Forklifts operating in potentially explosive atmospheres require special conversion to reduce the risk of ignition. But only a small percentage of forklifts are used for operations in such hazardous areas. Steve Noakes, Pyroban group engineering and operations director says: “As a result, fork lift manufacturers are not usually able to invest in making trucks that come off the production line compliant with explosion protection standards.”
Instead, forklift makers work with specialists like Pyroban which undertake conversions to conform with ATEX 2014/34/EU requirements, and standards such as EN1755:2015, which cover all equipment and protective systems intended for use in potentially explosive atmospheres.
When Pyroban receives a truck for conversion, it conducts a full assessment to identify and evaluate ignition risks. Using the requirements of EN1755:2015 as a guide, Pyroban engineers assess all mechanical and electrical components to decide whether they could cause ignition, by generating heat or a spark. This can include switches, sensors, relays, contactors, motors, generators and controllers, as well as brakes, transmission, hydraulics, forks, the engine and the exhaust. The interior and exterior are also evaluated extensively, including parts such as seats, armrests, panels, the cabin and tyres.
“The engineers assess each component for risk during normal operation with the intended zone for operation in mind – for example, the ignition of either gas or vapour for Zone 1 and 2 areas, or combustible dust for Zone 21 and 22 operations,” says Mr Noakes.
The conversion varies in complexity depending on both the truck and the specific needs of the user’s application. Sometimes original components will be replaced with an ATEX compliant explosion protected version. Other parts will be modified: for example the electrical interface between a part and the control system may be adapted. This is done in close collaboration with the original manufacturer to make sure the part and the truck still perform exactly as intended.
Pyroban then conducts tests to verify that the systems are functioning correctly, and in line with ATEX requirements. After the required modifications have been validated, the truck is then returned to the manufacturer where the CE mark can be applied, certifying the truck for use in the required hazardous zone in line with European legislation.
“The whole conversion process can take from 4 to 12 weeks, with up to 600 hours work,” says Mr Noakes. “However, as it only takes one small spark to cause a disastrous explosion, it’s important for businesses to understand why there are no short cuts when it comes to explosion protection.”
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