n 2022, 107 workers lost their lives due to a workplace fire or explosion. Installing intrinsically safe and explosion-proof equipment prevents explosions by controlling the thermal and electrical energy that equipment can release into the surrounding environment. They ensure that under normal or abnormal conditions, the equipment will not produce sparks or heat that can ignite an explosive atmosphere.
However, understanding what these terms mean and the differences between intrinsically safe vs. explosion-proof equipment can be confusing. This article aims to clear up the confusion and help readers understand these concepts to help prevent explosive events.
Understanding The Terminology
Grasping the concepts of “Intrinsically Safe” and “Explosion Proof” is essential for selecting appropriate safety protocols and equipment in hazardous environments. Understanding explosion-proof and intrinsically safe will allow you to choose the proper safety measures that align with the specific risks and regulations of your specific workplace.
What Does ‘Intrinsically Safe’ Mean?
Intrinsic Safety (IS) refers to equipment incapable of producing enough energy (either electrical or thermal) to cause ignition or explosion. Electrical sparks or high heat can ignite flammable gases, vapors, or dust present in the environment. Intrinsically safe devices use non-ferrous metals and limit the amount of energy to prevent sparks or high heat, even under faulty conditions.
For example, most cell phones are not intrinsically safe. They can create an internal spark, or lithium batteries can randomly explode. That would be a disaster in oil refineries, coal mines, chemical plants, and grain elevators.
What Does ‘Explosion Proof’ Mean?
The National Electrical Code considers equipment “Explosion-proof” or “Ex-proof” if it is capable of withstanding a gas or vapor explosion. An example is an explosion-proof light that can resist flammable gases, chemicals and high heat without exploding or causing an explosion.
An explosion-proof motor can contain an internal explosion should gases leak into the housing. The case will contain the flame, and the ventilation ports vent the gases without letting sparks or flames reach the outside.
Despite their similar goal of preventing explosions, there are significant differences between intrinsically safe and explosion-proof equipment.
Critical Differences Between Intrinsically Safe vs. Explosion Proof Equipment
Below is a comparison of the key differences.
| Feature | Intrinsically Safe Equipment | Explosion Proof Equipment |
| Basic Principle | Designed to prevent an explosion by ensuring the equipment cannot release sufficient energy to ignite hazardous atmospheres. | Designed to contain a flash or explosion within its housing, preventing it from igniting the surrounding atmosphere. |
| Application | Suited for low-energy applications where power limitation can prevent ignition. | Suited for high-energy applications where it’s impractical to limit energy to non-ignition levels. |
| Cost of Installation | Generally lower, as it requires less robust containment measures. | Higher because of the heavy-duty materials needed to withstand and contain internal explosions. |
| Maintenance and Inspection | More accessible and less costly. The equipment can often be inspected and maintained without shutdown. | More complex and costly equipment often requires shutdown for safe maintenance and inspection. |
| Ideal Use Cases | Used in environments with constant exposure to hazardous gases or dust, where it can limit energy levels that can cause ignition. | Commonly used in environments where electrical equipment might generate sparks or high temperatures that could ignite an explosive atmosphere. |
Three factors should guide the choice between intrinsically safe and explosion-proof equipment. They are a comprehensive risk assessment, the nature of the explosive atmosphere, and the operational requirements of the equipment. Download the Hazardous Materials Spec Sheet to help you make the right choice for your facility’s overall safety.
Which is Better? Intrinsically Safe or Explosion-Proof
Choosing between intrinsically safe and explosion-proof equipment hinges on the specific needs and conditions of your operational environment. Here are key considerations:
- Hazardous Material Type: Hazards include combustible gases, vapors, dust and fibers.
- Zone Classification: There are three zones, 0, 1, and 2, with 0 being the most hazardous.
- Power Requirements: High-power equipment like motors require more robust shielding to be explosion-proof. Modified low-energy equipment like sensors and switches use barriers for intrinsically safe operations.
- Maintenance and Downtime: For operations requiring frequent maintenance with minimal downtime, intrinsically safe equipment offers easier access.
- Installation and Maintenance Costs: Consider both the initial and long-term costs associated with each option, including maintenance and potential modifications.
- Regulatory Compliance: Both equipment types must meet specific regulatory standards.
The right choice depends on a thorough risk assessment, evaluating hazards, operational requirements, and costs alongside regulatory compliance needs.
When to Use Explosion-Proof Equipment
When equipment requires a significant amount of power to operate, Explosion-proof equipment is the only choice. It is ideal for use in environments where flammable gases, vapors, or dust can cause an explosion or fire. This equipment is necessary for the oil and gas industry, chemical processing plants, paint shops, grain processing facilities, and other areas where combustible materials are present.
Hazardous locations are classified by the type, concentration, and duration of explosive or flammable compounds present. For example, Class I locations are where flammable gases or vapors are present, Class II is for combustible dust, and Class III is for fibers. Explosion-proof equipment is used in these hazardous areas to prevent ignition from electrical sources.
Application of Intrinsically Safe Equipment in Oil Refineries
Oil refineries and production platforms have a risk of fugitive emissions. Flammable vapors can leak into confined spaces, causing an explosion hazard. Intrinsically safe equipment is engineered to limit electrical and thermal energy to levels below those that can ignite hazardous atmospheres.
In oil refineries, intrinsically safe devices are used for monitoring and controlling processes, data logging, and communication, ensuring safety without sacrificing operational efficiency.
Use of Explosion Proof Equipment in Hazardous Areas
Beyond oil refineries, explosion-proof equipment has diverse applications in hazardous areas, including mining operations, pharmaceutical manufacturing, wastewater treatment plants, gas stations, and grain elevators, among others. The robust design of explosion-proof equipment ensures that any internal sparks do not ignite the external hazardous atmosphere.
The Importance of IP Ratings in Equipment Safety
Ingress Protection (IP) ratings are a standardized way to measure the effectiveness of electrical enclosures against intrusion from dirt, dust, and moisture. Understanding IP ratings allows you to select equipment that can withstand the specific demands of various environments, ensuring longevity, reliability, and safety.
The first digit in the rating indicates the level of ingress protection against solid objects. The second number indicates the protection against liquids. For example, IP 67 would mean the device has total protection from dust and protection from liquids for a brief exposure. Equipment rated IP 68 can withstand immersion in water, and IP 69 can withstand close-range, high-pressure, and high-temperature water sprays.
Drum and Tote Heaters for Hazardous Areas
In hazardous locations, maintaining the proper temperature of materials stored in drums and totes is crucial for safety and operational efficiency. Powerblanket makes Drum & tote heaters for hazardous areas, designed to work safely in C1D2 hazardous locations where explosive vapors may be present.
These heaters safely increase or maintain the temperature of a container’s contents, preventing materials like chemicals or oils from solidifying or preserving the required viscosity for processing. They comply with safety standards for use in explosive atmospheres, providing a reliable heating solution that mitigates risk.
Hazloc Heaters: A Safe Heating Solution for Hazardous Locations
Hazloc heaters provide safe, reliable heating to specific equipment or the general environment in hazardous locations. Their design prevents the ignition of flammable gases, vapors, or dust. Applications include heating enclosures, process heating, and freeze protection in oil and gas, chemical processing, and other industries. Hazloc heaters adhere to strict safety standards. Click to learn more about Hazloc heaters.
Choosing the Right Equipment for Hazardous Areas
When selecting equipment for hazardous areas, consider the three factors of cost, environmental conditions, and regulatory compliance. It’s essential to evaluate the specific hazards present, the level of protection required, and the operational requirements of the equipment. Use a qualified specialist trained to know the classifications of hazardous locations and the certification of equipment to make an informed choice.
Common FAQs About Equipment in Hazardous Locations
The following are common questions that equipment buyers have about installing equipment in hazardous locations.
What is considered intrinsically safe?
Intrinsically safe equipment is incapable of producing enough energy to cause an explosion in hazardous environments. Even under faulty conditions, the equipment will not ignite an explosive atmosphere due to its low energy levels.
Is intrinsically safe the same as ATEX?
No, intrinsically safe is a safety standard for equipment, while ATEX is a regulatory framework for equipment and workspaces in explosive environments, primarily in the European Union. ATEX covers a wide range of equipment, including intrinsically safe devices, but not all ATEX-certified equipment is intrinsically safe.
What is the difference between explosion-proof and flameproof?
People use the terms explosion-proof and flameproof interchangeably, but the difference lies in the testing and certification. “Explosion-proof” is more commonly used in North American standards and uses the NEC protocol for testing. Explosion-proof enclosures can withstand up to 4 times the gas explosion pressure.
“Flameproof” uses the European International Certification System (IEC) and can withstand up to 1.5 times the gas explosion pressure.
Both designations and designs aim to prevent explosions from occurring.
Choosing Between Intrinsically Safe and Explosion Proof Equipment
Intrinsically safe equipment operates with low energy and uses barriers to prevent an explosion. Explosion-proof equipment is a more robust design for high-energy equipment. It can contain an internal explosion, making it suitable for high-risk environments. Regardless of the type of equipment chosen, proper installation and maintenance ensure its effectiveness and safety.
Keep your equipment running safely and prevent damage with Powerblanket’s advanced hazardous location heating systems. Explore Hazardous Location Heaters
Keep your equipment running smoothly and prevent damage with Powerblanket's advanced hazardous location heating systems.
