How Intrinsically Safe Devices Work for Oil & Gas Projects?

The oil and gas industry operates in some of the most hazardous environments on earth. Drilling rigs, refineries, and construction sites are often filled with flammable gases, vapors, and combustible dusts. In such high-risk settings, even a tiny electrical spark can trigger a catastrophic fire or explosion. This makes safety not just a priority, but a non-negotiable requirement. One technology that plays a critical role in ensuring safety is intrinsically safe (IS) devices.

Intrinsically safe devices are purpose-built to function safely in hazardous locations. They are designed to operate at low energy levels, ensuring they cannot ignite flammable atmospheres. For oil and gas contractors, these devices are indispensable for monitoring, communication, and workforce tracking tasks that must continue uninterrupted even in the most dangerous zones.

This blog will take a deep dive into how intrinsically safe technology works, its importance in oil and gas construction projects, how it compares to explosion-proof systems, certification standards like Class I, Division 1 and ATEX, and why intrinsically safe GPS tracking is changing the way contractors operate. Finally, we’ll look at how Kwant.ai partners with certified leaders like Abeeway and Bartek to deliver safe, reliable solutions to the oil and gas sector.

What Makes a Device Intrinsically Safe?

At its core, intrinsic safety is about prevention. Instead of building devices strong enough to contain an explosion, IS devices are engineered to ensure an ignition event never happens in the first place.

An intrinsically safe device is designed to eliminate risks such as sparks, excessive heat, or short circuits that could ignite a hazardous atmosphere. This is achieved through a combination of careful engineering and built-in safety mechanisms.

Key Design Features of Intrinsically Safe Devices

1. Energy Limitation: The most critical aspect of intrinsic safety is restricting the amount of electrical energy in the device. Circuits are designed to operate at voltage and current levels too low to cause ignition, even in the presence of flammable gases.
2. Protective Barriers: Devices often include barriers that absorb or block excess energy. If a fault occurs, these barriers prevent the energy from reaching dangerous levels.
3. Encapsulation: Many IS devices enclose sensitive components in protective housings. This encapsulation isolates heat-producing parts and minimizes the chance of sparks escaping into the environment.
4. Fail-Safe Design: Intrinsically safe equipment is designed so that even if a component fails, it won’t create a hazardous condition.

With these safeguards in place, workers can safely use radios, sensors, GPS trackers, or communication systems in oil and gas fields without introducing ignition risks.

Explosion-Proof vs. Intrinsically Safe: What’s the Difference?

A common point of confusion in hazardous work environments is the difference between explosion-proof and intrinsically safe equipment. While both approaches aim to prevent accidents, the underlying strategies are very different.

• Explosion-Proof Devices: These are designed to contain an explosion. If combustible gases inside the device ignite, the casing is built strong enough to withstand the blast and prevent flames or hot gases from escaping into the surrounding environment. Think of it as a containment strategy.
• Intrinsically Safe Devices: Rather than containing an explosion, IS devices prevent ignition altogether. By limiting energy levels inside the device, they ensure conditions that could trigger combustion never arise.

For general contractors, intrinsically safe devices are often the preferred solution. They are typically lighter, more portable, and easier to handle in the field. Explosion-proof equipment, while effective, can be bulkier and more difficult to integrate into everyday workflows.

Certification Requirements for Intrinsically Safe Devices

Not all devices can be labeled intrinsically safe. To carry that designation, they must meet strict certification requirements set by recognized safety authorities. For oil and gas projects in the United States and abroad, certification is the foundation of compliance.

Class I, Division 1 Certification in the U.S.

In the U.S., the National Electrical Code (NEC) defines hazardous location classifications. Intrinsically safe devices are tested and certified by organizations like UL (Underwriters Laboratories) to ensure compliance.

• Class I: Refers to environments where flammable gases or vapors may be present.
• Division 1: Indicates that hazardous substances are present under normal operating conditions.

Therefore, Class I, Division 1 devices are certified safe for the most dangerous environments where explosive gases are expected as part of routine operations.

For oil and gas contractors, this certification is essential when selecting tools or monitoring equipment for drilling sites, refineries, or chemical processing plants.

ATEX Certification for International Markets

Outside of the U.S., intrinsically safe devices often require ATEX certification, which applies across Europe and in many international markets. ATEX uses a slightly different classification system:

• Zone 0: Explosive atmosphere is continuously present.
• Zone 1: Explosive atmosphere is likely to occur during normal operation.

Like NEC standards, ATEX certifications ensure that devices used in hazardous zones cannot ignite explosive gases or vapors. Contractors managing projects across borders must be mindful of both NEC and ATEX systems to ensure compliance with local regulations.

While the frameworks differ, the goal is the same: making sure electronic devices do not compromise safety in high-risk environments.

Why GPS Tracking Matters on Hazardous Sites

In oil and gas environments, everyday communication tools like personal cell phones are often banned because they pose ignition risks. This creates a unique challenge for workforce management, communication, and emergency response.

This is where intrinsically safe GPS devices fill a critical gap. By combining location tracking with intrinsic safety design, contractors gain new levels of visibility and control over hazardous worksites.

Benefits of Intrinsically Safe GPS Devices

1. Real-Time Location Tracking: Supervisors can monitor the exact position of workers and equipment, ensuring no one enters unauthorized or unsafe areas.
2. Improved Safety Response: In the event of an accident, explosion, or evacuation, real-time tracking helps direct emergency response teams and account for all personnel.
3. Compliance with Safety Protocols: With intrinsically safe certification, GPS devices can be used freely in hazardous areas without violating safety standards.

By bridging the communication gap created by cell phone restrictions, IS GPS devices become indispensable tools for oil and gas contractors.

Working with Certified Partners: How Kwant.ai Ensures Safety

Deploying intrinsically safe devices is not just about buying certified equipment. It’s about working with trusted partners who understand compliance, integration, and field deployment.

At Kwant.ai, we collaborate with industry leaders like Abeeway and Bartek, who specialize in intrinsically safe certification and device integration. Their expertise ensures that every sensor, tracker, or monitoring device we deploy meets both U.S. (NEC/UL) and international (ATEX) standards.

By leveraging these partnerships, Kwant.ai delivers:

• Reliable Tracking Systems: GPS-enabled, intrinsically safe devices designed for hazardous environments.
• Compliance Across Borders: Certified equipment for both U.S. and international projects.
• Seamless Integration: Devices that work within Kwant.ai’s smart construction platform for workforce monitoring, productivity tracking, and safety compliance.

This holistic approach gives contractors confidence that the technology on their job site enhances efficiency without compromising safety.

Final Thoughts

In oil and gas construction, safety and efficiency must go hand in hand. Intrinsically safe devices make it possible to use critical technologies like GPS tracking, communication tools, and sensors without increasing ignition risks. Compared to explosion-proof systems, they offer a lighter, more practical solution for field workers.

Compliance is non-negotiable, which is why certifications like Class I, Division 1 in the U.S. and ATEX in international markets are essential. For contractors working across borders, understanding these certifications ensures the right equipment is deployed in the right zones.

At Kwant.ai, we recognize the importance of safety-driven technology. By partnering with certified providers like Abeeway and Bartek, we bring intrinsically safe GPS devices and monitoring solutions directly to hazardous oil and gas environments. The result? Contractors gain real-time visibility, compliance assurance, and peace of mind knowing their teams are protected.

About Kwant.ai

Kwant.ai is a leading workforce management and safety platform designed for the construction and industrial sectors. Our solutions combine smart sensors, GPS tracking, and AI-driven insights to enhance safety, productivity, and compliance on job sites. By integrating intrinsically safe devices into our platform, we help contractors in oil and gas projects achieve operational excellence while keeping their workforce safe in the most hazardous environments.