If your business uses or supplies explosion proof lift trucks, do you know what your audit obligations are during their lifetime?
Tori Knight, Pyroban’s Service Manager, puts facts on some of the frequently asked questions that cross the Pyroban service desk.
Why do I need an audit for an ATEX forklift?
When a lift truck leaves the Pyroban facility, we can be confident that its safety systems are working as they should to help prevent ignition in a potentially explosive atmosphere – at that point in time. However, it’s important to check that it stays that way, particularly after heavy or improper use, impacts and planned and unplanned maintenance.
When you are dealing with potentially hazardous materials, the smallest spark or increase in temperature could become an ignition source, so it is imperative that all Pyroban equipment is maintained to the highest order. A safety audit ensures that the Ex integrity and safety of your ATEX material handling equipment is not compromised during its working lifetime.
It’s important for site compliance too.
Is an ATEX forklift audit required by law?
Yes. ATEX 1999/92/EC, which is a European Directive transposed into local laws, requires the end user to “demonstrate that work equipment is designed and maintained with due regard for safety.”
To achieve that, all equipment should be maintained in accordance with EN60079-17 (the international standard that tells you how to inspect and maintain such equipment) which states that an inspection routine should be introduced to ensure the continued safe operation of equipment.
How often should you inspect an explosion proof forklift?
In Europe, an ATEX (also known as flameproof or explosion proof) forklift should be audited at least once a year depending on the environment and duty cycle. Some applications may require more frequent inspections.
What is a Pyroban Ex-ASA?
A Pyroban Ex-ASA is Pyroban’s version of an Annual Safety Audit, which is a complete inspection of the safety critical components in our explosion protection conversions. The Ex-ASA ensures that the integrity and safety of material handling equipment is not compromised during its working lifetime, ensuring compliance (if the equipment passes).
All safety critical components of Pyroban’s explosion protection system are inspected and recorded, including Exd enclosures, cables and glands, shutdown devices, conductivity and fork cladding.
Where can an ATEX lift truck audit take place?
In the case of Pyroban inspections, the inspection can be carried out at any location across the world by one of Pyroban’s CompEx accredited engineers.
Is an Annual Audit for an ATEX truck the same as the UK’s Thorough Examination?
In the UK, a “Thorough Examination” is a mandatory inspection required by law to ensure that the mechanical parts of ANY lift truck are in safe working order. Other countries have similar requirements under different names.
Putting laws and names to one side, the facts remain that, for best practice, any forklift truck should be inspected at specific intervals throughout its lifetime to make sure it is still safe. But when it comes to ATEX trucks, the “Thorough Examination” is still important, but it does not highlight any ignition risk factors! In other words, a truck may be safe mechanically, but it may still present an ignition source and could cause an explosion.
Not to be confused with the lift truck Thorough Examination, Pyroban’s Ex Annual Safety Audit (Ex-ASA) is a complete inspection of the safety critical components in the explosion protection conversions by specialist Engineers.
What is covered in an annual safety audit of an ATEX truck?
During the safety inspection, such as Pyroban’s Ex-ASA, we inspect all that are relevant from the following:
- Increased safety enclosures. This will typically be motors. It is necessary that the protected device is checked such as thermal cut-off devices and general condition.
- Gas detection. Visual and functional inspection of component integrity and connections.
- Lamps and luminaires, which might also include dashboard indication lights, shall be checked for conditions that may lead to excessive temperatures.
- Restricted breathing enclosures with provision for routine checking shall be subjected to periodic pressure test measurement.
- General inspection. We check that equipment is appropriate for the application. That there is no damage or unauthorised modifications.
- Insulation resistance. The insulation resistance for intrinsically safe apparatus and associated cabling shall be measured and recorded.
- Inlet system (diesel). Check condition and fixings of the inlet manifold and inlet shutdown valve including function.
- Exhaust system (diesel). Check exhaust temperature switch for correct rating. Check condition of the spark arrestor according to the manufacturer’s instruction.
- Earthing and equipotential bonding. Earthing and potential equalisation bonding provisions in hazardous areas should be maintained in good condition.
- Cable glands. Suitability and integrity of the gland including tightness shall be confirmed.
- Type of cable. The type of cable shall be in accordance with the site requirements and relevant standards for the classification of the truck.
- Overload protection. It is necessary to check that the protective device is set at the correct value for the application.
- Flexible cables. Flexible cables, flexible conduit and their terminations are particularly prone to damage.
- Intrinsic safety. It is necessary to check the integrity of the components that make up the i.s. circuit such as labelling, connecting devices, cables and cable screening, point-to-point connections and many other aspects that make up intrinsic circuits.
- Cooling system (diesel). Hoses should be checked for suitability and integrity of connections and leaks. To ensure that the surface temperatures are maintained coolant levels should be maintained.
- Environmental conditions. Electrical equipment in a hazardous area can be adversely affected by environmental conditions in which it is used
Can a forklift service engineer maintain the forklift before, or after, an audit?
Yes, a forklift service engineer trained on the Pyroban system can maintain the forklift before, or after, an audit.
We estimate there are several thousand lift truck engineers in the UK alone trained to maintain Pyroban explosion protected lift trucks, with many more across Europe and the rest of the world. This means that service support is available from a wider network than ever before to conduct planned and unplanned maintenance.
But beware that an unqualified person making any change to an explosion protected truck could prove disastrous, so it’s important that only correctly ATEX trained engineers work on Pyroban converted lift trucks. We offer in person initial training and refresher engineer training online or in person.
And don’t forget that keeping up with preventative maintenance (with the correct parts) is an ideal way to avoid danger and make sure systems function correctly. And ensuring that equipment is regularly audited for safety provides extra reassurance and should be a priority for any operation with trucks operating in ATEX Zone 1, 2, 21 or 22 areas.
Can Forklift Service Engineers conduct Annual Safety Audits?
No, forklift truck dealer engineers trained to maintain Pyroban equipment are NOT ABLE to carry out an Ex-Annual Safety Audit (Ex-ASA) which is clearly stated on the official Pyroban training courses. The audit can only be carried out by Pyroban specialists which supports compliance with ATEX 1999/92/EC.
Does Pyroban issue a Certificate if the explosion proof forklift passes the audit?
If no irregularities are found, the truck will be declared safe for use and a certificate will be issued to support your Explosion Protection Document (EPD).
We recommend that an Ex-ASA is carried out yearly (or sooner if advised) to ensure your equipment is fully protected and working correctly.
What happens if the ATEX forklift fails an audit?
Irregularities need to be repaired immediately by either the Pyroban service engineer or it can be done by a Pyroban trained engineer from the service provider. Once correctly repaired a truck can be re-inspected and a certificate issued.
We previously reported that up to 20% of explosion protected lift trucks in operation may not pass an Annual Safety Audit.
What’s the most common failure when auditing an explosion proof forklift?
Among the most common reasons for failing a Pyroban safety audit are issues with fork cladding and earth straps, worn tyres, poorly maintained batteries and even seat cushion wear. Badly maintained or worn inlet shut-down valves are also common reasons for an Ex-ASA failure on diesel forklifts, none of which would be declared on a standard “Thorough Examination” or inspection.
On occasion, Pyroban’s audits have found serious problems where the motors have been repaired or altered by unqualified engineers with no experience of explosion protection. This compromises the integrity of the whole safety system and could render elements of it completely useless putting employees and the supply chain at risk of explosion.
I’m about to buy a pre-owned explosion proof truck, can you help audit the equipment?
An Ex-ASA can also prove beneficial when purchasing a used piece of equipment or following a full refurbishment, or significant change, to give peace of mind and legal compliance.
I have a forklift converted by another company, can Pyroban audit it?
Pyroban can audit forklifts converted by any manufacturer and can provide a full report as to whether it is safe for use within a potentially explosive atmosphere.
If you’d like to book an Ex-ASA, click here or contact the friendly Pyroban team on +44 (0) 1273 456825 or info@pyroban.com.