In places where people work with Everything from explosive gases to dust to chemicals, safety is a requirement—there are no two ways about it. With a plethora of choices available on the market, it often becomes difficult to choose between Intrinsically Safe and Explosion Proof equipment without sacrificing safety. Using the right equipment can make the difference between catastrophic accidents and safely carrying out operations. In this article, we will explore the two types of equipment to assist you in making an informed decision.
1) What are Intrinsically Safe and Explosion Proof?
Safety is essential when you are in dangerous working conditions. You have to ensure that your devices and equipment will not cause a spark, flame, or explosion. That is why two key safety features known as Intrinsically Safe (IS) and Explosion Proof (EP) exist. These are two different methods of safeguarding electrical apparatuses available in places where there is gas, dust, or vapour that can burn.
Now let’s simplify them so that you understand what each one stands for, how it works, and when to use it.
IS (Intrinsically Safe)
As the name clearly states, Intrinsically Safe, or IS, refers to a type of protection that limits the use of certain electrically powered devices to specific areas classified as hazardous. The concept is quite straightforward: Reduce the energy of the system, so if a system fails, the energy it possesses cannot initiate combustion or explosion.
➔ Core Principle
IS’s core idea is called “energy limitation.” To put it in simpler terms, it restricts the flow of electrical as well as thermal energy in a particular device. If a short circuit is likely to occur, or if a wire gets severed, the energy will not go beyond a level that is capable of initiation.
The IS system guarantees safety regardless of the presence of flammable gas, vapour, or dust. Fuel and power control is done at every level of the system using barriers, circuits, and designs to ensure heat or spark won’t ignite a fuel source.
Kenneth Lundgren shared in a Quora post that to be intrinsically safe, the equipment should not generate more than 1.2V, 0.1A, 20 microjoules, and 25mW.
➔ Typical Use Cases
- Gas Detectors in oil refineries: Supervise gas leakage where vapours can accumulate safely. Monitoring devices are lightweight and easy to service.
- Handheld Radios in chemical plants: They enable the workers to talk to each other as a team without the possibility of static igniting sparks. Critical in noisy environments.
- Sensors in pharmaceutical lines: Can comprise pressure or temperature sensors that use low-power signals that have a very low risk of contamination or fire hazards in powder rooms.
- Data Loggers in grain silos: Measure humidity and temperature in regions with extremely fine, flammable dust particles suspended in air. They are used in preventing dust explosions.
- Flow Meters in water treatment plants: Monitor flow in the presence of methane or other gases which can catch fire. Most suitable for use in underground pipes.
- Transmitters in mining tunnels: Obtain the data from the deepest tunnels where the signals are safe from being overwhelmed by strong, rough moisture and heavy conditions.
- Mobile Phones for hazardous areas: Smartphones for notification purposes in approved areas like gas plants or refineries. You remain protected while communicating.
- Alarm Devices in paint spray areas: Activate alerts in regions where vapors of solvent are likely to ignite.
Explosion Proof
The equipment is called “Explosion Proof” if it can operate safely during an explosion, even if it happens inside the equipment. It may sound like it stops an explosion, but not quite. It does not allow flame or spark to escape towards the very hazardous environment outside.
➔ Core Principle
The principle of explosion-proof protection is based on containment. The equipment is built with strong metallic covers that withstand internal explosions.
In case of any spark or fire within a device, the possible explosion is contained within the enclosure. The housing is so strong and sealed that the explosion cannot escape. Even the hot gases that are vented can no longer ignite anything outside because they have been cooled down by the enclosure.
This design provides you with a level of security that allows the use of even more powerful equipment in hazardous areas.
➔ Typical Use Cases
- Petrochemical Lighting Fixtures: Stubby lights resistant to pressure and harsh chemicals, supporting strong illumination in flammable areas.
- Industrial Motors: Offshore rig propulsion systems supporting heavy equipment in gas-laden environments. Their sealed enclosures endure harsh climates and internal sparking.
- Fans and Blowers: Air management devices in gas-saturated showers, circulating air while preventing dangerous motor spark emissions.
- Switch boxes in spray painting stations: Ensures safe operator control of tools/lights for operators. Blocks the efflux of vapours and traps internal sparking.
- Heaters: Heaters in vortical dust or vapour-rich zones support space and warming in cold environments.
2) Intrinsically Safe and Explosion Proof Key Differences
When making a decision between Intrinsically Safe (IS) and Explosion Proof equipment, it depends on what level of fire or explosion risk you wish to manage. Both protect you from dangerous areas – but in very different fashions. We will analyse the key differences one by one.
i) Safety Method
- Intrinsically Safe: Intrinsically Safe devices limit the energy in a system where ignition can occur. Even if the fail case occurs, energy is limited, so it doesn’t boost the ignition level.
- Explosion Proof: Normal or high energy is deemed acceptable, even on the inside. Any explosion that might occur is controlled. The focus is to ensure that the explosion does not spread
ii) Design and Build
- Intrinsically Safe: These devices are equipped with low-power circuits, and special barriers make gaining access easy. Components are lightweight and are usually small in size.
- Explosion Proof: It is permissible for Explosion Proof to be bulky and heavy, requiring strong material while encased in a heavy-duty enclosure.
iii) Maintenance and Installation
- Intrinsically Safe: Unlike other systems, Intrinsically Safe devices enable easy and secure repair and installation due to limits on energy. Non-Intrinsically Safe Systems require a complete shutdown for maintenance to take place, often termed the downtime.
- Explosion Proof: Requires precautionary seals. If it is opened, there might be a need to de-energise the system and make it safe before starting any repairs.
iv) Application Suitability
- Intrinsically Safe: Most suitable for portable sensors, handheld tools, transmitters, and similar devices that require low power and functions in hazardous locations.
- Explosion Proof: Best suited for high-powered equipment such as industrial motors, lights, junction boxes, and similar devices used in industrial areas.
v) Initial Costs And Long-Term Costs
- Intrinsically Safe: IS equipment has a lower initial cost because of the relative ease of maintenance, which increases the cost savings over time by decreasing downtime and repairs.
- Explosion Proof: Explosion-proof devices involve a higher initial cost. However, less frequent maintenance requirements make them more economical in long-term use.
| Feature | Intrinsically Safe | Explosion Proof |
| Protection Method | Prevents ignition by limiting energy | Contains an explosion within the enclosure |
| Equipment Size | Light, compact | Heavy, large due to strong housing |
| Power Usage | Low-power devices | Supports higher power |
| Maintenance | Easy, often safe to do live | Needs shutdown for safe maintenance |
| Best Use Case | Sensors, small electronics | Motors, lights, and large equipment |
3) Application Scenario Analysis
Deciding between Intrinsically Safe and Explosion Proof protection is subject to how and where you intend to utilise your equipment. Both have distinct advantages. We’ll analyse where it makes sense to pick either one of the two.
When to Choose Intrinsically Safe?
You can choose IS (Intrinsically Safe) equipment when:
- Low-power devices are used: IS is applicable for tools that work on low-powered equipment, such as sensors with transmitters or handheld radios.
- Need a compact lightweight: Since enclosures do not need to be thickened and covered with heavy industrial materials, IS equipment is less bulky.
- Areas with a consistent danger of gas or vapour leaks: For people in chemical plants, fuel storage areas, and even pharmaceutical labs, IS shields the individuals by making sure they do not get ignited or bombed in explosive situations.
- You prefer Peace of mind: Having satisfaction makes installation and maintenance, even with systems running, easier.
When safety is prioritised over power, IS offers a range of features when there is no requirement for high current or voltage, ensuring safety and simplicity.
When to Choose Explosion Proof?
Go with Explosion Proof protection when:
- Your equipment needs additional power: The IS restraint can’t safely provide enough power to most lights, controls, and pumps. You can safely operate powerful devices configured in explosion-proof housings.
- You’re working in rugged industrial settings: Refineries, oil rigs, paint booths, and grain silos use mixers and motors configured with Explosion Proof protections because they are built to last in tough conditions.
- You can handle heavier, larger devices: If size and weight are not a problem, these devices, configured with explosion-proof protection, come in strong, thick enclosures.
- You need protection from internal failures: Explosion-proof equipment protects the devices from ignition by the outside environment.
- You need durability and strength: These units withstand harsh use while protecting your team and space.
Overall, select Intrinsically Safe for small and low-power equipment used in sensitive regions. Select Explosion Proof if your tools require more power and enduring conditions. Well, choosing the right option ensures safety and convenience while working.
4) Common Misconceptions
When it comes to Intrinsically Safe devices and Explosion Proof equipment, there are a few common misconceptions. Understanding them will enhance your safety decision-making skills.
“Intrinsically safe devices don’t require any protective enclosure.”
This is a misunderstanding. As previously stated, devices labelled as Intrinsically Safe (IS) do not need to be contained in an explosion-proof heavy housing. However, they still need protective enclosures. Such enclosures allow the device to achieve an IP (Ingress Protection) rating, which certifies protection against dust, water and other elements.
In other words, although the housing does not need to be explosion-proof, it does need to protect the item.
“Explosion-proof devices will never explode.”
This is also incorrect. Equipment defined as explosion-proof is not built to prevent an explosion from occurring inside it, but the avoid the explosion from spreading outside. Means it protects the area outside of the device. However, it is still possible for internal components to get damaged during an explosion. Regular inspection and maintenance become very important in this case.
Knowing this information helps prevent you from injury by being overly dependent on the incorrect concepts of an explosion-proof device. Always verify what the equipment is intended for and how it was designed to be used.
5) Advantages of Hexlon Explosion-Proof Equipment
When it comes to ensuring safety, Hexlon is a safe choice. The company protects people, equipment, and facilities situated in hazardous areas with explosion-proof equipment. There are a lot of advantages of Hexlon explosion-proof equipment, let’s explore.
+ Safety Standards Certification: Devices manufactured by Hexlon guarantee international safety certifications such as ATEX, IECEx, CCC, and ISO9001. Each one of these products gives you an ease of mind since they are thoroughly checked and accepted for use in explosive surroundings.
+ Available Products: Hexlon provides flexible explosion-proof auxiliary items like LED lights, control boxes, ventilation units, pipe fittings, etc. Ranging from various devices makes them available for almost any purpose or requirement you may have.
+ Trustworthy and Durable Design: The equipment of Hexlon can endure extreme situations like high temperatures, exposure to moisture, or abrasive chemicals. These add-value devices enable you to maintain for lesser amounts while still using them in the long run.
+ Custom Solutions: Since every part of the globe has certain distinct features, Hexlon acknowledges this by offering OEM and ODM services. Hexlon’s creative team designs, under your guidance, tailor-made explosion-proof items that serve your exact needs.
+ Localised Assistance: Global Coverage Hexlon has been in operation for more than 17 years, expanding on a global scale, serving over 50 countries.
Wherever you are, our global footprint facilitates rapid support and service. Be satisfied, when investing in Hexlon, you choose quality, safety, and reliability. Our commitment to excellence in explosion protection has made us a trusted supplier. You can contact us by clicking here.
6) Conclusion
Selection between Intrinsically Safe and Explosion Proof equipment is solely based on your requirements. Low power, sensitive environments benefit greatly from safety-maintained equipment, thus ideal for Intrinsically Safe features. Harsh and hazardous regions, however, demand robust equipment, so use high-power: Explosion features. While each offers unique and distinct benefits, knowing them deeply for your safety and operational preferences is crucial. We help you make the choice at Hexlon explosion-proof products.
