Standard forklift trucks can, and do, cause explosions in areas where flammable material is processed and stored. Such accidents can be devastating and pose as the most serious health and safety risks found in the forklift truck industry. Malcolm Davis of safety expert, Pyroban, explains how explosion proof forklifts can be cheaper, safer and easier to supply than ever before.

This risk of explosion is a daily concern for many large and small businesses processing or storing flammable gases, liquids, powders or dusts. It is also a major concern for forklift suppliers who should be fully aware of their responsibilities.

Safety laws for the use of forklifts in such hazardous areas vary throughout the world, however many are very similar to those found in Europe. Specific EU legislation in the form of the ATEX directives regulates sites where flammable materials are present and the equipment to be used in such areas. This means that if an area is classified hazardous, the forklift should be suitably protected and maintained.

Pyroban converts almost any forklift truck for almost any explosive atmosphere across the world, from facilities in Europe, Asia and North America. Pyroban modifies forklift trucks to ensure that there are no sources of ignition present on any of the components, such as sparks, hot surfaces or static energy.

Due of the complexities of converting the latest forklift trucks, the testing and certifications involved, most forklift suppliers have formed a strong relationship with Pyroban in their local regions. The company makes it relatively easy for forklift suppliers to access market sectors such as the chemical, pharmaceutical, food and drink, paint/coatings, logistics and various other manufacturing industries where hazardous areas exist.
Strong relationships with Pyroban have helped end users and suppliers reduce costs significantly and improve safety through providing leading technology and correctly specifying equipment. This is true across the world with North American companies also looking more closely at the real risks posed to their operations by their forklifts.

REDUCING COSTS & INCREASING SAFETY

When ATEX 1999/92/EC was published in 2000, its primary objective for businesses was "the prevention of the formation of explosive atmospheres". Prior to this many companies involved in the chemical, pharmaceutical, paints/coatings and food/flavour industries had been specifying Zone 1* rated trucks despite the fact that the inherent safety culture of their business was focussed on eliminating or limiting such areas. Zone 1 rated trucks were costing twice as much as standard forklifts, Zone 1 Ex parts were expensive and not always available from stock. Zone 1 service maintenance was also a frequent and expensive necessity.

Many companies have updated their site risk assessments and reclassified many of their Zone 1 areas as Zone 2 based on their latest work processes. In response to customer demand and the move towards a Zone 2 philosophy, Pyroban's System 5000 gas protection was designed to protect all brands of both battery electric and diesel engine trucks at minimum cost. Based on the harmonised European standard EN 1755:2000 it is certified to the ATEX 94/9/EC directive by SIRA a leading ATEX certification authority and the technology is constantly evolving with the latest generation of energy efficient forklifts.

Since System 5000 was introduced in 2001, thousands of System 5000 protected trucks have entered service around the world and truck suppliers and users have benefited from its low cost of ownership.
System 5000 also provides the highest level of zone 2 safety. Features include:

• Gas detection providing visual and audible warnings to the truck operator when gas/vapour is detected at 10% of the LEL (Lower Explosive Limit) of Propane in Air. This allows the truck operator to leave the danger area before an explosive atmosphere becomes present.


• Automatic truck shutdown at 25% LEL Propane in Air, provides maximum safety to the truck operator and minimum risk to his/her colleagues working in the immediate vicinity. If the operating area becomes explosive the safest course of action is to isolate the truck and its potential ignition sources.


• After truck automatic shutdown the only person able to restart the truck is the POA (Person in Authority) who can investigate the incident and use the System 5000 master key to restart the truck when the area is free of gas/vapour.


• Control of access to the protected truck via the System 5000 Operator key


• Automatic 90 second gas calibration test at truck start up when beginning each day/truck shift. This feature ensures the truck operator knows the heart of the safety system is functioning correctly and keeping him/her safe at work.


• All sparking and arcing components are contained within restricted breathing enclosures allowing the original truck ergonomics to be retained and safety features such as speed restrictors, weighing devices and lighting to be easily integrated.


• Temperature limitation to Class T.3 or T.4 to suit the chemical, coatings and pharmaceutical industries. System will provide visual and audible temperature alarms


• Designed and certified for 95% of hydrocarbon gases and vapours so suited to virtually all applications involving products of Gas Groups IIA and IIB.


• Plug and Play technology so in event of a failure repairs can be carried out simply and quickly. System 5000 ensures maximum truck uptime for operators.

Contact Pyroban for further information on System 5000 and other Pyroban Ex forklift truck safety systems at www.pyroban.com or info@pyroban.com.

Click here to view the Pyroban Shopfront