This guide provides a comprehensive overview of intrinsically safe measurement instrumentation, crucial for ensuring safety in hazardous environments. It explains the core principles of intrinsic safety, focusing on limiting electrical and thermal energy to prevent ignition in potentially explosive atmospheres.
The guide details the key components of an intrinsically safe system, including sensors, barriers, and cabling, and how they interact to safeguard personnel and equipment. It also explores the importance of certification, regulatory compliance, and proper installation and maintenance practices. Finally, the guide illustrates the diverse applications of intrinsically safe measurement instrumentation across various industries, highlighting its significance in protecting against the risks of explosions and fires.
- Intrinsic safety prevents explosions by limiting energy in hazardous areas, unlike containment methods.
- Systems comprise a hazardous-area sensor, safe-area barrier, and connecting cables. The barrier restricts energy flow.
- Sensors must be certified for the specific hazardous area classification to prevent ignition.
- Compliance with regulations is mandatory; proper installation and maintenance are crucial.
- Intrinsically safe instrumentation is used across diverse industries with explosive atmospheres.
Browse intrinsically safe measurement instrumentation by product type for use in hazardous areas with an intrinsic safety barrier.
Intrinsically Safe Pressure Data Loggers - Select from our range of battery powered, intrinsically safe pressure data loggers for hazardous zones. Features include configurable logging, event triggers, and data analysis.
Intrinsically Safe Liquid Level Sensors - Explore intrinsically safe liquid level sensors designed for hazardous areas (ATEX/IECEx). Options for external tank mounting & submersible use with IP68 seals.
Intrinsically Safe Pressure Transmitters - Intrinsically safe pressure transmitters which are certified for use with zener barriers or galvanic isolators, as part of an hazardous area installation.
DM01 Multi-Range High Accuracy Pressure Gauge
LMP307 Submersible Level Transmitter
DMK 331 Ceramic Diaphragm Industrial Pressure Transmitter
DMP331 Precision Pressure Transmitter
LEO Record (Ei) Pressure Data Logger
LEO Record (Ei) Capo Low Pressure Logger
DS200P Sanitary Low Range Pressure Gauge, Switch and Sensor
DPT200 Pressurised Tank Level Differential Pressure Transmitter
DMP 335 All Welded Stainless Steel Diaphragm Pressure Sensor
LMK458 Marine Approved Hydrostatic Level Transmitter
DMP457 Marine Approved Pressure Transmitter
DM01-500-HD High Range Digital Pressure Gauge
- -10…30 kPa g compound range inert gas pressure transmitter for ship IG system - An intrinsically safe, marine approved compound range pressure transmitter for ship cargo tank IG system use to measure pressure of inert gas over a range of -10 to 30 kPa g from the G1/2 male process connection, and sending the corresponding 4-20mA signal through the DIN plug electrical connection.
Biogas ATEX 4-20mA pressure transmitter for low pressure anaerobic digestion monitoring - Enhance process safety in methane production with this intrinsically safe pressure transmitter featuring 316L stainless steel and FKM seals for superior chemical compatibility in low-pressure biogas environments.- Fuel and freshwater level sensor with adjustable hydrostatic range for small vessel tanks - A marine-approved hydrostatic sensor designed for fuel and freshwater tanks up to 1.6 meters, featuring a high-purity ceramic diaphragm and field-adjustable HART communication for precise shipboard level monitoring.
Wastewater holding tank submersible hydrostatic level monitoring pressure transmitter - Monitor liquid levels in wastewater holding tanks with a flush diaphragm sensor designed to prevent clogging from grease and particulate matter in hazardous zones.- Bi-directional room pressure sensing in explosive gas and dust atmospheres - Optimize facility safety in chemical and pharmaceutical plants by maintaining accurate pressure gradients between labs and hazardous production areas.
- Monitoring low pressure waste gas in zone 0 hazardous areas - Pressure datalogger for accurately measuring and logging very low, bidirectional waste gas pressures within ATEX Zone 0 and Gas Group IIC hazardous locations. Ideal for portable field calibration and process monitoring.
Ammonium nitrate level sensing in agitated tanks at high temperature - Measure the liquid level of hot, concentrated ammonium nitrate using a flush ceramic sensor designed to withstand agitation and prevent crystallization issues.- Data logger for ATEX zone 1 area to measure up to 5000 psi - I am looking for a data logger that is ATEX approved for zone 1, battery operated, have ample memory, sample every second, and pressure range to 5kpsi
- Anaerobic digestion methane gas 2bar pressure transmitter - ATEX pressure transmitter to measure the pressure of methane gas line in an anaerobic digestion plant.
- Low range ATEX approved 100 Pascal range DP transmitter - The DPT200 is a robust ATEX approved differential pressure transmitter which has a very low range of 100Pa.
High temperature de-ionised water bath 300mm ATEX level sensor - Level sensor for high temperature liquids up to 125°C, ATEX approved intrinsically safe 4-20mA output and a low range to measure 0 to 300 millimetres.
Bulk powders silo fluidisation blower aeration ATEX approved HART pressure transmitter - We are looking for a HART compatible ATEX dust approved pressure transmitter for measuring the outlet pressure on blowers used for silo fluidisation when discharging bulk powder.
The Essence of Intrinsic Safety
Intrinsically safe measurement instrumentation plays a crucial role in ensuring safety within hazardous environments. These environments, often found in industries like chemical processing, oil and gas, and mining, may contain potentially explosive atmospheres. The core principle of intrinsic safety is to limit the electrical and thermal energy within these hazardous areas, preventing ignition of flammable gases, vapors, or dust. This is achieved by carefully designing and certifying equipment to ensure that even under fault conditions, the energy released is insufficient to cause ignition. This approach differs from other protection methods, such as explosion-proof enclosures, by preventing the explosion from occurring in the first place.
The Role of Barriers and Sensors
A typical intrinsically safe measurement system consists of a sensor located within the hazardous area, connected via cables to a barrier device situated in a safe area. The barrier, which can be either a Zener diode barrier or a galvanic isolator, acts as a safeguard. It restricts the amount of electrical energy that can travel into the hazardous area, effectively limiting voltage and current to intrinsically safe levels. Zener barriers divert excess energy to ground, while galvanic isolators use transformers to provide isolation and limit energy transfer. The selection of the appropriate barrier type depends on the specific application requirements, including the type of sensor, the signal characteristics, and the safety requirements of the hazardous area.
Sensor Design and Certification
The sensor itself is a critical component. It must be designed and certified to operate safely within the designated hazardous zone. Certification bodies, accredited by relevant government agencies, rigorously test and assess the sensor’s design and performance to ensure compliance with stringent safety standards. This certification process involves evaluating the sensor’s electrical parameters, its operating temperature, and its construction to ensure that it cannot become a source of ignition. The sensor’s certification details, including its permissible energy levels and installation requirements, are essential for proper system design and installation.
Sensors must be certified for the specific hazardous area classification to prevent ignition. This certification process involves rigorous testing and assessment by independent bodies to ensure compliance with stringent safety standards. Manufacturers seeking to market their intrinsically safe products globally often obtain certifications from multiple national approval bodies to facilitate acceptance in different regions. Some of the most commonly sought-after certifications include:
- ATEX (Europe): Mandated by the European Union, ATEX certification covers equipment used in potentially explosive atmospheres.
- IECEx (International): A globally accepted scheme for certification of equipment for explosive atmospheres, providing a basis for mutual recognition between participating countries.
- UL (North America): Underwriters Laboratories (UL) offers certification and safety testing services for a wide range of products, including those used in hazardous locations.
- FM (North America): FM Approvals, part of FM Global, provides testing and certification services for industrial and commercial products, with a focus on loss prevention.
- CSA (North America): The Canadian Standards Association (CSA) offers certification and testing services for various products, including those used in hazardous environments.
Featured intrinsically safe products
- DM01 Multi-Range High Accuracy Pressure Gauge - High precision digital pressure gauge with 0.1% full scale accuracy, exchangeable pressure range modules from 100 mbar (1.5 psi) up to 400 bar (6000 psi).
- LMP307 Submersible Level Transmitter - Submersible level transmitter for measuring liquid level with a 4-20mA current loop or a 0-10V voltage output plus optional ATEX approval for intrinsically safe use in hazardous areas in ranges from 1mH2O up to 250mH2O. The LMP307 is suitable for use on potable water with no leaching, and can be supplied with a drinking water certificate according to DVGW and KTW.
Cabling, Grounding, and Bonding Considerations
The cables connecting the sensor to the barrier are also carefully considered. They must be selected to minimize the risk of energy storage or transfer, and their installation must adhere to specific guidelines to prevent damage or degradation that could compromise safety. Furthermore, the entire system, including the sensor, barrier, and cabling, must be properly grounded and bonded to prevent the buildup of static electricity, which could also serve as an ignition source.
Regulatory Landscape and Compliance
Intrinsic safety standards and regulations vary by region. It’s crucial to consult the local regulations and guidelines to ensure that the measurement instrumentation is compliant. These regulations often specify the types of hazardous areas, the required protection levels, and the certification procedures for equipment used in those areas. Choosing certified equipment from reputable manufacturers is essential for ensuring compliance and maintaining safety. Regular inspection and maintenance of intrinsically safe systems are also critical to verify their continued integrity and proper operation. This includes checking cable connections, verifying barrier performance, and ensuring that the sensor remains within its certified parameters.
Diverse Applications of Intrinsic Safety
Use cases for intrinsically safe measurement instrumentation are diverse. In chemical plants, these systems are used to monitor process variables such as temperature, pressure, and flow in areas where flammable or explosive materials are present. In oil and gas exploration and production, intrinsically safe sensors and transmitters are essential for monitoring well conditions and pipeline integrity in hazardous offshore or onshore environments Mining operations rely on intrinsically safe instrumentation to detect gas levels and monitor equipment performance in underground areas where explosive atmospheres can accumulate.
Featured intrinsically safe products
- -10…30 kPa g compound range inert gas pressure transmitter for ship IG system - An intrinsically safe, marine approved compound range pressure transmitter for ship cargo tank IG system use to measure pressure of inert gas over a range of -10 to 30 kPa g from the G1/2 male process connection, and sending the corresponding 4-20mA signal through the DIN plug electrical connection.
- DS200P Sanitary Low Range Pressure Gauge, Switch and Sensor - All in one electronic switch, gauge and sensor designed specifically for use in the food, drink and biomedical industry for measuring process pressures.
Questions & Answers
USA version of ATEX II 2 G
What is ATEX II 2 G classification and what is the USA equivalent?
This refers to the ATEX Ex coding which is the European regulatory directive for using equipment in hazardous areas.
- II = Non-Mining
- 2 = Non-Mining: High Protection – Equipment must be safe during regular functioning and likely failures, required for Gas zone 1 and/or Dust zone 21
- G = Explosive Gas environment
Hazard area equipment is approved by FM Approvals (Factory Mutual) in the USA, and this chart shows a comparison between FM (top) and ATEX (bottom) markings, according to this chart the equivalent FM marking for ATEX II 2 G is:
- 2 = Division 1, Zone 1
- G = Class 1 (Gases, Vapours or Liquids)
Related Help Guides
Related Application Questions and Answers
- Data logger for ATEX zone 1 area to measure up to 5000 psi
- Anaerobic digestion methane gas 2bar pressure transmitter
- Low range ATEX approved 100 Pascal range DP transmitter
- High temperature de-ionised water bath 300mm ATEX level sensor
- Engine test cell fuel filter 2.5 bar differential pressure sensor with ATEX approval
- Measuring level of stoddard solvent in a sealed tank
- 5 to 20 psi absolute ambient 4 to 20 ma pressure transmitter
- Powder filter blockage monitoring pressure transmitter
- Glycol/Water mixture peak pressure gauge to measure up to 15 bar
- Fleet management system submersible 3000mm height petrol tank level ATEX rated pressure sensor
Contact us about this Intrinsic Safety page to request more information, or to discuss your application requirements.