Diesel and electric have seen (and are seeing) very significant developments in how they are used with forklifts but LPG just seems to keep on trucking. Is it really that simple? We spoke to leading LPG provider Calor to find out.
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Simon Duddy: Emissions regulations for forklift engines are getting much tighter. What impact has this had on LPG as a fuel option?
Andy Kellet: While some highly efficient diesel engines omit less CO2 than similar sized LPG powered engines, this is more to do with engine design and the relative efficiencies of engine models. Ultimately, LPG has the lowest overall CO2 emissions compared to both diesel and UK-generated electricity (www.bre.co.uk/sap). It is also a cleaner fuel in terms of nitrous oxides, sulphur oxides and particulates omissions. In tests carried out at the Millbrook Proving Ground in Bedfordshire, LPG trucks produced up to 98% fewer air particulates compared to diesel. If burnt efficiently, LPG does less harm to our environment than other fossil-based fuels and will continue to deliver these benefits – assuming that engine design for all types of forklift trucks continues to focus on improved efficiencies.
The emergence of dual fuel technology (diesel / LPG mix) in long-haul transport and investment in LNG powered HGVs suggests that LPG / gas could play a larger role in reducing both CO2 and particulate emissions in years to come.
SD: Many forklift manufacturers are producing increasingly robust, long-life, high capacity electric models. How much of a threat is this to LPG? How can you respond?
AK: Electric trucks are used almost exclusively indoors, and although LPG trucks fitted with a three-way catalytic converter can also be used indoors, as well as outdoors, there is an understandable aversion to using combustion engines deep inside a warehouse for extended periods. Unless there is a sudden swing towards using electric trucks outdoors, improvements in electric truck technology are unlikely to affect sales of LPG trucks.
However, it should not be forgotten that although electric trucks are very clean, at point of use, and are also increasingly efficient, they rely mainly on national grid electricity to charge their batteries. Much of the UK’s centrally generated electricity is produced using coal, and essentially this electricity, which charges most electric truck batteries, has been generated at below 40% efficiency (http://peprenewables.com/electricity-generation-efficiency-uk-/) and by a fossil fuel. These supply-line factors are not always taken into account when calculating an electric truck’s overall efficiency, CO2 output and general cleanliness at a UK level.
SD: Calor recently made a breakthrough in bio-LPG. Does this have implications for forklifts? If so, please explain.
AK: Calor’s bio-LPG can be used as a direct substitute for fossil-based LPG, thereby offering a relatively low carbon, renewable option for powering conventional LPG engines, boilers and the like. Large corporate organisations are certainly keen to reduce their carbon footprints in whatever way they can, so larger businesses with big forklift truck fleets might see a switch to bio-LPG as an attractive option.
SD: Do you offer a managed LPG cylinder service for forklift users?
AK: Calor’s local centres and dealers operate a ‘milk round’ service. This means they will visit weekly, or as many times as is required, and deliver whatever amount of gas the customer has ordered, while collecting any empty cylinders. The benefit of such a service is that the customer doesn’t need to store excess cylinders, which can tie-up space and potentially be a health and safety issue in line with the codes of practice. Storing excess cylinders can also adversely impact cash flow.
SD: How has the Calor Think Tank been received since its launch?
AK: Extremely well. It’s tried and tested technology that Calor fits free of charge wherever possible. The obvious benefit is that Calor takes on the responsibility of ensuring the customer has a continuous supply of LPG. Customers can forget about monitoring gas levels, and they don’t have to worry about manually placing an order for more LPG.
SD: Forklift users sometimes complain that indicators showing gas levels in a cylinder are inadequate. What is Calor doing to improve this?
AK: The indicators that measure cylinder contents are components that form part of the vehicle and are designed and specified by the forklift truck manufacturers; they are not something that Calor supplies on, or with its cylinders. This particular problem needs to be brought to the attention of the vehicle manufacturers who in turn can approach Calor for advice when attempting to improve their existing designs.
SD: LPG forklifts are safer to use indoors than diesel powered models, but they are not safe if the room is not well ventilated. Does the reputation of LPG as a cleaner fuel blind operators to its potential dangers? (Click here for an example of what can go wrong)
AK: Not at all. Any business that burns a fuel in a confined space should be aware of potential carbon monoxide poisoning and should be applying government regulations to ensure the health and safety of staff.
Despite LPG’s clean reputation, businesses should still observe standard safety practice through the implementation of properly designed buildings, ventilation systems and installation of certified monitoring equipment. Regular inspections of both buildings and the forklift trucks themselves are also essential and should be standard practice for every business. Dangerous levels of carbon monoxide only occur if the fuel is not being burnt efficiently so regular servicing and inspections are paramount.
LPG is clean if burnt efficiently. It is testament to the fuels’ cleanliness that an LPG forklift truck, fitted with a three-way catalytic converter, can legally operate inside a warehouse whereas diesel has the added problem of a high particulate count and confirmation from the World Health Organisation that diesel exhaust fumes are potentially carcinogenic.
SD: An LPG burning forklift in a warehouse can ‘leave an oily film’ on goods. What can be done about this?
AK: LPG when burnt efficiently gives off CO2, water vapour, and heat – plus a tiny amount of other trace elements. The oily film, comprising hydrocarbon particles, is largely due to inadequate ventilation, which of course can be resolved by ensuring that a building or space has suitable ventilation to match its purpose and volume. Again, any LPG truck that is used inside a warehouse should be fitted with a three-way catalytic converter.
Forklifts run mainly on gasoline, diesel, or electricity. But do forklifts run on propane? Yes, they do. Now, let’s answer some of the key questions surrounding forklift propane safety.
A propane-powered forklift operates in a similar fashion to other types of lifts. It differs from comparable lifts, however, in that it relies on propane for fuel.
In terms of forklift options, many companies prefer propane because it is clean, affordable, and emits no odor. Propane forklifts tend to have lower operating costs and offer greater reliability than other types of lifts. They can require less maintenance than various lift options, too.
Yet, as is the case with any gas product, propane is risky to use. Therefore, it needs to be handled with care at all times. Forklift propane safety must be taken incredibly seriously given the potential for dangerous accidents on the job.
If your business has a propane forklift or intend to use one, you need to plan accordingly. As part of your planning, you need to consider forklift propane tank safety.
OSHA requires training for drivers and maintenance personnel for everything from changing a propane tank on a forklift to proper storage and much more. Thus, forklift propane tank safety is a vital part of overall job safety.
If you’re not sure about your company’s current forklift propane tank safety training and certification, sign up with ForkliftCertification.com today! Our training modules cover all the crucial safety concepts for safe forklift operation, including propane-run lifts!
Many people ask us: are propane forklifts safe indoors? When operated correctly, these lifts are perfectly safe to use in both indoor and outdoor settings. Too often, though, forklift propane safety best practices are ignored. Fail to guard against the worst case scenario and you may have one of the following issues to contend with:
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Propane is highly flammable. If it builds up in a room, it can easily catch fire from cigarettes, heaters and other sources. That’s why propane tanks include a leak detection chemical with a bad odor. When you can smell the odor, safety measures should be taken to stop the leak.
Propane is designed to burn at a mixture of four parts propane to 96 parts oxygen. When it doesn’t burn completely, carbon monoxide is produced, which can be fatal if it is inhaled.
Propane is stored in tanks under high pressure. If the tank gets ruptured, it could explode.
Even if propane is not burned, buildup of the gas can be dangerous. In fact, inhaling the gas can cause hypoxia, a form of oxygen deprivation that can be fatal.
OSHA propane forklift regulations require operators to account for the aforementioned risks at every stage of forklift use, including:
Let’s examine these stages in detail.
Even a simple task like changing a forklift propane tank needs to be handled with care. The impact that changing propane tanks has on forklift safety should not be underestimated. Following these guidelines will keep you safe:
Some companies exchange empty propane tanks for full ones through a service provider. Others prefer to fill their own tanks. If you opt for this method, here’s how to do it safely.
First, OSHA propane forklift regulations recommend you don PPE. Then, locate the fill valve on the cylinder and remove the cap. Securely attach your fill line to the fill valve and open the bleed valve. You may hear a hissing sound when the valve is open. This is okay if air is being vented rather than propane.
Slowly open the valve on the fill line and check for leaks as the propane enters the tank. When the tank is full, the bleeder valve will emit a spray of white propane gas. Turn the fill valve all the way off. Then close the bleeder valve. Carefully remove the fill line from the tank. Replace the cap on the fill valve and make sure all valves are closed. The tank is now full and ready to use.
One final note about filling forklift propane tanks: never leave the tank unattended when filling. The tank must be shut off as soon as it is full.
The safest method of transporting forklift propane tanks is to have them delivered to your place of business by a propane exchange service. If you prefer to buy the cylinders and bring them back to your facility, follow these safety tips. Changing propane tank on forklift safety comes down to personal responsibility, so it’s important to proceed with caution.
To maximize forklift propane safety during transport, never carry more than four propane cylinders in a sedan or SUV at one time. No single cylinder should contain no more than 45 lbs. of propane. The combined weight of all the cylinders in an enclosed vehicle should not exceed 90 lbs. All cylinders should be secured in a vertical and upright position.
The safest way to secure a cylinder is with a propane tank holder and stabilizer. Sturdy crates can also be used. Securing a propane cylinder with rope, twine, or strap is okay as long as there is a good anchor point in the car.
If you have a pickup truck or trailer, you can safely transport up to 1,000 lbs. of propane in the back. Make sure the cylinders are stowed in a vertical and upright position. If you use 100-pound propane cylinders, have two people lift them into the truck or trailer to avoid dropping them.
Propane is a hazardous material, and should always be treated with respect. For proper forklift propane tank safety, here are some suggestions for things to do and NOT to do.
These are all important considerations relative to forklift propane tank safety.
Still have questions about forklift propane tank safety best practices? Allow us to address them below:
The length of time a forklift propane tank lasts varies based on the lift’s engine. Ultimately, the bigger the engine, the more propane the lift requires to run at peak levels.
Most forklifts can hold an 8-gal. (33-lb.) tank of propane. So, a lift with a 4-cylinder engine and an 8-gal. tank can typically run for up to eight hours before it needs to be refueled. Comparatively, if the lift has a 6-cylinder engine and an 8-gal. fuel capacity, its tank may last up to six hours.
A diesel forklift may include an 8-cylinder engine, too. In this instance, the lift may have a 10-gal. tank. If the lift’s tank is full, it can usually run for up to six hours.
A forklift propane tank with a capacity of 100 lbs. or less expires within 12 years of manufacture. Following the tank’s expiration date, it can typically be exchanged for a replacement. Or, the tank can be inspected for requalification for five years.
Forklift propane tanks are marked with a requalification date. They must be requalified every five to 10 years, according to the U.S. Department of Transportation (DOT). The exact requalification date depends on a tank’s cylinder type, condition, and prior requalification method.
DOT requires all forklift propane tanks must be visually inspected before they can be filled. If any defects are discovered, a tank must not be refilled. And, if a forklift propane tank exceeds its requalification date, the tank must not be refilled.
Many people wonder about carbon monoxide and are propane forklifts safe indoors. While it’s true that propane forklifts do emit carbon monoxide, the levels are typically very low. This can vary, of course, from machine to machine – an older lift will emit far more carbon monoxide than a brand new one. So long as you regularly maintain your forklift and replace dirty air filters frequently, the carbon monoxide emitted from the vehicle should not pose a health hazard.
Yes, propane explosions are not out of the realm of possibility. That’s why it’s so important to put a focus on education and on forklift propane tank safety in the workplace. Even the smallest of sparks can ignite a fireball if forklift fuel is not handled with care. Never smoke or use a lighter around a forklift powered by propane.
The answer to this question depends greatly on the size of your propane tank. Generally speaking, more forklift propane tanks weigh between 56 and 70 pounds when full. Be sure to check the exact figures on your specific lift before proceeding. It’s the best way to prioritize forklift propane safety and prevent accidents.
Whether you use propane, gas, diesel, or electric forklifts, forklift propane tank certification is essential. ForkliftCertification.com provides OSHA-approved online forklift propane safety certification at a price that’s affordable for any business, including yours!
Classes take about an hour to complete. Whether you need help with learning about changing a propane tank on a forklift to other critical safety concepts, we’ll help get you the certification necessary for 100% OSHA compliance! Our training modules can be taken anywhere you have an Internet connection. And they teach workers how to safely handle propane when operating their forklift. Keep your people and your trucks safe with our forklift propane tank safety certification today!
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