the vehicle will not exceed 30 mph at any point on the course, and when the vehicle is being driven towards the othercars in the lot, the speed will be limited to 20 mph. Cones will be placed to ensure that the vehicle is forced to slow down whenapproaching the perimeter of the track. All track activities will be suspended when a pedestrian or vehicle appears to be entering1

Sample Project Safety Planor exiting . Cones will be placed around the central light post as well as around harsh road imperfections to ensure asmooth operating of the vehicle in order to prevent damage to the vehicle.Proposed Project ScheduleHazard AssessmentUsing the attached table for Example Hazards and Mitigation/Safety Measures as a reference, identify the hazards associatedwith the proposed project along with controls that will be used to mitigate them.Potential hazards include moving parts, high voltage system on the car, internal combustion engine, on-board fuel, componentfailures and driving obstacles. It is understood that such hazards that are inherent to race cars can be successfully handled byincorporating safety systems in the design, operator training or control of the environment. Below is a list of potential hazards:HazardLoss of control - driverLoss of control – fixedobjectsDriver AwarenessLoss of control - bystandersExternal impactDrivetrain failureDriver entrapment andequipmentDriver control unitsDriver emergency egressComponents snaggingdriver’s clothesCompromised hot body inthe engine bayEngine overheatMitigation/Safety Measure(s)Brake pedal has an over-travel protection switch that shuts down the internal combustionengine and the high voltage system in case of brake failure. Rear and front hydraulic brakelines have separate reservoirs and separate master cylinders. Throttle system is completelyelectronic, and in the unlikely case of a failure, the pedal assembly is designed to spring backto zero throttle position.A mechanical throttle limit will be introduced to limit the speed to about 15 mph for the testruns.The car will not be tested for its agility. The course will not contain sharp turns, hairpins orother challenging features. The main objective will be to familiarize people with the race carand test its reliability.The cones that mark the course will be strategically placed away from any fixed objects.Signs that read “BRAKE” will be placed wherever there is a 25m or longer straight toindicate when to start braking.All drivers will be required to hold a valid driver’s license (US or other) or a race carlicense. Anyone who exhibits dangerous or on-the-limit driving or a lack of understanding ofthe car’s operation will, at the sole discretion of the Responsible Safety Officer or the TrackSafety Officer, have their driving privileges suspended for the day.High visibility cones will be used to mark the test track. There will be a designated paddock area and nobody will be allowed to leave that area when the car is in motion. There is a highvisibility LED light mounted on the main roll hoop, which flashes when the car is active andready to be driven.Race car has an external impact attenuator (11 kJ energy absorption potential) and a threepiece carbon fiber body, as well as a thick aluminum front anti-intrusion plate, front steelbulkhead and triple steel side impact protection bars. The frame is made out of chrome-molysteel, professionally welded. Two roll hoops will prevent any impact to the driver’s head inthe very unlikely case of a rollover.All components in the engine bay of the car, including the high voltage system, are shieldedfrom the drivetrain and the chain by means of a chain guard.Driver’s seat is made out of one-piece carbon fiber, with a multi-point seat belt design.Shoulder and lap belts can withstand up to a force of 13 kN. Drivers will wear race helmets,fire suits, race gloves and will use hearing protection. Seat belts will be tightened by a crewmember.There are dedicated engine shut off, High Voltage shut off, emergency shut off buttons on thedashboard.The steering wheel and the seat belt harness employ quick release systems, enabling thedriver to egress the vehicle within 5 seconds in an emergency situation.All moving parts in the driver’s compartments, such as the steering wheel column, are housedin protective cases to prevent snagging. All pedals are made out of steel, body panelsincorporate carbon fiber and aluminum.An aluminum firewall separates and insulates the driver from all hot bodies, high voltagesystem, gas tank and drivetrainThere is a dedicated radiator to cool the engine.2

Sample Project Safety PlanFuel leakageVehicle visibilityExposure to energizedequipment – hybrid highvoltage systemElectric potential on theframeAccidental activation ofelectrical systemElectric system coolingBig red buttonsComplete electrical failureInjurySafety equipmentNoiseCertificationGas tank (1 gal capacity) is made out of aluminum, has a sealing cap and is vented to preventvapor buildup. There will be a designated track marshal with a fire extinguisher, ready toengage in case of an emergency.There is a high-visibility LED light mounted on the main roll hoop, which flashes when thecar is active and ready to be driven. There is a dedicated brake light at the back.Battery box is made out of fire-resistant and insulating Kevlar. All high voltage connectionscoming out of the battery box are housed in fire-resistant and insulating conduit. All lowvoltage is separate from the high voltage.Ground fault detector shuts down the high voltage system in the event of a faulty groundingof the circuit.All high voltage components are marked by High Voltage signs. Both the low voltage andthe high voltage keys need to be inserted and turned, then the high voltage system needs to beactivated by a crew member, but it is live only when the driver presses the HV button on thedashboard. When the High Voltage system is activated there is a buzzer loud enough to wakethe dead, and flashing LEDs that are mounted at the top of the highest roll hoop of the car.One of the two radiators is dedicated to the cooling of the high voltage system.All around the car there are multiple emergency shut off buttons that shut down the highvoltage circuit and the engine – these are wired in series with the brake over-travel switchand each other, so any one of them shuts down the entire car. They need to be manually resetbefore the car can be powered again.Steering, suspension and the brakes are entirely mechanical so they are fully functionalregardless of the operation of the car.A first aid kit designated for 25 people will be on-site. Responsible Safety Officer willmaintain the communication with the medical personnel, faculty adviser and EHS.Race helmets, race gloves, hearing protection, fire suits, high visibility cones, safety glasses,fire extinguisher, first-aid kit and spill absorber will be brought to the testing site by the team.There will be a designated Responsible Safety Officer present throughout the event.The car complies with the noise limits set forth by the Formula Hybrid committee.The entire race car was scrutinized by the Formula Hybrid Committee of 2014 and iscertified to be mechanically and electrically safe and track-worthy.Pre-Test Checklist: Nut/Bolt check: One person will be responsible checking that every bolt and nut on the car is tightened to a certaintorque specificationFluids Checko Fuelo Hydraulic Fluido Engine Oilo Transmission Oilo Engine coolantWheel checko Tire wear and pressureo Brake calipers and padsPacking listo Basic tools to be able to put the body and wheels on/off the car during testing to inspect componentso Fire extinguishero Spill absorbero Fluids mentioned aboveo Starter fluido Fire suitso Race helmets, gloves and shoeso Safety glasseso Hearing protectiono First aid kito Extra 12 V batteries and chargero Jumper cableso Infrared (or Penetration) Thermometer3

Sample Project Safety Plan o Computers for data collection and transmissiono High visibility coneso Marking tapeo Wheel chockso Tie-down strapso Jack stands (for inspection) and jacko Water to prevent dehydrationo Radio-phoneso Race flagso CamerasTransportationo Car will be strapped on a certified trailero Only the students with valid driver’s licenses will driveCommunicationo Assignment of the Responsible Safety Officer Responsible Safety Officer oversees the entire event and is present on the site at all times. RSO iseither a captain or the faculty adviser. If s/he has to leave, s/he will assign their duty to someone else.The RSO is the point person for the communication with the faculty adviser and EHS.o Assignment of the Track Safety Officer Track Safety Officer oversees the safety of the driver, the car and the track. TSO is a captain, a facultyadviser or a team leader. S/he will be present throughout the entire event. If s/he has to leave, s/he willassign their duty to someone else. It is in the TSO’s and RSO’s sole discretion to suspend the drivingprivileges of anyone who exhibits a lack of understanding of the operation of the car or knowledge ofthe track, dangerous driving or any action that puts the driver, bystanders, the car and theenvironment in danger. TSO will make sure that the track is constructed such that the fixed objects areat least 1ft away from any cones, the course is clearly marked for directions and that the signage (ieBRAKE signs, flag system) are being used properly.o Assignment of the Track Marshals Track Marshals use the flags to sign the driver what they should be doing, and they are in charge ofthe fire extinguishers. One will be at the paddock while the other will be on the opposite side of thetrack. They are to maintain the communication between the RSO, TSO and the drivers. They report tothe TSO.o Coordinate with the faculty adviser about the departure/arrival timeo Communicate with EHS in advanceo Read the weather reportDuring Testing Marshals at entry points to courseEither a captain or the faculty adviser will be present and will act as RSO. The RSO will appoint the TSODesignated marshal with fire extinguisherCourse marked by cones, with indicators denoting which way to goInspect car at every driver changeo Shut down the high voltage system and the engine before the driver exits the carDriver briefing before each driver changeo Emergency egresso Dashboard buttons, in particular Dashboard Emergency Stop Buttono No loose clothing/hairAll members except for the driver and the designated marshals must be at the paddocko Safety glasses are requiredAt every lap the designated marshals and the paddock chief will sign the driver:o Red – stop immediatelyo Yellow – keep going at a slower paceo Green – keep goingo Checkered flag – pull to the paddock after the current lapStrictly enforced 5mph speed limit when approaching the paddock4

Sample Project Safety PlanPost Testing Shut down engine and high voltage systemOnly the Responsible Safety Officer, Track Safety Officer and the designated marshals are allowed to be in physicalcontact with the caro Hot bodies should be avoidedStrap the car on the trailer and drive backPreparation and Testing ProtocolUpon obtaining appropriate approvals to perform testing and using a designated test site, the following procedure will befollowed to ensure the safety measures referenced in the Risk Assessment are in place. Verify all required approvals are obtained.o Risk Managemento Securityo EHS Communicate to the EHS scheduled test dates and times to allow the option for oversight. When required, ensure appropriate supervision is available and onsite during testing procedures. When applicable, ensure nearby building occupants are informed of the event. Ensure all team membe