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Case Study: British Solar Renewables – Operational Safety On Solar Farms
The requirement: Protecting pedestrians and their fleet
At British Solar Renewables (BSR), a leader in developing utility-scale solar farms, safety must be flexible. On sites like their 149-acre project at Coldharbour Farm near Chulmleigh, their core requirement was a safety system that could achieve two things at once: eliminate a critical collision risk for pedestrian workers operating near machinery, while being portable enough to seamlessly transfer between new project sites.
The challenge: Collision risk on site
British Solar Renewables recognised a significant collision risk during installation, as teams fitting solar panels worked near skid steers used for carrying pilings. This situation was dangerous because:
- Poor driver visibility (especially at the rear of the vehicle) was common.
- Vehicles could manoeuvre quickly.
- Pedestrian workers often needed to work or walk right next to the moving machinery.
The goal was clear: significantly reduce the risk of potential accidents and improve on-site safety across all BSR sites.
The Solution: ZoneSafe Mobile V2P Alert
British Solar Renewables required a unique solution. Since they primarily hire their machinery and return it after each project, a permanently installed system was impractical. They required a system that could be unplugged, packed up, and immediately redeployed on the next site’s hired equipment.
ZoneSafe delivered the customised Vehicle-to-Person (V2P) Alert Mobile Kit, built specifically for portability and rapid deployment.
The ZoneSafe V2P system provides a crucial two-way warning using RFID technology. This dual warning mechanism significantly improves situational awareness and reduces the risk of contact.
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Detection Zone: An antenna fitted to the vehicle creates an adjustable 360-degree detection zone (or bubble), reaching up to ten metres.
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Two-Way Feedback: The control unit alerts the driver with audible and visual warnings, while a tag alerts the worker by vibrating.
Implementation: Portability & scalability
Mobile kit design and deployment
To meet the portability requirement, ZoneSafe engineers integrated magnetic fittings for the antenna and the in-cab control unit, allowing for easy, tool-free attachment and removal onto any vehicle.
- The complete system, designated as a demo/mobile kit, is transported safely in a protective case with a specially designed foam interior.
- To ensure the system is correctly operational and plugged into a 12V socket, a flashing purple beacon was fitted next to the main antenna unit. This beacon indicates the system is actively running and receiving power.
Tag management
For effective tag management across multiple sites, BSR purchased additional gear:
- Enough VibraTags and protective cases were supplied to cover two sites.
- Two large ZoneSafe Tag boards and two ZoneSafe 5-bay chargers were implemented.
- Temporary installation of these tag boards in an on-site portacabin, supported by new PPE procedures, ensures effective tag management.
- The rechargeable VibraTags offer low through-life costs, typically lasting up to three months between charges, with a long-life expectancy of eight to nine years.
Outcome and future impact
The initial rollout began across two sites, establishing the framework for future scalability. The project rollout was executed in two phases, successfully deploying a scalable safety system across BSR’s operations.
- Phase 1: The ZoneSafe Mobile Installation Day” served as the successful launch of the solution, immediately enabling BSR to carry out future installations confidently across their national sites using the full mobile kit.
- Phase 2: The subsequent fitting and integration of the flashing purple beacons to the mobile antenna units provided a crucial visual confirmation, ensuring site managers and drivers can verify the system is correctly operational and receiving power as soon as it is plugged into a 12V socket.
With the mobile V2P system providing the flexible, powerful, and easily managed solution, British Solar Renewables can confidently support their expanding national operations and is already considering expanding the systems to additional sites.
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