Comprehensive Guide to Selecting Electrical Safety Equipment for Low-, Medium-, and High-Voltage Systems

The selection of electrical safety equipment should not be based solely on system voltage, nor can all electrical risks be addressed simply by adding insulated gloves, insulated mats, or other protective gear. Proper selection should be based on the work task, equipment condition, potential hazards, applicable standards, and on-site environment to determine which protective measures are needed and how different pieces of equipment should be used in combination.

For power companies, substation operations and maintenance teams, EPC contractors, industrial procurement personnel, and distributors of electrical safety equipment, establishing a clear framework for equipment selection helps reduce issues such as specification mismatches, incomplete technical documentation, and improper on-site application.

Based on typical risks in low-voltage (LV), medium-voltage (MV), and high-voltage (HV) systems, this article introduces the functions, selection criteria, standard verification, and maintenance management methods for commonly used electrical safety equipment, helping procurement and technical teams translate on-site requirements into actionable product specifications.

Quick Takeaway: Select Equipment Based on Work Tasks and Risks

When selecting electrical safety equipment, it is recommended to prioritize the following considerations:

• The system voltage involved in the task, whether AC or DC, and the equipment’s current operating status.
• Whether hazards such as electric shock, arc flash, induced voltage, stored energy, or fault currents are present.
• Whether risks can be mitigated through power shutoff, isolation, lockout/tagout, and other engineering controls.
• What personal protective equipment (PPE), voltage detection tools, insulated operating tools, and temporary grounding equipment are required.
• Whether the product complies with applicable standards, project technical specifications, and the manufacturer’s specified operating conditions.
• Are the corresponding technical documentation, inspection records, maintenance requirements, and product traceability information available?

Electrical safety equipment is not merely a list of independent products. Each piece of equipment should serve a specific safety function and be aligned with work procedures, personnel qualifications, and on-site control measures.

What are the different risks associated with low-voltage, medium-voltage, and high-voltage systems?

Low-voltage, medium-voltage, high-voltage, and extra-high-voltage (EHV) are common voltage classifications in electrical engineering. Specific boundaries may vary depending on national standards, industry regulations, and utility company requirements; therefore, the classification used in a particular region should not be regarded as a globally uniform standard.

When selecting equipment, in addition to voltage levels, factors such as current, fault energy, equipment design, working distance, and environmental conditions should also be analyzed.

Low-Voltage Systems (LV)

Low-voltage distribution panels, industrial control cabinets, distribution boxes, and electrical equipment maintenance sites may present risks such as direct contact, accidental energization, short circuits, arc flashes, and residual stored energy.

Relevant equipment may include:

• Appropriate insulated gloves and other personal protective equipment.
• Voltage detection and measurement instruments matched to circuit ratings and testing tasks.
• Lockout/tagout (LOTO) devices and necessary isolation signage.
• Insulated tools suitable for specific work tasks.
• Arc-flash protective gear configured according to on-site risk requirements.

Low voltage does not necessarily mean low risk. Low-voltage equipment with high short-circuit currents can also cause severe arc flash incidents.

Medium-Voltage (MV) Systems

Work on medium-voltage switchgear, substations, and distribution lines may involve higher risks of contact voltage, higher fault energy, induced voltages, and equipment isolation and grounding requirements.

In addition to applicable personal protective equipment, assess whether the following are required based on the work task:

• A voltage tester matched to the system voltage.
• Insulated operating poles and compatible operating heads.
• Portable grounding and grounding short-circuiting devices.
• Insulated protective equipment with clearly defined electrical ratings and test documentation.
• Isolation, warning, and access control measures suitable for switch operation and maintenance areas.

Specific configurations should be determined by the condition of the equipment, work methods, and applicable regulations, rather than solely based on the “medium-voltage” classification.

High-Voltage and Extra-High-Voltage Systems (HV/EHV)

High-voltage transmission and distribution lines, substations, and related power facilities may involve significant electrical clearance requirements, induced voltages, fault currents, elevated ground potential, and complex arc flash risks.

Such operations typically require stricter engineering controls, work permits, personnel qualifications, and verification of equipment suitability.

When selecting equipment, focus on verifying the following:

• The equipment’s actual rated operating conditions and applicable voltage range.
• The length of insulated operating tools, their effective insulated sections, and accessory compatibility.
• The detection principle, applicable voltage range, and operating procedures of voltage detectors.
• The fault current withstand capacity, duration, and connection configuration of temporary grounding devices.
• The classification, testing criteria, and usage limitations of insulated protective equipment.
• On-site grounding design, personnel approach distances, and other necessary safety control measures.

Do not assume that a product is suitable for all high-voltage operations simply because it is labeled for a higher voltage rating.

Common Electrical Safety Equipment and Its Functions

Different pieces of equipment serve different safety functions. Purchasing personnel should first clarify the operational requirements and then verify the technical specifications of the corresponding products.

1. Personal Protective Equipment (PPE)

Personal protective equipment includes electrically insulated gloves, appropriate protective footwear, head and face protection, and arc-thermal protective clothing, among others.

When selecting products, a distinction must be made between protection against electric shock and protection against arc flash. Arc-rated clothing is primarily designed to address arc flash hazards under specified conditions; its performance does not directly prove that the product provides protection against electric shock.

Purchasing personnel should focus on confirming:

• The applicable electrical protection rating and product classification.
• Relevant standards, markings, and test reports.
• Inspection, retesting, and disposal requirements for insulated gloves.
• Compatibility between PPE items and overall donning requirements.
• Protection requirements determined by the arc flash risk assessment.

Personal protective equipment should be used in conjunction with engineering controls and safe work procedures; it cannot replace feasible power shutoffs, isolation, or other necessary control measures.

For further information, refer to JINPOWER’s Electrical PPE Selection Guide.

2. Electrical Insulation Mats and Insulation Barriers

Electrical insulation mats can be used at designated work locations to provide supplemental insulation protection for personnel. Insulating barriers and other isolation devices can be used, depending on their design and rated conditions, to restrict personnel access to hazardous areas or to control work zones.

When selecting insulating mats, verify the following:

• Applicable standards and product ratings.
• Electrical test documentation for specific models.
• Thickness, width, length, and surface texture.
• Moisture, oil, chemicals, and other environmental conditions.
• Installation, inspection, cleaning, and maintenance requirements.

IEC 61111:2026 is an important reference standard for electrical insulating mats. Its scope of application and rated voltage conditions should be verified in conjunction with specific product classifications and project requirements.

It is important to note that electrical insulation mats do not automatically eliminate the risk of step voltage, contact voltage, or elevated ground potential, nor do they replace grounding designs, isolation measures, or necessary PPE.

Furthermore, ESD (electrostatic discharge) mats serve a different purpose than electrical insulation mats. ESD mats should not be used as electrical shock protection products based solely on their appearance or rubber composition.

Please refer to JINPOWER’s electrical insulation mat product classifications.

3. Voltage Detectors and Electrical Test Instruments

Voltage detectors are used to detect the presence of voltage at a specified location in accordance with prescribed methods. They perform different testing tasks than multimeters, insulation resistance testers, and ground resistance testers.

For example, IEC 61243-1:2021 applies to specific types of portable capacitive high-voltage testers; it cannot be assumed that all testers are subject to the same standard.

When selecting a model, verify the following:

• Rated voltage range and AC/DC applicability.
• Detection principle and type of equipment to be tested.
• Insulation structure, connection methods, and required accessories.
• Self-test or functional verification requirements.
• Requirements for pre- and post-use inspections, calibration, or retesting.
• Applicable standards, product identification, and technical documentation.

The correct use of a voltage detector is a critical step in verifying that equipment is de-energized; however, it cannot replace energy isolation, lockout/tagout, and applicable protective grounding procedures.

4. Portable Grounding and Grounding Short-Circuit Devices

Portable grounding devices are used to provide protective grounding under specified electrical work conditions, while grounding short-circuit devices also perform the corresponding short-circuit connection function.

The selection of such equipment should not be based solely on conductor cross-sectional area or product length.

The following should be verified with particular attention:

• Expected fault current and its duration.
• The equipment’s rated current, thermal stability, and electrodynamic withstand capability.
• Compatibility of grounding conductors, clamps, connection terminals, and grounding points.
• Installation location, operating tools, and connection methods.
• Applicable standards and relevant test documentation.

IEC 61230:2008 is a key reference standard for portable grounding and grounding short-circuiting equipment. Its performance evaluation relates to electrothermal and electrodynamic effects during short-circuit conditions.

Grounding devices must be selected and installed in accordance with an approved plan. A grounding conductor should not be simply regarded as an ordinary wire used to discharge residual charge, nor should grounding equipment be connected without first verifying that the power is off.

View JINPOWER’s grounding wire and grounding device product categories.

5. Insulated Operating Rods and Live-Line Work Tools

Insulated operating rods (Hot Sticks) are used for specific remote operation tasks. Their specific applications depend on the rod structure, operating head, accessories, and product operating conditions.

For example, IEC 62193:2003 covers telescoping operating poles and telescoping measuring poles, but this standard cannot be applied indiscriminately to all insulated operating tools.

When selecting a model, verify the following:

• Specific work tasks and required operating heads.
• Extended length, retracted length, and actual working range.
• The effective insulated section and applicable electrical conditions.
• Telescoping sections, locking mechanisms, and mechanical maneuverability.
• Accessory compatibility, inspection requirements, and relevant test documentation.

The total length of the operating pole does not equal the minimum approach distance, and product suitability cannot be determined solely based on the pole’s length or voltage ratings listed in promotional materials.

For telescoping operating poles, see JINPOWER’s Triangular Telescoping Insulated Operating Pole .

6. Rescue Tools and On-Site Safety Equipment

Emergency preparedness for electrical accidents may involve rescue tools, first-aid supplies, automated external defibrillators (AEDs), communication equipment, emergency lighting, and hazard zone warning systems.

Consider the following when purchasing:

• Applicable scenarios and usage restrictions for rescue tools.
• On-site emergency response plans and personnel training requirements.
• Rescue routes, equipment accessibility, and communication conditions.
• Inspection, maintenance, and operational readiness of first-aid equipment.
• Deployment requirements for warning signs, barriers, and access control measures.

Tools such as rescue hooks may only be used by trained personnel in accordance with approved emergency procedures. Do not assume that any rescue tool can be used safely while the equipment is energized, nor should rescue tools be used as a substitute for on-site isolation and hazard source control.

Create an equipment selection matrix based on operational tasks

Procurement personnel should start with actual operational tasks, clearly define the safety functions the equipment must perform, and then determine specific product specifications.

This matrix is intended for preliminary screening during the procurement and planning phases. Specific configurations should still be confirmed based on on-site risk assessments, equipment technical documentation, and applicable safety procedures.

Which standards and documents must be verified for electrical safety equipment?

The scope of application varies by equipment type. Procurement teams should establish a correspondence between equipment categories and relevant standards and test documentation, rather than simply requiring suppliers to provide a generic certificate of conformity.

The above serves as a reference point for technical verification; it does not imply that all products must simultaneously comply with these standards, nor does the listing of a specific standard alone suffice to prove that a particular model is compliant.

Prior to formal procurement, verify the applicable national standards, contract-specified versions, certification requirements, and project acceptance specifications, and check whether the standards have been updated or revised.

What documents should procurement personnel request?

Depending on the product category and project requirements, it is recommended to verify the following:

• Product technical specifications and exact model number.
• Applicable standards, versions, and product classification descriptions.
• Relevant test reports and inspection records.
• Product identification, batch information, and traceability data.
• Instructions for use, inspection, maintenance, and storage.
• Calibration records, retest records, or certificates of compliance, where applicable.
• Customer-specified document formats and acceptance documentation.

Documents must correspond to the actual purchased model, configuration, and scope of application. Reports for other models in the same series cannot be used in place of the certification documents required for a specific product.

Inspection, Testing, and Maintenance Management of Electrical Safety Equipment

The safety performance of equipment depends not only on factory specifications but also on its condition during actual use.

It is recommended to establish an equipment management process covering procurement, warehousing, issuance, use, inspection, retesting, repair, and decommissioning.

Pre-use Inspection

Based on the equipment category and manufacturer’s requirements, inspect the appearance, markings, mechanical structure, connection points, and other critical conditions.

For example:

• Insulated gloves: Inspect for visible damage, markings, and applicable retest status.
• Electroscope: Verify the model, applicable voltage range, and specified functional verification status.
• Insulated operating rod: Inspect the surface, connection structure, operating head, and telescoping locking mechanism.
• Grounding devices: Inspect the conductors, clamps, connection terminals, and other critical components.
• Insulated mats: Inspect for cracks, cuts, contamination, deformation, and the condition of the edges.

Pre-use inspections do not replace periodic testing or other formal verification required by standards.

Periodic Testing and Calibration

Test methods, intervals, and acceptance criteria may vary depending on the equipment.

A schedule should be established based on applicable standards, manufacturer’s instructions, local regulations, and on-site safety procedures, rather than setting a uniform retest cycle for all electrical safety equipment.

Test or calibration records should include equipment identification information, the date of the test, results, applicable limits, and necessary follow-up actions.

Storage and Disposal

Storage conditions should comply with the product specifications to prevent excessive moisture, contamination, mechanical compression, damage from sharp objects, and exposure to chemicals.

If equipment exhibits unacceptable damage, fails testing, or otherwise fails to meet operational requirements, it should be taken out of service in accordance with management procedures, and its suitability for use should be reconfirmed after assessment, repair, or replacement.

Common Mistakes in Selecting Electrical Safety Equipment

Mistake 1: Selecting Products Based Solely on Voltage Rating

Even within the same voltage rating, different work tasks, equipment configurations, and environments may require different safety equipment.

Improvement Method: First, clearly define the work task and risks; then determine the required equipment functions, rated conditions, and product specifications.

Mistake 2: Believing that PPE Can Replace Engineering Controls

Personal protective equipment (PPE) can reduce specific risks, but it does not automatically eliminate hazardous energy sources, nor can it replace applicable power-off, isolation, and grounding procedures.

Solution: Prioritize the assessment of implementable engineering controls and safe work practices, then select PPE that matches the residual risk.

Mistake 3: Confusing the Functions of Different Devices

ESD mats, electrically insulated mats, insulated operating rods, electroscopes, and grounding devices serve different functions.

Improvement Method: Verify based on the product’s intended use, applicable standards, and technical documentation; do not infer a product’s protective capability based on its appearance or material name.

Mistake 4: Ignoring Fault Current and Connection Configuration

Portable grounding devices should not be selected based solely on cable length or cross-sectional area.

Improvement Method: Verify the expected fault current, duration, connection points, clamps, and applicable equipment performance requirements.

Mistake 5: Verifying Only Certificates, Not Specific Models

A single standard declaration or test report does not necessarily cover all models, lengths, accessories, and operating conditions.

Improvement Method: Cross-reference the purchased model, configuration, identification, test documentation, and project technical requirements item by item.

Mistake 6: Failure to Establish Complete Equipment Records

Without records of inspections, tests, issuance, and maintenance, it is difficult to verify the actual condition and traceability of the equipment.

Improvement Method: Establish a unified equipment ledger to record key identifiers, inspection results, test status, responsible parties, and follow-up actions.

When is a more detailed electrical safety equipment procurement guide needed?

When a project moves from general equipment planning to the formal procurement phase, a general guide is insufficient to replace a detailed technical review.

Substations, power distribution facilities, and EPC projects typically also require clarification on equipment lists, rated parameters, technical documentation, deviation handling, delivery acceptance, and on-site usage requirements.

It is recommended to confirm at least the following during the RFQ phase:

• Equipment categories, models, and quantities.
• Specific operational tasks and operating environments.
• Applicable standards and project-specified versions.
• Rated parameters and compatibility requirements.
• Testing, inspection, and traceability documentation.
• Packaging, delivery, and acceptance requirements.

If further guidance is needed to establish procurement and acceptance processes, please refer to JINPOWER’s Procurement Guide for Electrical Safety Equipment in Substations.

Frequently Asked Questions (FAQ)

Do low-voltage systems also require specialized electrical safety equipment?

Yes. Low-voltage equipment can still pose serious risks of electric shock, short circuits, and arcing. Appropriate test tools, isolation measures, and personal protective equipment should be selected based on the condition of the equipment, fault energy, work tasks, and site conditions.

Do high-voltage systems require a wider variety of protective equipment?

The number of equipment items cannot be determined solely by voltage rating. Proper configuration depends on actual hazards, work methods, engineering controls, and applicable standards. Certain high-voltage tasks require specialized insulated operating tools, voltage detectors, or grounding devices, but the specific combination should be determined by risk assessments and work procedures.

Can a voltage detector replace a lockout/tagout system?

No. Voltage detectors are used to detect the presence of voltage, while lockout/tagout is used to prevent the accidental re-energization of hazardous energy sources. The two serve different functions and cannot be used interchangeably.

Can an insulated mat replace protective grounding?

No. Insulated mats can provide supplemental insulation protection under specified conditions, but they do not automatically establish protective grounding or an equipotential zone, nor can they replace applicable grounding designs and other safety measures.

What is the most important document when purchasing electrical safety equipment?

No single document applies to all products. Generally, you should cross-reference technical specifications, applicable standards, relevant test reports, product markings, and traceability documentation based on the equipment category, and supplement these with inspection, calibration, or acceptance records as required by the project.

Final Selection Checklist: From Tasks and Risks to Product Configuration

The core of procuring electrical safety equipment is not to purchase as many products as possible, but to establish an appropriate combination of safety controls for specific work tasks.

Before finalizing procurement specifications, it is recommended to complete the following checks:

JINPOWER provides electrical insulation mats, grounding devices, insulated operating poles, and related electrical safety equipment. Project procurement personnel can review our electrical insulation mat products, grounding wires and grounding devices, and insulated operating rod products. During the request-for-quote phase, they should specify the models, technical parameters, and required documentation.

Safety Notice: This document is intended for the preliminary selection and procurement planning of electrical safety equipment and is not a substitute for local regulations, on-site risk assessments, formal electrical engineering designs, or approved operating procedures.