Driver awareness systems

The recent changes to EN1755 affect chemical companies, whisky distilleries and any manufacturing or logistics business using a system to alert lift truck drivers to the presence of an explosive atmosphere. 

“In Zone 2 hazardous areas, an explosive atmosphere is not likely to occur in normal operation,” Rob Vesty from safety company Pyroban said. “If it does occur, it will persist for a short time only, possibly due to an accident, which is why forklift driver awareness is so important.”

Zone 2 areas are usually storage areas in which flammable liquids or gas is contained in sealed drums, tins or IBCs and where forklift trucks are widely used. For example, to transport bottled gas or materials in gas cylinder filling operations, or at distribution centres.  

“ATEX compliant lift trucks are usually specified featuring an active gas detection system which alerts the driver visually and audibly,” he says. "But the standards have become even more stringent and this has led to Pyroban investing in a two-year change programme to meet the new requirements.”

These new requirements have affected the technical design of Pyroban’s system6000. system6000 incorporates gas detection to continuously monitor the direct environment around the protected equipment. When a mixture of flammable gas or vapour in air is detected, system6000 gives an audible and visual warning to the driver at 10% Lower Explosive Limit (LEL) propane in air. At 25% LEL it shuts down the protected equipment, automatically eliminating the risk of an explosion.

In addition to the systems that alert the driver, EN1755 changes have affected tyre, seat, battery and other ancillary product requirements. Service engineers also need to be trained for the new requirements.

“Driver awareness is an important safety factor in Zone 2 as the explosive atmosphere is not expected,” Rob said.  “In Zone 1 applications, passive protection is used as trucks need to operate through the explosive atmosphere.  EN1755 also applies to these conversions.”

Pyroban’s Zone 1 conversions include explosion proof Exd enclosures, surface temperature limitation on motors, brakes, electrics and other components, Exd or Exe motors, Exi intrinsically safe circuits, Exm encapsulation and more. Diesel trucks also feature air inlet shut off valves and water-cooled exhaust gas coolers.