Using Flow Switches to Improve Safety at Emergency Showers and Eye Wash Stations

In chemical processing plants and industrial facilities, emergency safety showers and eye wash stations are critical protective measures. These systems are designed to immediately flush hazardous chemicals or gases from a worker’s body or eyes in the event of accidental exposure.

However, a common safety concern arises when an incident occurs while an employee is working alone. Although the individual may be able to activate the shower or eye wash station, they may not be physically capable of calling for assistance. Without a clear alert, valuable response time can be lost.

How Flow Detection Enhances Emergency Response

By integrating a flow switch into the water supply line of a safety shower or eye wash station, system activation can be automatically detected. When water flow increases, the flow switch is triggered and its internal reed contact changes state. This signal can be used to activate warning lights, audible alarms, or a building management system, immediately notifying supervisory or safety personnel that an emergency station is in use.

Application Challenge

Emergency showers and eye wash stations require high and unrestricted water flow to be effective. Any monitoring device installed in the line must therefore:

• Withstand relatively high flow rates

• Introduce minimal pressure drop

• Provide reliable and repeatable switching performance

• Operate consistently over long service periods

Selecting an unsuitable flow switch could compromise flushing performance or lead to unreliable signaling.

Recommended Solution: BST BW2 Series Flow Switch

The BST BW2 Series in-line flow switch is well suited for safety shower and eye wash station applications. Designed with a shuttle-based sensing mechanism, it allows water to pass through an optimized internal flow path, keeping line pressure loss extremely low — a key requirement for emergency flushing systems.

The BW2 Series is available with durable metal housings, making it suitable for demanding industrial environments where mechanical strength and corrosion resistance are required.

Performance Advantages in Safety Applications

With process connection sizes ranging from ¾" NPT to 2" NPT, the BW2 Series supports a wide range of installation requirements. It is capable of monitoring flow rates from approximately 0.5 GPM up to 50 GPM, covering both eye wash stations and full-body safety showers.

Once the preset flow threshold is reached, the switch delivers high repeatability, ensuring that every activation of the emergency station is accurately detected. This consistency is essential for dependable alarm signaling and rapid emergency response.

For facilities where operating conditions may vary, the BW2 Series is also available with multiple adjustable setpoint ranges, allowing users to fine-tune actuation levels to match system requirements.

Supporting a Safer Workplace

By combining robust mechanical design, low pressure loss, and dependable switching accuracy, the BST BW2 Series flow switch provides an effective monitoring solution for emergency showers and eye wash stations. Its use helps ensure that safety systems not only function as intended, but also trigger timely alerts—supporting faster response times and improved protection for personnel in hazardous environments.