Explosion-Proof & Intrinsically Safe Level Solutions for Hazardous Industries

March 4, 2025

In hazardous environments where flammable gases, combustible dust, and extreme operating conditions are present, safety and reliability are critical. Explosion-proof (EP) sensors and intrinsically safe (IS) systems play a crucial role in protecting people, equipment, and processes across industries such as oil & gas, chemicals, mining, wastewater, agriculture, and hydrogen fuel systems.

For decades, Gems Sensors has been a trusted partner, providing FM-approved EP level sensors, Suresite® Visual Liquid Level Indicators with transmitter and switch modules, and intrinsically safe system solutions using Gems Safe-Pak® relays, Zener barriers, and Warrick IS Controls. These solutions ensure compliance, operational efficiency, and safety in hazardous applications, including fuel storage, chemical processing, lubrication systems, wastewater treatment, and more.

Explosion-Proof vs. Intrinsically Safe Systems: Choosing the Right Protection*

Explosion-Proof (EP) Sensors

EP sensors are designed to contain any internal explosion and prevent ignition of the surrounding environment. Certified for Class I, Division 1, Groups B, C, and D and Dust-Ignition proof for Class II/III, Division 1, Groups E, F, and G hazardous (classified) locations. These sensors are ideal for:

• Oil & Gas Processing – Monitoring fuel tank levels in refineries and storage facilities.
• Chemical & Petrochemical Plants – Ensuring safe level detection of volatile chemicals.
• Mining Operations – Providing reliable liquid level monitoring in fuel storage and cooling systems

Intrinsically Safe (IS) Systems

Rather than relying on IS-certified sensors, Gems Sensors renders standard sensors intrinsically safe when paired with Warrick IS Controls, Safe-Pak® relays, and Zener barriers. These devices limit energy levels, ensuring safe operation in hazardous environments such as:

• Agriculture & Grain Handling – Preventing ignition in grain silos and fertilizer processing.
• Wastewater Treatment – Safeguarding chemical dosing and sludge level monitoring.
• Hydrogen Fuel Systems – Monitoring cryogenic hydrogen storage with Suresite® Visual Liquid Level Indicators equipped with transmitter and switch modules.

With both EP sensors and IS system solutions, Gems Sensors helps engineers meet regulatory requirements while optimizing safety and performance.

Industry Applications: Gems Level Products in Hazardous Environments

Oil & Gas Industry

• Fuel Storage & Transfer – LS-700 & LS-800 and Suresite® Visual Liquid Level Indicators provide reliable level detection in crude oil and refined fuel tanks.
• Compressor & Pump Systems – LS-700 & LS-800 protect critical lubrication systems from disruptions.

Chemical & Petrochemical Processing

• Solvent & Chemical Storage – LS-52100 & XT-800 and Suresite® Visual Liquid Level Indicators monitor liquid levels in volatile chemical tanks.
• Cooling & Heat Exchanger Systems – LS-700 & LS-800 prevent overheating by ensuring proper coolant level.
• Reactor Level Monitoring – XM/XT-36490 & LS-2050 and Suresite® Visual Liquid Level Indicators provide accurate readings in high-temperature reaction vessels.

Mining & Aggregates

• Fuel & Hydraulic Fluid Monitoring – LS-700 & LS-800 ensure proper levels in mining equipment.
• Dust Suppression & Water Systems – ELS-1150XP & LS-52100 monitor water level for dust control operations.
• Conveyor Lubrication Systems – LS-700 & LS-800 maintain proper oil level to prevent equipment failures.

Wastewater Treatment

• Chemical Dosing & pH Control – LS-2050 & ELS-1150XP regulate chemical levels in treatment processes.
• Sludge & Water Separation – XM/XT-800 & XM/XT-36490 ensure effective phase separation in clarifiers.
• Pumping Stations & Lift Stations – Series M with Warrick 47 Series protects pumps from dry-run conditions by rendering the application intrinsically safe.

Agriculture & Grain Handling

• Fertilizer & Pesticide Storage – LS-800 & LS-52100 monitor tank levels to prevent overflows.
• Grain Silos & Dust Collection – Standard sensors rendered IS with Warrick 27 Series and Safe-Pak® relays prevent ignition risks in dust-heavy environments.

Hydrogen Fuel Systems

• Cryogenic & High-Pressure Storage – XM/XT-800 & XM/XT-36490 and Suresite® Indicators provide reliable level control for hydrogen tanks.
• Fuel Cell Cooling Level Monitoring – LS-700 & LS-2050 protect cooling systems in hydrogen fuel applications.

Why Gems Sensors? Built for Safety, Reliability & Compliance

Engineered for Extreme Conditions

Our explosion-proof sensors and intrinsically safe system solutions are designed with rugged materials ensuring durability in high-pressure, corrosive, and extreme-temperature environments.

Certified for Global Compliance

Gems Sensors’ EP and IS-compatible solutions meet stringent industry safety standards, including:

• FM Approved certification for hazardous locations.
• Class I, Division 1, Groups B, C, and D and Dust-Ignition proof for Class II/III, Division 1, Groups E, F, and G hazardous (classified) locations
• Additional certifications such as CE, UL, and CSA, ensuring global acceptance.

Pairing Gems level sensors with Safe-Pak® relays, Zener barriers, and Warrick IS relays ensures:

• Safe, energy-limited operation in explosive atmospheres.
• Reliable signal transmission to control systems and PLCs.
• Compliance with hazardous location regulations.

The Warrick Series 27, 47, and 67 Intrinsically Safe Control Relays play a critical role in rendering conductivity probes and non-voltage storing devices intrinsically safe for use in hazardous locations. These relays are an essential part of Gems Sensors' IS system solutions, ensuring safe and compliant operation in oil & gas, chemical processing, mining, wastewater, agriculture, and hydrogen fuel applications.

Partner with Gems Sensors for Hazardous Applications

Gems Sensors is a proven leader in hazardous location sensing solutions, trusted across industries where safety is paramount. Our FM-approved explosion-proof sensors, Suresite® Indicators, and intrinsically safe system solutions provide precise, reliable performance in oil & gas, chemicals, mining, wastewater, agriculture, and hydrogen fuel applications.

Learn about all industries we serve >