How to Develop an Electrical Safety Equipment Configuration List for Oil Refineries and Petrochemical Plants?

When developing an electrical safety equipment inventory list for oil refineries and petrochemical plants, first divide the facility into substations, medium-voltage switchgear rooms, motor control centers (MCCs), outdoor electrical facilities, and maintenance workshops based on the site layout. Then, determine the required equipment, technical specifications, and supporting documentation according to the electrical work tasks in each area. Key equipment includes electrical insulating mats, voltage detectors, portable earthing sets, insulating gloves, insulated operating poles, electrical insulating blankets, and safety equipment storage cabinets. For hazardous areas containing flammable gases, vapors, or combustible dust, the explosion-proof suitability of the equipment must be verified separately; standard electrical insulation products cannot be directly considered explosion-proof equipment.

Electrical Safety Equipment Requirements for Different Refinery Areas

Refineries and petrochemical plants typically consist of multiple production units, power distribution facilities, and equipment maintenance areas. Although all these areas may involve electrical safety risks, equipment configuration cannot follow exactly the same standards.

For example, main substations require a focus on medium- and high-voltage electrical operations, voltage testing, and temporary grounding; MCC rooms primarily involve the inspection and maintenance of motor feeders and low- and medium-voltage control equipment; while outdoor transformers and electrical facilities require consideration of insulation operating distances, grounding connections, and environmental conditions.

Therefore, the first step in developing an Equipment Schedule is to divide the plant site into specific electrical work zones and clearly define the primary tasks for each zone.

This table serves as a preliminary configuration framework and does not imply that every area requires all listed equipment. The final quantities and specifications should be determined based on electrical system diagrams, equipment inventories, operational risk assessments, and project technical specifications.

For projects with existing industry application solutions, refer to JINPOWER Petrochemical Plants & Oil Refineries to further determine the correspondence between different areas and product categories.

What electrical safety equipment should be installed in substations and medium-voltage switchgear rooms?

The Main Substation and the MV Switchgear Room are areas that require priority consideration in the configuration of electrical safety equipment at oil refineries.

These areas typically contain transformers, circuit breakers, busbars, switchgear, and related protective equipment. Maintenance personnel may need to perform tasks such as voltage verification, equipment isolation, temporary grounding, and electrical maintenance.

Electrical Insulating Mats: Electrical Insulating Mats

Insulating mats are primarily used at electrical operating locations that meet the applicable criteria to provide auxiliary electrical insulation protection for personnel on the standing surface.

In substations and medium-voltage switchgear rooms, the following areas should be prioritized for assessment:

• The area in front of medium-voltage switchgear operating panels.
• Work locations where personnel need to perform electrical inspections.
• Operating areas for transformers and related power distribution equipment.
• Designated standing areas requiring electrical maintenance.

The following must be confirmed during procurement:

IEC 61111:2026 is a key product standard for electrical insulating mats, applicable to mats made of flexible insulating materials. When purchasing, suitability should be verified based on the grades, operating conditions, and product test documentation specified in the standard.

For oil refineries, attention must also be paid to the potential effects of oil contamination, cleaning agents, and other chemicals on the rubber surface. A product’s oil resistance or slip-resistant properties alone do not guarantee that it meets electrical insulation requirements.

Similarly, standard chemical-resistant mats cannot directly replace electrical insulating mats that comply with IEC 61111 requirements.

JINPOWER offers Electrical Insulating Mats in various specifications; product configurations can be confirmed based on project voltage conditions, installation dimensions, and surface requirements.

Voltage Detectors: Voltage Detectors

Voltage detectors are used to confirm the presence of voltage in specified electrical equipment or conductors and are essential testing tools for electrical maintenance and equipment isolation management.

Purchasing personnel at substations and medium-voltage switchgear rooms should select appropriate equipment based on the system voltage and the target to be tested.

Key considerations:

• AC or DC system.
• Rated voltage and detection range.
• Detector operating principle and applicable standards.
• Contact or non-contact detection method.
• Insulated operating rod and connection interfaces.
• Functional verification methods.
• Product identification and test documentation.

It is important to note that the IEC 61243 series includes standards for different types of voltage detectors; a single part of the series cannot be directly applied to all testing equipment.

For example, IEC 61243-1:2021 applies to capacitive contact-type voltage detectors in the 1 kV to 800 kV AC range and does not cover all voltage detection technologies.

Therefore, procurement personnel must verify the applicable standard based on the actual type of detector, rather than simply requesting a single IEC standard number from the supplier.

For projects requiring high-voltage detection equipment, please refer to JINPOWER High Voltage Detectors, and select products based on voltage level, detection location, and operating conditions.

Portable Earthing Sets: Portable Temporary Earthing Devices

After completing the required electrical isolation and voltage verification, temporary earthing equipment may be used for earthing and short-circuit connections in accordance with an approved work plan.

Substation and switchgear areas in refineries may require different types of grounding clamps, grounding conductors, and operating rods.

When procuring equipment, focus on verifying the following:

• Expected short-circuit current.
• Fault current duration.
• Peak current withstand capacity.
• Grounding conductor material and cross-sectional area.
• Grounding conductor length.
• Compatibility between grounding clamps and equipment connection points.
• Length and connection configuration of insulated operating poles.

IEC 61230:2008 applies to portable temporary earthing and short-circuit equipment. This standard expresses the equipment’s short-circuit withstand capability in terms of parameters such as rated current, duration, and peak factor, and does not specify a universal rated voltage value.

Therefore, the specifications of grounding conductors cannot be determined solely based on the system voltage of the substation. Equipment configuration must also be confirmed in conjunction with the project’s short-circuit calculations and protection trip times.

For projects requiring the procurement of complete earthing equipment sets, please refer to JINPOWER Portable Earthing and Short Circuit Kits.

Insulating Gloves and Operating Poles: Insulating Gloves and Insulating Operating Poles

Insulated gloves should be selected based on the actual voltage of the electrical work, applicable standards, and personal protective requirements.

IEC 60903:2014 is a key product standard for electrical insulating gloves. Purchasing personnel should verify:

• Insulating glove rating.
• Size and comfort.
• Product identification and manufacturer information.
• Electrical test and re-inspection records.
• Storage and transportation conditions.
• Whether leather protective gloves are required.

Leather protective gloves are used to reduce the risk of mechanical damage to rubber insulated gloves; they are not a substitute for the insulated gloves themselves.

For insulated operating poles, the length and connection interfaces must be determined based on equipment voltage, operating distance, mechanical structure, and specific work tasks.

For situations requiring work in the vicinity of live parts, an assessment based on the work plan should also determine whether Electrical Insulating Blankets are needed as supplementary protection.

Related products:

• JINPOWER Electrical Insulating Gloves
• JINPOWER Electrical Insulating Blankets

Equipment Configuration for MCCs and Industrial Electrical Maintenance Workshops

Motor Control Centers (MCCs) and industrial electrical maintenance workshops are responsible for a significant portion of the routine inspection and maintenance tasks for motors and power distribution equipment.

Pumps, compressors, fans, and other rotating equipment in oil refineries typically rely on motors and associated control systems. Therefore, the configuration of safety equipment in the MCC area must account for the differences between low-voltage and medium-voltage motor feeders.

MCC Room: Motor Control Center

The equipment configuration in the MCC Room should be determined based on motor feeders, circuit breakers, control panels, and actual maintenance tasks.

It is important to note that MCC does not represent a uniform voltage rating.

Insulation protection requirements for low-voltage MCCs and medium-voltage motor control centers may differ. Specific products should be selected based on the equipment’s rated voltage, work tasks, and on-site safety procedures; a single insulation rating cannot be directly specified for the entire MCC room.

Additionally, the coverage area for electrical insulating mats should be determined based on the operating space around the cabinets and the actual standing positions of personnel; a uniform mat depth not supported by project documentation should not be used.

Electrical Maintenance Workshops: Electrical Maintenance Workshops

Maintenance workshops typically handle tasks such as inspecting insulated tools, repairing electrical equipment, managing PPE, and storing safety tools and equipment.

Equipment configuration in these areas focuses not only on the products themselves but also on the分类 management and condition tracking of tools.

Recommended Configuration:

• Insulated Hand Tools.
• Electrical Insulating Gloves.
• Voltage Detection Instruments.
• Electrical Insulating Blankets.
• Safety Equipment Storage Cabinets.

Different tools should be stored according to their intended use, rated specifications, inspection status, and the department using them.

For example, insulated operating poles, voltage detectors, and portable grounding devices should not be haphazardly stacked together to prevent surface damage, the mixing of accessories, or the inability to identify the condition of the equipment.

For products that require regular inspection or testing, such as insulated gloves and voltage detectors, it is recommended to establish separate asset numbers and inspection records.

JINPOWER offers Electrical Safety Tool Cabinets; cabinet configurations can be selected based on tool dimensions, the number of items, storage environment, and internal management requirements.

Equipment Requirements for Outdoor Electrical Facilities and Hazardous Areas

Outdoor electrical installations at oil refineries may include transformers, power distribution equipment, overhead lines, power supply facilities for pump stations, and other electrical installations.

Compared to indoor power distribution areas, outdoor operations must also account for rain, humidity, temperature fluctuations, dust, oil contamination, and equipment accessibility.

Outdoor Electrical Installations: Outdoor Electrical Facilities

For transformers and outdoor switchgear, it is recommended to evaluate the following equipment based on the specific work task:

For products intended for outdoor use, environmental suitability must also be verified.

For example, grounding wires and clamps must account for corrosion and mechanical damage at connection points; insulated operating poles must account for surface contamination, moisture exposure, and storage conditions; insulated gloves must be protected from prolonged exposure to sunlight, high temperatures, and inappropriate chemical environments.

For electrical safety equipment intended for use outdoors or in humid environments, suitability for all on-site conditions cannot be determined solely based on indoor test results.

Hazardous Areas: Applicability Boundaries for Equipment in Hazardous Areas

Petrochemical plants and refineries may contain flammable gases, vapors, and combustible dust, so equipment must be selected based on the results of hazardous area classifications.

For explosive gas atmospheres, common zone classifications include Zone 0, Zone 1, and Zone 2. Specific classifications should be assessed based on the on-site combustible substances, sources of release, and ventilation conditions.

Purchasing personnel must clearly distinguish between two distinct types of technical requirements:

Electrical Insulation Protection: Electrical Insulation Protection

This primarily addresses the risk of electric shock when personnel come into contact with electrical equipment and involves items such as insulating mats, insulated gloves, insulated operating rods, and temporary grounding equipment.

Explosion Protection: Protection for Explosive Atmospheres

This primarily concerns the structure, protection type, marking, and certification requirements for equipment in specific explosive atmospheres.

These two types of protection are not interchangeable.

For electrical equipment and portable instruments in hazardous areas, verify the equipment’s protection type, gas group, temperature class, equipment protection level (EPL), and scope of certification in accordance with the project’s hazardous area classification and the applicable IEC 60079 series requirements.

Key considerations during procurement:

• Whether the equipment is approved for use in the specified hazardous area.
• Whether it holds the ATEX or IECEx certifications required by the project.
• Whether the product nameplate and certificates match the actual model.
• Whether the equipment meets the requirements for the corresponding gas or dust environments.
• Whether use and maintenance comply with on-site management procedures.

For standard Electrical Insulating Mats, Insulating Gloves, and Portable Earthing Sets, compliance with electrical insulation standards alone does not constitute proof of explosion-proof certification or authorization for use in all hazardous areas.

It is also necessary to distinguish between three types of flooring materials:

If a hazardous area also poses a risk of electrostatic charge buildup, a suitable electrostatic control solution must be selected based on an electrostatic risk assessment.

ESD products that require grounding must not be used indiscriminately in areas requiring electrical insulation protection, nor should standard insulating mats be treated as a validated electrostatic control system.

How to Develop an Electrical Safety Equipment Procurement List for EPC Projects?

For EPC contractors, refinery operators, and industrial equipment procurement departments, it is recommended to establish a standardized Electrical Safety Equipment Schedule prior to issuing requests for quotation.

This list should not only include product names and purchase quantities but also document the product’s intended use areas, operational tasks, technical specifications, applicable standards, and acceptance documentation.

Establishing a Correspondence Between Areas and Equipment

It is recommended to use the following configuration table as the basis for project procurement:

The documents listed in the table are procurement audit recommendations and do not imply that all products must provide exactly the same certification documents. Specific requirements should be determined in accordance with product standards and project specifications.

Confirm the key technical parameters for each product

The most common issue in procurement lists is listing only the product name and quantity without specifying the actual conditions of use.

For example:

• Listed only as “Electrical Insulating Mat,” without specifying the IEC class, dimensions, or intended use.
• Listed only as “High Voltage Detector,” without specifying AC/DC or the detection voltage range.
• Listed only as “Portable Earthing Set,” without providing fault current and duration.
• Listing only “Insulating Gloves” without specifying the IEC 60903 class and size.
• Listing only “Storage Cabinet” without specifying which tools need to be stored or their dimensions.

This information is insufficient to support accurate supplier quotes and technical reviews.

It is recommended that at least the following details be specified for each product:

Product Identification Information: Product Name, Model, Quantity, Installation Area.

Electrical Parameters: Rated Voltage, AC/DC Application, Electrical Class, Short-Circuit Rating (if applicable).

Structural Parameters: Dimensions, Cable Length, Cross-Section, Clamp Type, Operating Pole Length.

Environmental Conditions: Temperature, Humidity, Chemical Exposure, Indoor/Outdoor Installation.

Quality Documentation: Applicable Standard, Test Report, Product Marking, Batch Traceability.

Preparing EPC Technical Submission Documents

For large-scale refineries and petrochemical projects, product technical documentation typically requires review by engineering, procurement, quality, and safety departments.

It is recommended to prepare the following during the procurement phase:

• Technical Datasheet.
• Product Catalog.
• Applicable Standard and Edition.
• Type Test Report.
• Factory Test Report (if applicable).
• Certificate of Conformity (if required by the project) .
• Product Identification and Marking Information.
• Batch Traceability Information.
• Operation and Maintenance Instructions.
• Inspection and Testing Records (if applicable).
• Ex Certification (applicable only to equipment requiring explosion-proof certification).
• Technical Deviation List.

It is particularly important to note that test reports must correspond to the actual product models and configurations being supplied. Test reports for one specific product model cannot be used to directly demonstrate that products of other models, thicknesses, or structures meet the same requirements.

If the project involves special technical specifications, a Compliance Matrix should be established in advance to map each technical requirement to the corresponding product documentation and test evidence.

For projects requiring a complete technical submission package, please refer to JINPOWER’s Electrical Safety Equipment Technical Submittal Package Guide.

Establishing Equipment Storage and Traceability Management Mechanisms

The procurement of electrical safety equipment should not end upon product delivery.

Refineries typically have multiple maintenance crews, power distribution areas, and equipment management departments. If the insulated tools and testing equipment used in different areas are not managed uniformly, issues such as equipment mix-ups, unclear inspection statuses, and missing records are likely to arise.

It is recommended to establish the following management information:

For products requiring inspection or testing—such as insulated gloves, electroscopes, and portable grounding equipment—management cycles should be established in accordance with relevant standards, manufacturer requirements, and project regulations.

Equipment storage cabinets should be configured based on product dimensions, environmental conditions, and management processes. Standard storage cabinets should not automatically be considered explosion-proof cabinets suitable for hazardous areas; their installation locations and equipment certifications must be verified separately.

Conclusion: Establish a procurement list based on areas, work tasks, and technical specifications

When developing an electrical safety equipment configuration list for refineries and petrochemical plants, products should not simply be listed by category. Instead, the list should be based on actual electrical operations, establishing a correspondence between equipment areas, maintenance tasks, product performance, and technical documentation.

For substations and medium-voltage switchgear rooms, priority should be given to Electrical Insulating Mats, Voltage Detectors, and Portable Earthing Sets; MCCs and maintenance workshops require insulated tools, insulated gloves, and testing equipment configured for low- and medium-voltage electrical work; outdoor electrical facilities require further consideration of operating distances, grounding connections, and environmental adaptability.

For hazardous areas, the explosion-proof suitability of equipment must be verified separately; electrical insulation performance, antistatic performance, and explosion-proof certification must not be conflated.

JINPOWER provides electrical insulating mats, voltage detectors, portable earthing sets, insulated gloves, insulating blankets, and storage equipment for electrical safety tools. Based on the equipment lists, technical specifications, operating environments, and procurement requirements for refineries and petrochemical projects, we can assist in confirming the appropriate product specifications and supporting technical documentation.

For EPC contractors, refinery operators, and industrial electrical equipment distributors, we recommend providing the equipment category, area of use, rated voltage, quantity of products, and project technical specifications when requesting a quote to facilitate more accurate product configuration and technical review.