When working in hazardous environments such as oil rigs, refineries, or chemical plants, safety is non-negotiable. Intrinsically safe (IS) devices are designed to operate safely in explosive atmospheres—but only if they are properly maintained. Neglecting even basic maintenance can lead to equipment failure, costly downtime, and increased risk of ignition.
In this guide, we’ll explore everything you need to know to maintain your IS equipment effectively. From weekly inspections to long-term recertification, this intrinsically safe maintenance checklist will help ensure your gear remains safe, compliant, and functional.
What Is an Intrinsically Safe Device and Why Maintenance Matters?
Intrinsically safe devices are engineered to prevent sparks or high temperatures that could ignite flammable gases, vapors, or dust. These devices comply with stringent certifications such as ATEX (EU), IECEx (global), and NEC/CEC (North America).
Regular maintenance is critical for two reasons:
Safety: Damage, wear, or improper handling can compromise a device’s ability to contain energy within safe limits.
Compliance: Ignoring maintenance may invalidate certifications, putting personnel and facilities at risk of regulatory penalties.
What Should Be Included in an Intrinsically Safe Maintenance Checklist?
Maintaining intrinsically safe equipment isn’t a one-size-fits-all task. Here’s how to break it down.
Daily to Weekly Visual Inspections
Check for external signs of wear: cracks, dents, faded labels, or exposed wires.
Verify the integrity of seals and enclosures.
Confirm connectors and cables are secure.
Look for corrosion or discoloration on metal parts.
Document findings with date-stamped photos.
Monthly Battery and Power Checks
Inspect batteries for swelling, leaks, or discoloration.
Use only OEM-approved or certified batteries.
Ensure battery housings are properly sealed.
Record battery changes in maintenance logs.
Quarterly Functional and Electrical Testing
Test for correct voltage and current ranges.
Verify functionality of safety barriers and isolators.
Ensure no bridging or shorting in circuits.
Use certified test tools designed for use in hazardous zones.
Annual Detailed Inspection and Cleaning
Disassemble per manufacturer guidelines (if allowed).
Clean dust, grime, and residue using non-conductive tools and wipes.
Check internal seals, gaskets, and circuitry for deterioration.
Reassemble with proper torque settings and seals intact.
3–5 Year Recertification and Intrinsic Barrier Checks
Perform a full system verification to IEC 60079-17 standards.
Validate isolation barriers and Zener diodes.
Replace aging components nearing end-of-life recommendations.
Retest to confirm the equipment still meets explosion-proof standards.
Need help with recertification or barrier testing?
Request support from our certified IS specialists
How Can You Clean and Protect Intrinsically Safe Devices Safely?
Proper cleaning is essential—but only when done with the right tools and practices.
Use anti-static, non-conductive wipes or brushes.
Avoid flammable solvents. Instead, use manufacturer-approved cleaning agents.
Do not open the device unless explicitly authorized by the manual or trained technician.
Store equipment in dry, dust-free areas with temperature control.
Can Firmware & Software Updates Affect Intrinsic Safety?
Yes. Software changes can potentially alter the device’s energy characteristics.
Only install firmware provided or approved by the manufacturer.
Always verify version compatibility with the certification.
Document the update, including date, firmware version, and technician name.
Re-test or recalibrate post-update to ensure continued safe operation.
Who Should Perform Maintenance on IS Devices?
Maintenance should only be performed by trained and certified personnel.
Follow IEC 60079-19 standards for repair and overhaul.
Utilize lockout-tagout procedures or gas clearance certification before opening equipment.
Use personal protective equipment (PPE) rated for hazardous areas.
Keep a log of who performed what maintenance and when.
How Do You Document and Track Maintenance Activities?
Documentation is key to compliance and operational transparency.
Maintain digital or paper logs of all inspection and service activities.
Include serial numbers, technician name, parts replaced, and findings.
Take before-and-after photos for internal inspections.
Store all manuals, certificates, and calibration records in a central archive.
Not sure where to start?
Chat with a safety expert now or request a custom quote
FAQ
How often should intrinsically safe devices be inspected?
Inspections should be performed as follows:
Visual checks: Weekly
Battery checks: Monthly
Functionality tests: Quarterly
Internal inspections and cleaning: Annually
Recertification: Every 3–5 years, depending on use and environment
What happens if I use the wrong battery or part?
Using unauthorized parts can void your certification and compromise safety. Always purchase OEM-approved components to maintain explosion protection.
Can I open the device for cleaning?
Only if permitted by the device’s manual. Unauthorized disassembly may breach intrinsic barriers and void safety ratings.
Are firmware updates necessary?
Yes, but only install updates approved by the manufacturer. After updating, verify that the device still operates within certified parameters.
Is live maintenance allowed?
In some cases, yes—but only in certified IS circuits and with proper lockout/tagout procedures in place. Always follow manufacturer and regulatory guidelines.
Maintenance Checklist Table
| Task | Frequency | Who Performs It | Documentation Required |
|---|---|---|---|
| Visual inspection | Weekly | Technician | Photo, checklist log |
| Battery inspection | Monthly | Technician | Battery log, part number |
| Electrical testing | Quarterly | Electrical engineer | Test report, signatures |
| Internal inspection & cleaning | Annually | Certified technician | Disassembly checklist |
| Recertification | Every 3–5 yrs | Manufacturer/service ctr | Full audit report |
Comparison of Maintenance Tools & Consumables
| Item | Certification | Use | Frequency | Price Range |
|---|---|---|---|---|
| Non-conductive wipes | ISO 9001/ATEX safe | Surface cleaning | Weekly+ | $15–$30 |
| IS-rated screwdriver set | ATEX Zone 1 rated | Disassembly/reassembly | As needed | $45–$100 |
| Zener barrier tester | IEC 60079-11 | Electrical verification | Quarterly | $250–$600 |
| Battery storage trays | Antistatic, OEM | Safe battery transport | Ongoing | $20–$50 |
Best choice by role:
Field technician: Wipes, IS-rated tools, battery trays
Maintenance engineer: Barrier tester, diagnostics toolkit
Safety supervisor: Full documentation archive, recertification kit
Conclusion
Maintaining intrinsically safe equipment is more than a best practice—it’s a regulatory and operational necessity. By following a comprehensive intrinsically safe maintenance checklist, you ensure your equipment performs reliably, certifications remain valid, and your team stays protected.
Don’t wait until downtime costs you thousands. Be proactive with maintenance.
