1. Purpose
The purpose of this policy is to establish standardized requirements for the selection, use, inspection, maintenance, and storage of intrinsically safe (IS) tools and equipment used by ESCO Group employees and contractors working in hazardous (classified) locations where flammable gases, vapors, combustible dusts, or ignitable fibers may be present. This policy is designed to prevent ignition-related incidents and ensure compliance with applicable federal, state, and industry safety standards.
2. Scope
– All ESCO Group employees, contractors, and subcontractors who work in or near hazardous (classified) locations.
– All intrinsically safe tools and equipment, including but not limited to non-sparking hand tools, IS-rated electrical test instruments, IS-rated communication devices, IS-rated flashlights and headlamps, IS-rated gas monitors, and IS-rated cameras.
– All work activities conducted in areas classified as Class I, II, or III, Division 1 or 2, or Zone 0, 1, or 2 under NEC (NFPA 70) and OSHA 29 CFR 1910.307.
3. Regulatory & Reference Basis
– OSHA 29 CFR 1910.307 — Hazardous (Classified) Locations
– NFPA 70 (NEC) — National Electrical Code, Articles 500–506 (Class/Division and Zone systems)
– ANSI/UL 913 — Standard for Intrinsically Safe Apparatus and Associated Apparatus for Use in Class I, II, and III, Division 1 Hazardous Locations
– ANSI/ISA RP 12.6 — Installation of Intrinsically Safe Instrument Systems for Hazardous (Classified) Locations
– IEC 60079-11 — Explosive Atmospheres: Equipment Protection by Intrinsic Safety “i”
– FM Approval Standards 3610 & 3615 — Intrinsically Safe and Explosion-Proof Equipment
– OSHA General Duty Clause — Section 5(a)(1) of the OSH Act
– ESCO Group Safety Manual and related policies (Hand & Power Tools, Electrical Safe Work Practices, Brass Tool Policy)
4. Definitions
– Intrinsically Safe (IS) Equipment: Equipment and circuits designed so that no spark or thermal effect produced under normal operation or specified fault conditions can ignite a given explosive atmosphere.
– Hazardous (Classified) Location: An area where fire or explosion hazards may exist due to the presence of flammable gases/vapors (Class I), combustible dusts (Class II), or ignitable fibers (Class III).
– Non-Sparking Tools: Hand tools made of non-ferrous metals such as copper alloys, aluminum bronze, or beryllium copper that do not produce sparks when struck against other surfaces.
– Protection Levels:
- Ex ia — Suitable for Zone 0/1/2 (highest level; safe with two faults)
- Ex ib — Suitable for Zone 1/2 (safe with one fault)
- Ex ic — Suitable for Zone 2 only (safe under normal operation)
5. Hazardous Area Classification
Before any work begins, the job site must be assessed to determine the applicable hazardous area classification.
| NEC 500 (Class/Division) | NEC 505 (Zones) | Hazard Frequency | Example |
| Class I, Division 1 | Zone 0 / Zone 1 | Continuous / Intermittent | Refineries, chemical plants |
| Class I, Division 2 | Zone 2 | Abnormal conditions only | Warehousing near processes |
| Class II, Division 1 & 2 | N/A (U.S. only) | Dust hazards | Grain silos, sugar processing |
| Class III, Division 1 & 2 | N/A (U.S. only) | Fibers / flyings | Textile mills, woodworking |
All classification documentation shall be available to those authorized to design, install, inspect, maintain, or operate equipment at the location.
6. Selection of Intrinsically Safe Tools
6.1 General Requirements
– Only tools and equipment that are properly certified (UL, FM, CSA, ATEX, or IECEx) for the specific hazardous classification of the work area shall be used.
– Employees must verify that tool ratings match or exceed the classification of the work environment (Class, Division/Zone, Group, and Temperature Code).
– Non-sparking hand tools shall be made of approved non-ferrous metals such as copper alloy, aluminum bronze, or beryllium copper. Coated tools that do not meet intrinsic safety standards are not permitted.
6.2 Types of Approved Tools
| Tool Category | Material / Rating | Application |
| Non-sparking hand tools | Copper alloy, aluminum bronze, beryllium copper | Where flammable gases, vapors, or dusts are present |
| Electrical test instruments | IS-rated (Ex ia, ib, or ic) | Measurement in classified areas |
| Communication devices | IS-rated radios and phones | Communication in classified areas |
| Flashlights / headlamps | IS-rated | Illumination in classified areas |
| Gas monitors | IS-rated | Atmospheric monitoring |
6.3 Factors for Selection
– The type of material being worked on
– The type of work being performed
– The specific hazardous classification of the work enviornment
– The size and shape of tool needed
– Manufacturer certifications and rating
7. Safe Use Procedures
7.1 Before Use
– Inspect all tools and equipment before each use to ensure they are in good condition and free of damage, defects, or unauthorized modifications.
– Verify certifications – Confirm the tool’s IS markings match the area classification before entering the hazardous zone.
– Check batteries – Only use manufacturer-approved, IS-rated batteries in IS-certified devices. Never swap batteries in a hazardous area.
– Complete a Pre-Job Hazard Analysis (PJHA) that identifies all IS tool requirements for the task.
7.2 During Use
– Use tools only as intended by the manufacturer. Do not modify, alter, or bypass any safety features.
– Use the right tool for the job. Never substitute a standard tool for an intrinsically safe tool in a classified area.
– Do not open, repair, or service IS-rated electronic devices while in a hazardous area unless authorized procedures permit live maintenance.
– Wear appropriate PPE as required by the work conditions and site requirements.
– No loose clothing or jewelry may be worn when operating tools.
7.3 After Use
– Clean tools after each use to remove contaminants that may compromise non-sparking or IS properties.
– Return and log tools per ESCO Group’s tool issuance and return procedures.
– Report any damage, defects, or malfunctions immediately. Tag defective tools as “DANGER — UNSAFE — DO NOT USE” and remove from service.
8. Inspection & Maintenance
8.1 Routine Inspections
| Inspection Type | Frequency | Performed By |
| Visual pre-use inspection | Before each use / each shift | User |
| Detailed condition inspection | Monthly | Designated Safety Coordinator |
| Certification verification | Quarterly | Equipment Inventory Manager |
| Calibration (electronic IS tools) | Per manufacturer’s schedule | Qualified Technician |
8.2 Inspection Criteria
– Non-sparking hand tools: Check for cracks, mushrooming, excessive wear, deformation, or contamination with ferrous material.
– IS-rated electronic equipment: Check housings for cracks, damage, or missing components; verify labels and markings are legible; confirm batteries are the correct type and not expired.
– Gas monitors: Follow the Personal Gas Monitor Calibration Policy for bump testing and calibration requirements.
8.3 Maintenance
– Only manufacturer-authorized service centers or qualified technicians may repair IS-rated electronic equipment.
– Replacement parts must be OEM-specified to maintain IS certification.
– Non-sparking tools that are cracked, deformed, or contaminated with ferrous material shall be retired from service.
– All maintenance activities shall be documented and recorded.
9. Storage & Handling
– Store intrinsically safe tools in dry, clean, secure locations separate from standard tools to prevent mix-ups.
– Clearly label storage areas for IS tools (for example, “INTRINSICALLY SAFE TOOLS ONLY”).
– Do not store IS tools with ferrous metal tools or in areas where they may become contaminated.
– Transport IS tools in protective cases to prevent damage.
10. Training Requirements
All employees who use or may encounter intrinsically safe tools shall receive training that includes:
· Understanding of hazardous (classified) locations and area classifications
· Identification of IS-rated tools and how to read IS markings and labels
· Proper selection, use, inspection, and storage of IS tools
· Differences between non-sparking tools, intrinsically safe electronic equipment, and explosion-proof equipment
· Emergency procedures in the event of tool failure in a classified area
· Refresher training conducted annually or when procedures change
Training shall be documented and records retained per ESCO Group’s record retention policy.
11. Prohibited Actions
– Using non-IS-rated tools or standard tools in classified hazardous areas
– Modifying, altering, or tampering with IS-certified equipment
– Using damaged, defective, or expired IS equipment
– Swapping batteries or opening IS electronic devices in a hazardous area
– Using coated tools that do not meet intrinsic safety standards
– Bringing personal non-approved electronic devices into classified areas
– Performing unauthorized repairs on IS equipment
12. Roles & Responsibilities
Management
· Ensure adequate IS tools are available and properly maintained
· Provide training and resources for compliance
· Conduct periodic audits of the IS tool program
Supervisors / Foremen
· Verify area classifications before assigning work
· Ensure workers are using proper IS tools for the environment
· Enforce this policy and take corrective action for violations
Equipment Inventory Manager
· Maintain inventory of all IS tools and equipment
· Track certifications, calibration dates, and inspection records
· Coordinate procurement of approved IS tools
Employees / Contractors
· Follow all requirements of this policy
· Inspect tools before each use
· Report damaged or defective tools immediately
· Complete all required training
13. Disciplinary Action
Violations of this policy may result in disciplinary action up to and including termination, in accordance with ESCO Group’s Corrective Action Procedures.
14. Policy Review
This policy shall be reviewed annually or whenever changes in regulations, standards, work processes, or incident investigations warrant a revision.