Green Fleets

Despite manufacturers' reassurances, vehicle delivery delays are expected.

In February, Ford began deliveries of its E-Transit EV van to fleet customers, one of the earliest of the highly anticipated commercial-grade battery-powered vehicles to have its orders fulfilled. It's a bright spot in the electric vehicle market as fleet managers keep an eye on shifting EV delivery dates.

Some delays are out of the manufacturers' control as the supply chain, including semiconductor manufacturers, struggles with its own set of challenges.

A utility fleet manager who is considering integrating electric vehicles into their operation faces a range of questions, including how telematics data will be tapped when running a mix of trucks powered by either internal combustion engines or electric drivetrains.

In other words, will it be difficult to blend the data streams from these two vehicle types to continue conducting a singular equipment analysis to gain overall fleet cost/performance insights? Or will the information gleaned from the two fleet segments have to be analyzed separately? Further, is analytical software sophisticated enough to present integrated data for the whole fleet as well as separated by power source?

Tracking brake cost and performance is just one example of this conundrum. If brake wear is less on EVs, thanks to regenerative braking, would the fleet have to analyze EV and ICE brake system separately?

Even as electric utilities and other fleet operators are embracing battery-electric medium- and heavy-duty trucks to move to zero-emission power, another wave of alternative power is rolling in: the hydrogen fuel cell. Just as a battery-electric vehicle (BEV) delivers zero-emission power, so does a fuel-cell vehicle (FCV).

Thanks to several key advantages of FCV design, expect to see heavy-duty trucks powered by fuel cells arrive on the market in the U.S. within the next five years – and maybe as soon as 2022.

The power drawn from a BEV’s onboard batteries is recharged by plugging in the vehicle as well as by regenerative braking. In contrast, a fuel cell generates electricity via an internal electrochemical reaction. When hydrogen and oxygen are combined, electricity, heat and water are generated. Because of that advantage, fuel-cell power is being developed for a wide range of vehicles, from forklifts to trucks.

Most fleet professionals understand the benefits of idle reduction. It's the lowest of the low-hanging fruit.

Unfortunately, too many fleet managers and drivers still believe certain old-school conventional wisdom, like starting a truck uses more fuel than letting it idle.

Up-to-date research pokes holes in those old beliefs, but it can be hard to change minds. Various programs are available to help fleets build new policies and procedures to make the training stick. Yet it's difficult to break old habits and create new ones.

For fleet managers, there doesn't seem to be a downside to reducing idling. There's a direct correlation between reducing carbon dioxide pollution and fuel use. Each gallon of fuel burned produces about 20 pounds of CO₂. Reducing emissions also lowers fuel costs.

Despite all the technology available in today's utility trucks, the most critical connection is still between the driver's brain and foot.

But OEMs and the aftermarket are also offering tools to monitor driver and vehicle performance, and upgraded equipment can reduce the need for idling. Making smart fleet acquisition decisions can pay off as well.

American Idle
As fuel prices rise, cutting back on idling is low-hanging fruit that fleets can grab to make quick improvement. In the typical fleet, idling behavior accounts for 40% of engine hours, according to Ron Zima, founder and CEO of GoGreen Communications Inc. and a consultant known as the Idle Free Guy.

It may be too early in the game for fleet operators to factor in the impact of battery-electric trucks on maintenance costs and resale values.

Some experts hold that the cost of maintenance may be lower thanks to fewer moving parts on electric vehicles, yet it may be higher for other aspects, such as future battery replacements. But they also contend that the savings generated from not consuming diesel fuel may make maintenance costs a wash initially, and then they will improve in favor of battery-electric vehicles as rising demand brings down acquisition costs. Another factor to consider is fear over accurately predicting future resale values for battery-electric trucks.

Will all that in mind, a utility fleet may want to consider leasing versus buying their first batches of medium- to heavy-duty electric vehicles, such as bucket trucks and Class 8 on-highway haulers.

Jessica Lauer, fleet analyst for Detroit-based DTE Energy, is responsible for overseeing metrics for the company’s 3,700 Class 1-8 vehicles. That’s not always easy to do, particularly with some of DTE’s Class 5-8 vehicles. Problems have occurred after telematics devices were installed on the assets but before they were driven by the business units.

“It may be weeks before I can see [a vehicle],” Lauer said. “I may have missed an ignition event, so I have to wait until the business unit drives the vehicle to see if the device is reporting correctly. It just causes issues.”

She doesn’t have the same challenge, however, with Class 1-4 vehicles these days. Lauer said that’s because she uses the Ford Telematics system, which comes built into a Ford vehicle when it’s delivered.

If your utility operates electric vehicles – or is planning to do so – the emergence of wireless charging technology could impact vehicle selection and charging infrastructure decisions.

Currently, wireless charging is available for smartphones and other small electronics. But wireless EV charging could be a key to widespread transportation electrification.

In the utility industry, EV adoption is just beginning to take off. This September, Duke Energy announced an EV initiative that will convert 100% of its light-duty vehicles to electric and 50% of its combined fleet of medium-duty, heavy-duty and off-road vehicles to EVs, plug-in hybrids or other zero-carbon alternatives by 2030. The utility company already has about 600 EVs in its 10,000-vehicle fleet.

Duke will deploy new Level 2 plug-in charging stations at operations centers, field offices and power generation facilities – essentially, "wherever we are deploying the bulk of the EV fleet at any given time," according to Jennifer Sharpe, a spokeswoman for Duke Energy. "As we see growth in the fleet, we'll deploy additional fast-charging facilities for longer-distance travel of any fully electric vehicles."

In the midst of the COVID-19 pandemic, some utility fleets have discovered that their idling has increased. So – perhaps now more than ever – it’s imperative for fleets to identify instances where idling can be controlled and act on them. UFP recently spoke with three fleet industry professionals who shared tips on how to do just that.

Get Staff on the Same Page
According to Dale Collins, fleet services supervisor for Virginia-based Fairfax Water, the greatest idle mitigation is achieved through operators intentionally turning off their engines when possible.

“The best practice is to have a well-trained workforce that understands state and local statutes regarding idling, company expectations, and the difference between necessary and unnecessary idling,” he explained.

That may require some coaching. Several years ago, Collins asked the local Clean Cities coalition to provide idle reduction training for all his field staff. As a result, the fleet experienced almost 10% less fuel consumption the following quarter.

With fuel being one of the greatest expenses for any fleet organization, a fuel card program can be a helpful and efficient way to keep track of spending, usually at little or no cost to fleets. Recently, Utility Fleet Professional spoke with two fuel card experts who shared tips for what to look for in such a program.

While a number of organizations house on-site fuel stations and can easily track fuel spend and consumption that way, there are still instances when drivers are unable to make it back to the garage site to fill up. For example, drivers who are dispatched for emergency or weather-related work may have to fill up at an outside retailer or truck stop instead (i.e., an area where fuel activities can no longer be monitored).

Using a fuel card program can supplement these operations to give clients flexibility and appropriate oversight of fuel use, according to Steve Jastrow, vice president of consulting and analytics for Element (www.elementfleet.com).

“If fleets don’t have a managed program today, the fuel card is a great solution,” he said. “Fraud prevention, oversight of usage, productivity and the data to report/benchmark can all deliver savings.”

For several years, Joe Korn, a truck and alternative fuel consultant with ARI’s (www.arifleet.com) business intelligence and analytics team, has been working with some of the company’s North American customers to implement alternative fuel strategies.

One of his priorities is to provide fleet expertise to clients aiming to bridge the gap between internal combustion engines and battery electric vehicles.

Korn said that, with the proper infrastructure in place, there can be a long-term cost benefit to implementing EVs into utility fleets, and the reduction of fossil fuel emissions is a significant benefit as well.

“I am 100% behind electric vehicles,” Korn said. “There’s been a lot of interest from companies on how to incorporate electric vehicles and other alternative fuels into their fleet and how they can work towards sustainable strategies and lower pollutions.”

Over the last decade, Southern California Edison has worked with a handful of telematics providers. That’s meant plenty of learning opportunities with both traditional and electric vehicles. The utility company’s fleet has roughly 6,300 units; about 10% of those are electrified. And it’s an ongoing challenge to be able to report the data that the company desires.

“The ability of telematics providers to provide data on EVs has increased, but the complexity of EV software and frequency of software updates can leave the telematics providers chasing data,” said Todd Carlson, principal manager for fleet asset management at SCE. “It’s a constant effort to keep providers current with what is offered in the EV space, and there’s generally a lag.”

Randy Scodellaro, technical specialist in telematics at SCE, is tasked with overseeing the telematics hardware performance across the utility’s fleet and providing technical assistance to field personnel for diagnostics and repair, among other things. He likened the transition of a telematics provider from a gas-powered vehicle to a plug-in hybrid or EV to a computer upgrade from Windows 8 to Windows 10: It may be more powerful and have better functionality, but more learning will still be required – every time.

CPS Energy, which serves approximately 820,000 electric customers and more than 345,000 gas customers in the San Antonio area, wanted to help convince its utility customers to explore electric and hybrid vehicles. But rather than roll out a marketing campaign touting the benefits of EVs, the company opted to roll out its own trucks.

Today, CPS Energy has 44 hybrid plug-in Ford F-150s and 15 hybrid Ford F-250s among its fleet of 2,000 vehicles. It also has plans to deploy 14 fully electric sedans. While the sedans will come from the OEM, the Ford F-150s and F-250s were upfitted by XL (www.xlfleet.com). XL offers two versions: a standard hybrid, which is available on several OEM platforms, including Ford, Chevrolet, GM and Isuzu; and a plug-in hybrid, currently available only for Ford F-150s and F-250s.

XL introduced the F-250 plug-in hybrid earlier this year. According to Eric Foellmer, XL’s marketing director, “That’s really generated a huge amount of interest in the utility community.” The plug-in hybrid makes sense for electric utilities in particular, Foellmer said, because “they have unlimited electricity access and a charging infrastructure.”

New Jersey-based Public Service Electric and Gas Co. (PSE&G) has a little over 500 bucket trucks in its fleet. Of those, 327 have some degree of electrification. That might mean an original Bohlinger electric drive system from decades back, or perhaps a more current and elaborate work-up that operates the boom and provides climate control of the cab and exportable power for the crew.

“A lot of the technology [crews were] using, years ago, it would have been very hydraulically driven,” said Jay Marchitello, PSE&G transportation supervisor. “For instance, up at the pole top, they would use hydraulic tools to drill holes, screw conductors together and what have you. Now, however, that’s changed to battery-powered tools; they’re lighter, there’s less impact on the people, and less impact on the truck.”

The exportable power of the complete system, then, allows the crews to charge and use these battery-powered tools at the top.

Remember the days when fuel consumption was likely to be documented on a clipboard near the pump?

Chris Lindquist does, too. Lindquist, who spent almost 30 years managing fleet and fleet operations for Colorado Springs Utilities before other opportunities, said vehicle numbers and gallons used were marked, “but reconciling those wasn’t very accurate.”

Times have changed.

Fleet professionals now have access to telematics, employee and vehicle tracking technology, fuel card controls and more. Data is there for the taking – but a careful eye is still required to ensure proper fuel use.

“Fuel is the largest-volume operations and maintenance expense a fleet manager has,” Lindquist said. “It represents the most transactions in the month. It takes a tremendous amount of time to reconcile, but when you consider the amount spent on fuel in the overall budget, you have to allocate the associated amount of time to manage it.”

When utility fleets use telematics as intended, the benefits of the technology can be wide-ranging. Each asset, each mile driven and each minute spent idling generate data and insight that tell a story about the fleet.

And telematics data can be analyzed to determine not only what is currently happening with fleet assets, but also what could happen in the future. That’s why some utility fleets have begun to use the data for both preventive and predictive maintenance. However, where predictive maintenance is concerned, there are some operational hurdles to overcome.

At Baltimore Gas & Electric Co., telematics was implemented in heavy-duty vehicles in 2011 and in all light- and medium-duty vehicles in 2014 when the utility was acquired by Exelon Corp. Now, telematics is available on 1,289 vehicles and about 40 other assets, according to America Lesh, manager of fleet at BG&E.

Every three hours, Verizon provides the mileage, engine hours and GPS coordinates of all enabled BG&E vehicles and equipment. That data is uploaded to BG&E’s fleet management system.

Even if you closely follow the news, it’s difficult to pin down which direction electric vehicles (EVs) will be heading over the coming year. Production of certain hybrid models is ending, while other OEMs have promised to roll out more all-electric vehicles. Some car enthusiasts have proclaimed 2019 as the “year of the electric.”

Scott Shepard, senior research analyst/energy for market research and advisory company Navigant Research (www.navigantresearch.com), believes there’s plenty worth watching in the coming year – but not necessarily for fleets. “It looks like most of the conversation is going to be around long-range SUVs coming onto the market,” he said.

Jaguar, Audi, BMW, Hyundai and Kia are among the automakers with a U.S. presence that will be introducing new electric SUVs in 2019. A number of Chinese startup manufacturers also are expecting a big year ahead. “That’s all a big deal,” Shepard said. “These are the first vehicles that are competitive with a Tesla, with similar range characteristics as well as purchase price characteristics.”

For his part, Ted Davis, vice president, North American supply chain for fleet management company ARI (www.arifleet.com), pointed to California OEM Chanje Energy, which is “already taking orders for its Euro-style electric van.” Others, like ROUSH CleanTech, with its all-electric Ford F-650, and Mitsubishi Fuso, with its eCanter, should be taking orders later this year, pending road tests. Shepard pointed to Rivian, the talk of the Los Angeles Auto Show, for its sport pickup truck. “As the first models hit the road, we’ll begin to see how these units perform in real-world scenarios, and hopefully this insight will encourage more fleets to embrace this ever-evolving trend,” Davis said.

In the transportation sector, fuel cell technology has long been on the brink of breaking through for a variety of medium- and heavy-duty applications. We’re still not quite there yet, the experts say – but the promise continues.

“Increasingly, the toughest remaining challenges for heavy-duty fuel cell trucks relate to the hydrogen fuel they run on,” said Jon Leonard, senior vice president at Gladstein, Neandross & Associates (www.gladstein.org), a clean transportation and energy consulting company. “Like compressed natural gas vehicles, most fuel cell vehicles run on compressed hydrogen [CH₂] that must be carried onboard the vehicle using heavy, expensive, high-pressure tanks. Although this presents tradeoffs on cost, range and other factors, onboard CH₂ storage is robust and proven.”

Other challenges include the high cost of the hydrogen fuel and its limited availability due to a paucity of hydrogen fueling stations. “Moreover,” Leonard added, “the limited number of existing hydrogen stations are largely geared for light-duty vehicles like the Toyota Mirai, Honda Clarity, etc. The only hydrogen stations that can accommodate heavy-duty vehicles are mostly found on transit properties.”

All the same, there is forward movement. Light-duty fuel cell vehicles manufactured and sold by the likes of Toyota, Honda, Hyundai and Mercedes-Benz are proving their worth – and inspiring the promise of other, heavier-duty applications in the future.

Idling work trucks can be an annoyance to those who have to listen to them, damaging to the environment and, increasingly, they are unnecessary and undesirable in the field.

For one thing, the Environmental Protection Agency’s Phase 2 greenhouse gas emissions and fuel-efficiency standards for medium- and heavy-duty engines and vehicles will be in place relatively soon, impacting work trucks beginning with the 2021 model year.

But fleets don’t even need to wait that long to address the issues that idling vehicles present. Already, a number of new anti-idling technologies are ensuring that workers can do their jobs without their vehicle’s engine running.

While anti-idling technologies have been around for a while, the last year has brought several advances that are providing better results at a lower cost. Perhaps the greatest technology that could lead to successful adoption in the field is one that powers heating and cooling.

“That’s a neat next step,” said Bill Van Amburg, executive vice president of CALSTART (www.calstart.org), the nation’s leading clean transportation technology organization. “That has been a limitation. If you’re in a hot or cold climate, shutting down the engine is good. But you’re getting into a cold or hot cab. Who wants to do that? To be able to say, ‘You’ll not lose the ability to stay comfortable while doing your job’ will help people be willing to comply.”

John Adkisson, transportation manager for Pennsylvania-based PPL Electric Utilities, keeps an eye on the fuel consumption of the company’s vehicles through the use of fuel cards.

Each vehicle in the utility’s fleet is assigned one of these cards when the vehicle is put in service, and each employee is assigned a unique driver ID. Assigning fuel cards and driver IDs serves two purposes: “This allows anyone who operates a company vehicle to fuel any vehicle that he or she may be driving with the fuel card,” Adkisson said. “This also allows the fleet department to track fuel consumption down to an individual vehicle.”

Monthly exception reporting provides Adkisson insight into any unusual activity, such as an out-of-state purchase or purchase of a large quantity of fuel. If needed, he can limit driver transactions by number or amount via the fuel card’s website.

An Attractive Solution
It is this type of data, flexibility and control that make fuel cards an attractive solution for today’s utility fleets, often winning out over other options, such as on-site fuel tanks and driver reimbursement.

“Customizable controls and program parameters are among the top benefits of a fuel card, as compared to other options,” said Andy Hall, assistant manager of fuel and GMS products for fleet management company ARI (www.arifleet.com). “Reimbursement programs and general credit cards typically allow drivers to purchase virtually anything they want without restriction, resulting in misuse and abuse.”