Installation of an Intrinsic Safety (IS) System
Install with Confidence. Verify with Precision. Maintain Intrinsic Safety Throughout the Lifecycle.
Intrinsically safe systems are widely used in hazardous locations because they prevent ignition by limiting the electrical and thermal energy available within a circuit. However, equipment certification alone does not guarantee compliance. Intrinsic safety depends on the correct selection, installation, verification, inspection, and maintenance of the entire system.
This practical one-day course provides participants with the knowledge and skills required to install and verify intrinsically safe systems in hazardous locations. Participants will learn how to interpret Ex markings, select barriers and isolators, apply the Entity Concept, verify loop compatibility, interpret control drawings and Descriptive System Documents (DSDs), and apply installation requirements in accordance with recognized industry practices and applicable standards.
By the end of this training, successful participants will be able to:
- Describe the components and characteristics of an intrinsically safe system
- Use intrinsic safety terminology correctly
- Navigate intrinsic safety Standards
- Interpret markings used to communicate elements of an IS system
- Select and match proper safety barriers with IS devices
- Verify an intrinsically safe system
- Describe installation requirements and IS system maintenance to ensure safety and compliance
This course is intended for:
- Instrumentation Engineers
- Electrical Engineers
- Controls and Automation Engineers
- Project Engineers
- System Integrators
- Designers of hazardous-area installations
- Electrical and Instrumentation Technicians
- Instrument Installers
- Maintenance Personnel
- Field Service Technicians
- Inspectors and Auditors
- Plant Operations Personnel
- Anyone responsible for installing, verifying, inspecting, or maintaining intrinsically safe systems in hazardous locations.
Introduction to Intrinsic Safety (IS) Systems
- What is intrinsic safety
- Components and characteristics of an IS system
- Applications of IS, advantages and disadvantages of this protection technique
- How intrinsic safety helps protect circuits in hazardous locations
- Ex markings and applicable Standards
- Levels of protection (Ex ia, Ex ib, Ex ic)
- Equipment Protection Level (EPL) achieved by intrinsic safety
- Fault applications
- Definition of important terms in intrinsic safety
Zener Diodes & Galvanic Isolators
- Fundamentals of associated apparatus
- Basic circuitry and its functions
- Safety components
- Earthing requirements
- Safety barrier selection
- Comparison of Zener Diodes & Galvanic isolators
- Entity Parameters (Uo, Io, Po, Co, Lo)
- Fault consideration
- Selecting a safety barrier for a given application
- Intrinsically safe system using one safety barrier
- Intrinsically safe systems using more than one safety barriers (IEC 60079-25)
- Type of cables for intrinsically safe system
- Entity Concept verification and connection of the IS barrier and IS field device
- Cable inductance calculation & cable capacitance calculation
Installation and Maintenance of IS Systems
- Control Drawing and Descriptive System Document
- Wiring installation and separation from other non-IS wiring
- NEC, CEC and IEC 60079-14 wiring installation requirements for intrinsic safety systems
- The importance of earthing and grounding
- Practical rules for maintenance and inspection of IS assemblies
Questions and answers; definition of terms and concepts
Self-Administered Test: Application of terms, definitions, and concepts; Case Study that incorporates topics covered in this course
Intrinsic safety is one of the most widely applied explosion protection techniques for instrumentation, sensors, analyzers, and other low-power electrical equipment installed in hazardous locations. Unlike other protection concepts, intrinsic safety protects by limiting available energy to levels below those capable of igniting a hazardous atmosphere. The effectiveness of this protection method relies on the proper design, installation, verification, and maintenance of the complete system.
This one-day instructor-led course provides a practical understanding of intrinsically safe systems and their application in hazardous locations. Participants will learn the fundamental principles of intrinsic safety, the purpose and characteristics of associated apparatus, and the differences between zener barriers and galvanic isolators. The course also explains applicable protection levels, Ex markings, important terminology, and the role of standards and codes in achieving compliant installations.
A significant focus is placed on system verification using the Entity Concept. Participants will learn how to evaluate compatibility between barriers and field devices, verify electrical parameters, account for cable capacitance and inductance, and confirm that a complete intrinsically safe loop satisfies installation requirements. Practical examples and exercises are used throughout the course to reinforce these concepts.
The course also provides detailed guidance on installation practices, including the use of Control Drawings, Descriptive System Documents (DSDs), wiring segregation requirements, grounding and earthing practices, cable selection, labeling, documentation, and commissioning activities. Participants will gain an understanding of how installation decisions directly affect compliance and safety performance.
Through practical exercises, installation scenarios, inspection examples, and a final knowledge assessment, participants will develop the skills needed to confidently install, verify, inspect, maintain, and troubleshoot intrinsically safe systems in real-world industrial environments.
By the end of this training, you will be able to:
- Explain the principles of intrinsic safety and its role in hazardous locations.
- Describe the components and characteristics of an intrinsically safe system.
- Use intrinsic safety terminology correctly.
- Interpret Ex markings and Equipment Protection Levels (EPLs).
- Navigate applicable standards, codes, and installation requirements.
- Differentiate between zener barriers and galvanic isolators.
- Select and match appropriate associated apparatus and field devices.
- Apply the Entity Concept to verify intrinsically safe loops.
- Perform voltage, current, power, capacitance, and inductance verification.
- Interpret Control Drawings and Descriptive System Documents (DSDs).
- Apply grounding, wiring segregation, labeling, and installation requirements.
- Identify common installation errors and non-conformities.
- Inspect, maintain, and commission intrinsically safe systems.
- Verify compliance of installed intrinsically safe systems.
Upon completion of this course, you will be able to:
- Understand the principles and applications of intrinsic safety.
- Recognize the components of an intrinsically safe system.
- Select appropriate barriers and isolators for a given application.
- Interpret Ex markings and protection levels.
- Apply the Entity Concept for system verification.
- Verify cable capacitance and inductance requirements.
- Interpret Control Drawings and Descriptive System Documents.
- Apply grounding, earthing, segregation, and wiring requirements.
- Identify common installation non-conformities.
- Perform inspection, maintenance, and commissioning activities.
- Improve compliance with hazardous location installation requirements.
- Reduce risks associated with improper installation and maintenance of intrinsically safe systems.
This course is delivered through instructor-led training and uses a combination of:
- Lectures and guided discussions
- Real-world examples
- Practical installation scenarios
- Barrier selection exercises
- Entity verification exercises
- Control drawing interpretation exercises
- Group discussions
- Case studies
- Knowledge checks and quizzes
- End-of-course assessment
The delivery approach combines theoretical understanding with practical application to reinforce learning and encourage problem-solving in real-world hazardous-area installations.
Participants will complete a self-administered assessment consisting of theoretical questions and practical application scenarios covering:
- Intrinsic safety terminology
- Ex markings
- Barrier selection
- Entity verification
- Wiring requirements
- Documentation requirements
- Grounding and segregation
- Inspection and maintenance concepts
Participants who attend at least 90% of the total training duration will receive a Certificate of Attendance from TÜV SÜD Academy.
Participants receive:
- Comprehensive course presentation materials
- Verification worksheets
- Practical installation examples
- End-of-course glossary of intrinsic safety terms
- Self-administered knowledge assessment
- Certificate of Attendance (subject to attendance requirements)
There are no formal prerequisites.
However, the following are beneficial:
- Basic understanding of electrical or instrumentation systems
- Familiarity with industrial process equipment
- Experience with hazardous locations or process facilities
A calculator is recommended for verification exercises.
Is this a design course or an installation course?
This course focuses on the installation, verification, inspection, maintenance, and commissioning of intrinsically safe systems. It is not intended to teach the detailed design and certification of intrinsically safe equipment.
Does the course cover IEC 60079-14 requirements?
Yes. The course includes wiring, segregation, grounding, and installation practices commonly associated with IEC 60079-14 requirements.
Will I learn how to select a safety barrier?
Yes. Participants learn how to select and match associated apparatus with field devices and evaluate system compatibility using the Entity Concept.
Does the course include practical verification examples?
Yes. Participants complete practical verification exercises involving voltage, current, power, capacitance, and inductance assessments.
Are cable capacitance and inductance calculations covered?
Yes. The course includes practical cable capacitance and cable inductance calculations as part of entity verification.
Will Control Drawings and DSDs be covered?
Yes. Participants learn how to interpret Control Drawings and Descriptive System Documents and understand their importance during installation and maintenance activities.
Does the course compare zener barriers and galvanic isolators?
Yes. The course explains the operating principles, advantages, limitations, grounding considerations, and selection criteria for both technologies.
Is grounding and earthing discussed?
Yes. Proper grounding, earthing, shield termination, and single-point grounding principles are covered in detail.
Does the course include inspection and maintenance topics?
Yes. Participants learn inspection grades, inspection checklists, maintenance considerations, and common field non-conformities.
Is there an assessment?
Yes. Participants complete a self-administered assessment that tests terminology, concepts, and practical application scenarios.
What standards and schemes are discussed?
The course references concepts associated with intrinsic safety installations, including IEC 60079-14, IEC 60079-25, NEC, and CEC installation considerations as relevant to system installation and verification.
Do I need prior hazardous location experience?
No. While helpful, prior experience is not required. The course begins with intrinsic safety fundamentals before progressing to installation, verification, inspection, and maintenance topics.
TÜV SÜD is a leading provider of training and certification in hazardous locations (HazLoc) safety and compliance. Its programs are widely recognized in the United States and internationally. The experts at TÜV SÜD Academy possess in-depth knowledge of global standards such as IECEx, ATEX, and North American requirements, and are committed to delivering practical, application-focused training. Professionals responsible for equipment and systems in explosive atmospheres play a critical role in ensuring operational safety and compliance, and their competence is essential for the safe and efficient functioning of industrial facilities.