What does Intrinsically Safe Mean?

Intrinsic Safety (IS) is a protection technique for safe operation of electrical equipment in hazardous areas by limiting the energy, electrical and thermal, available for ignition.

It refers to equipment and wiring that are designed to operate safely in hazardous environments where flammable gases, vapors, or dusts are present. The idea behind intrinsic safety is preventing ignition by ensuring that the electrical energy in a circuit is kept below the level that could cause a spark or excessive heat. To prevent explosion, you need intrinsically safe equipment in hazardous areas.

In normal use, electrical equipment often creates tiny electric arcs (internal sparks) in switches, motor brushes, connectors, and in other places. Compact electrical equipment generates heat as well, which under some circumstances can become an ignition source.

There are multiple ways to make equipment safe for use in hazardous areas. Intrinsic safety (denoted by “i” in the ATEX and IECEx (Explosion Classifications) is one of several available protection methods for electrical equipment.

Key points about Intrinsically safe equipment:

Prevents explosions: limits electrical and thermal energy to avoid igniting hazardous substances.
Used in hazardous areas: common in oil & gas, chemical plants, refineries, mining, and pharmaceuticals.
Regulated by standards: must comply with certifications like ATEX (Europe), IECEx (International), and NEC 500/505 (USA).
Requires special components: uses low-power designs, barriers, and isolators to control electrical energy.

Intrinsically safe equipment

For handheld electronics, intrinsic safety is the only realistic method that allows a functional device to be explosion-protected. A device which is termed “intrinsically safe” has been designed to be incapable of producing heat or spark sufficient to ignite an explosive atmosphere, even if the device has experienced deterioration or has been damaged.

The concept of intrinsic safety becomes relevant because of the classification of hazardous areas. For example:

In a Zone 0 area, where explosive gases are always present, only the safest equipment can be used. Intrinsically safe equipment is ideal because it:

Prevents ignition at the source.
Doesn’t rely on containment (unlike flameproof enclosures).
Allows for easier maintenance and calibration without shutting down operations.

Hazardous Area	Risk Level	Protection Method	Why Intrinsic Safety?
Zone 0	Highest (continuous)	IS, Encapsulation	IS prevents ignition at very low energy
Zone 1	High (likely presence)	Flameproof, Increased Safety, IS	IS is safer and allows live maintenance
Zone 2	Lower (occasional)	General Purpose or IS	IS still preferred for ease and flexibility

For instance, during marine transfer operations when flammable substances are moved between tanker ships or barges and marine terminals—continuous two-way radio communication is essential. This ensures the transfer can be halted immediately in the event of an unexpected incident, such as a spill. To meet safety regulations, the United States Coast Guard mandates that these radios be certified as intrinsically safe.

Similarly, mobile phones used in hazardous areas like refineries must also adhere to strict safety standards. Devices classified as intrinsically safe or flameproof must be specially designed, particularly their batteries to comply with certifications such as UL, the ATEX Directive, or IECEx, which validate their safe use in explosive atmospheres.

Intrinsically safe solutions by BARTEC

BARTEC offers a range of products, including smartphones , tablets, handheld computers and scanners, Real Time Location System (RTLS) and wireless products and also enclosures, junction boxes, control stations and Human Machine Interfaces (HMIs) that are certified for use in hazardous areas and are also intrinsically safe:

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How to choose intrinsically safe products?

Choosing the right intrinsically safe (IS) products is a critical part of ensuring safety, regulatory compliance, and operational efficiency in hazardous environments. Here’s a guide to help you choose the right intrinsically safe products.

1. Understand your hazardous area classification

Before choosing any device, you need to know:

Zone classification: Zone 0/20, 1/21, or 2/22 (or Class I/II Division 1/2 in North America)
Type of hazard: Gas, vapor, mist, or dust
Temperature class: How hot a device can get before it might ignite the atmosphere (e.g., T1 to T6). Every IS product must be rated for a temperature class (T-rating): T1 to T6, with T6 being the coolest (≤ 85°C) — important for sensitive gases. Match the T-rating to the auto-ignition temperature of substances in your area.

A product suitable for Zone 2/22may not be safe for Zone 0/20. Similarly, some devices are certified only for gas groups like IIA, IIB, or IIC or dust groups IIIA, IIIB or IIIC.

2. Define your application needs

Data collection (e.g. mobile device, barcode scanner).
Communication (e.g. smartphone, Wi-Fi access point).
Process control (e.g. HMI Polaris).
Monitoring and diagnostics (e.g. temperature sensor).

3. Look for certifications based on your region and industry:

ATEX (EU).
IECEx (Global).
NEC (North America).
INMETRO (Brazil) etc.

Each product should include:

Explosion-protection marking (e.g., Ex ia IIC T4 Ga).

Clear zone and temperature class rating.
Certificate of Conformity from a Certification Body (IECEx), or a EU-Type Examination Certificate from a Notified Body + EU-Declaration of Conformity from the manufacturer(ATEX), or other certificates based on the relevant certification scheme of the point of installation (US, Canada, Brazil, etc).

4. Choose the right protection concept

For electrical devices, the main types of explosion-protection are:

Intrinsic safety (Ex i) – limits energy so ignition is impossible.
Flameproof (Ex d) – contains explosion inside a robust enclosure.
Increased safety (Ex e) – prevents sparks and limits surface temperature.

Choose intrinsic safety (Ex i) especially when:

You’re working in Zone 0/20 or 1/21.
You want to perform maintenance or calibration without shutting down the system.
You prioritize portability and low power consumption.

5. Evaluate usability and integration

Does it support your software and network infrastructure?
Is it rugged enough for your environment (e.g., IP rating, temperature range)?
Does it offer real-time data capture, wireless communication, or cloud sync?

6. Plan for maintenance and support and future scalability

Choose products or solutions that can easily be scaled and compatible with new standards like 5G, IoT and data integration and can be easily maintained and supported by your personnel.

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What is the difference between intrinsically safe (IS) and flameproof products?

The difference between flameproof and intrinsically safe

Intrinsically safe is the prevention of ignition by design – the circuit simply cannot generate enough energy to spark or heat up to dangerous levels.

Flameproof encloses the equipment in a strong, robust housing that can withstand an internal explosion and prevent the flame or hot gases from escaping and igniting the surrounding atmosphere. It’s made to contain any explosion that happens inside the device.

Intrinsically safe technology plays a vital role in protecting lives and assets in hazardous areas, especially in industries like oil and gas, mining, and chemical processing. By limiting the energy available for ignition, intrinsically safe equipment ensures that operations can continue safely even in the presence of flammable gases or dust. As safety standards evolve and technology advances, investing in intrinsically safe solutions is not only a regulatory requirement but a smart, forward-thinking decision for any company operating in explosive atmospheres.

Sources

ATEX

IECEx

INMETRO