Deploying intrinsically safe devices without proper inspection, verification, and documentation can lead to non-compliance, system failure, or even life-threatening emergencies in hazardous environments. Whether you’re outfitting teams for Zone 1 refinery work, Class I Division 1 tank inspections, or Zone 2 construction monitoring, readiness matters.
This guide delivers a complete, intrinsically safe checklist designed to help safety managers, supervisors, and technicians verify IS gear across all critical categories—communications, lighting, mobile computing, and visual inspection tools.
Why You Need a Pre-Deployment Intrinsically Safe Checklist
A pre-deployment checklist is not just a formality—it’s a safety protocol. These checks confirm that all gear is certified, functional, and suitable for explosive atmospheres. According to OSHA and ATEX guidelines, improperly labeled or damaged devices can void certification, making their use illegal and dangerous.
Hazardous environments demand full confidence in the gear used. This checklist ensures you never deploy under-tested or incompatible equipment into an ATEX or IECEx-rated zone.
What Categories of Intrinsically Safe Devices Should Be Included?
When preparing your gear, include every tool that emits energy, light, heat, or radio frequency—regardless of size or primary function. Here’s a breakdown of common IS gear to review:
Portable Communications (Radios & Smartphones)
Lighting Devices (Flashlights & Headlamps)
INTRINSICALLY SAFE USB IS DUAL-LIGHT HEADLAMP S553G
Vizion I eLED Headlamps (Helmet Mount)
Cameras & Inspection Tools
Extronics iCAM502
Mobile Tablets & Smart Devices
Power & Charging Accessories
CorDEX Rechargeable Battery Twin Pack
Ecom Tab-Ex SB T01 Safety Box
What Should Be on Your Deployment IS-Device Checklist?
Use the following checklist to prepare all IS-certified devices:
Documentation and Certification
Confirm ATEX, IECEx, UL, or CSA certification labels
Verify expiration dates or serial number traceability
Ensure Zone/Class compatibility with site requirements
Visual Inspection
Look for cracks, corrosion, or missing seals
Verify screens, ports, and buttons are undamaged
Confirm IP ratings (e.g., IP65, IP68) are met
Battery Status and Spare Power
Fully charge devices using approved chargers
Carry certified spare batteries
Inspect terminals for corrosion or looseness
Functionality Testing
Power on/off cycles
Push-to-talk radio transmission and range tests
Flashlight brightness and switch response
Camera shutter and image quality check
Software and Firmware
Ensure the OS is updated to latest supported version
Run diagnostic apps or manufacturer pre-deployment tools
Confirm calibration for sensors or inspection cameras
Accessories and Add-Ons
Install ATEX-approved holsters, cases, straps
Verify barcode scanners or mounts are IS-rated
Ensure accessories don’t obstruct safety labels
Labeling and Packing
Re-check asset ID, owner labels, deployment date
Use protective foam or antistatic bags during transport
Store in shock-proof, waterproof transit cases
How Do You Perform Functional Tests on IS Devices?
Functional tests should simulate field conditions as closely as possible. For radios and smartphones, test transmission clarity and Bluetooth/WiFi connections. Flashlights and headlamps should be tested in low-light conditions for beam distance and reliability.
For inspection cameras, capture sample footage to confirm zoom, focus, and recording functionality. Make sure all buttons, touchscreens, and interfaces are responsive under gloved use.
What Standards and Certifications Should Be Verified?
Before deployment, verify that every device meets relevant standards:
| Standard | Coverage | Typical Use |
|---|---|---|
| ATEX | Zones 0, 1, 2 (EU) | Refineries, Chemicals |
| IECEx | International | Global projects |
| UL/CSA | Class I Division 1/2 | North American zones |
| INMETRO | Brazil | Regional use |
Cross-reference site classification with device markings (e.g., Ex ia IIC T4 Ga). Keep updated datasheets or spec sheets in your deployment binder or digital database.
Why Is Packing and Transport So Important?
Even the most robust intrinsically safe devices can be damaged if mishandled in transit. Dropping an IS tablet may not create a spark, but it could disable critical features like Wi-Fi, GPS, or scanning functions.
Ensure devices are packed:
In padded, rugged containers
Away from magnets or metal that could affect calibration
In climate-stable environments (avoid high heat or freezing temps)
Include physical checklists or QR-coded digital ones for pre- and post-shipment inspections.
Recommended Products for Pre-Deployment Prep
| Product | Type | Certification | Key Use |
|---|---|---|---|
| Ecom Smart-Ex 02 | Smartphone | ATEX Zone 1, IECEx | Communication & data logging |
| NightStick XPP-5422G | Flashlight | Class I Div 1 | Illumination in low-visibility zones |
| CorDEX TP3EX | Camera | IECEx/ATEX | Photo documentation & inspection |
| Tab-Ex 03 D2 Tablet | Tablet | Zone 2, Div 2 | Workflow apps & field reports |
| Xciel iPad Mini 6 Case | Case | ATEX Zone 2 | Mobile device protection |
Not sure which gear is right for your hazardous zone?
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Frequently Asked Questions
Can I use uncertified accessories with IS devices?
No. Using non-certified accessories (chargers, mounts) can void ATEX/IECEx ratings and introduce ignition risks.
How often should I inspect IS devices?
Pre-deployment, post-deployment, and every 3–6 months as part of routine safety audits.
What if a label is worn off or unreadable?
Immediately remove the device from service. Certification labels are required for compliance.
Are software updates mandatory before deployment?
Yes. Outdated firmware can lead to instability, communication errors, or noncompliance.
Can I charge IS devices in the field?
Only with ATEX-certified charging equipment placed in appropriate non-hazardous or protected areas.
Conclusion
Intrinsically safe devices are only as reliable as the preparation behind them. A consistent, thorough intrinsically safe checklist ensures your communications, lighting, and inspection tools perform flawlessly in dangerous environments.
By following the steps above and verifying equipment across certification, function, and safety, you ensure compliance—and more importantly, you protect lives.
