Industry · refining, petrochemical, chemical
Refinery arc flash study planned around your turnaround, not your throughput
US arc flash studies, PE-reviewed, quoted in 24 hours. Built for units that cannot stop on our schedule.
- PE-reviewed
- Built on current NFPA 70E-2027
- IEEE 1584-2018
- Field engineers travel to every US state
- Written quote in 24 hours
A refinery arc flash study models the plant's medium and low voltage system, from the utility tie and cogeneration to every unit substation and motor control center, and sets incident energy, boundaries and PPE at each bus. AFSC collects data before your turnaround and installs labels while units are down, so production never pays for safety.
Why now
The moment to buy is before the turnaround plan freezes
Turnaround scopes lock months ahead. If the study is not in the plan, cover-off verification and label installation wait for the next outage, and the labels on your gear stay out of date for years. Book it while the turnaround team is still adding work packages.
Hazards and governing standards in process plants
| Reference | Why it matters here |
|---|---|
| NFPA 70E-2027 | Arc flash risk assessment, labels and PPE for every electrical task |
| IEEE 1584-2018 | Incident energy calculation for systems from 208 V to 15 kV |
| OSHA 29 CFR 1910.119 | Process safety management: electrical changes go through management of change |
| NEC (NFPA 70) Articles 500 and 505 | Classified locations change what equipment can be opened and how |
Typical scope and equipment in a refinery study
Process plants run more medium voltage than most sites, with large motors that add fault current, and switchgear spread across unit substations. Our scope covers each of them and the paths between.
| Equipment | What we model and label |
|---|---|
| Utility tie and main substation | Source fault current at kV level, main breakers and relays |
| Cogeneration and large motors | Their contribution to fault current at nearby buses |
| Unit substations | Medium voltage switchgear and transformers serving each unit |
| Motor control centers | Each bucket feeding pumps, compressors and fans at 480 V |
| Control and instrument power | UPS and distribution panels in control rooms |
Turnaround dates are fixed. Book the study to match.
Send the turnaround window and the unit list. We return a fixed price and a field plan that fits inside it within one business day.
What a typical project looks like
Illustrative scenario, no client named and no figures claimed: a Gulf Coast refinery books an update while its turnaround plan is still open. Field engineers walk down energized gear from outside the enclosures, the model is finished before units come down, cover-off checks happen during the outage, and labels are fixed to the gear before restart.
Petrochemical arc flash study, where the motors drive the numbers
A petrochemical arc flash study has to account for large induction motors, which feed fault current back into the system for the first cycles of a fault. Ignore them and incident energy at nearby switchgear is understated. We model every motor above the threshold that matters and confirm its data in the field.
Chemical plant arc flash study in classified areas
A chemical plant arc flash study has to respect hazardous area classification. Some equipment cannot be opened without a gas test and a hot work permit, so data collection is planned with operations, and labels are chosen for the chemicals and washdown in each area. We fit our work into your permit system, not around it.
Oil and gas arc flash study for upstream and midstream sites
An oil and gas arc flash study covers compressor stations, terminals and pipeline facilities as well as refineries. Sites are often remote and lightly staffed, so we plan field days around operator availability and bring every label needed to finish in one visit. Results come with the same PE review as plant work.
Frequently asked questions
Question not here? Ask an engineer
How is an arc flash study done at a refinery without a shutdown?
Most of it is done with units running. Engineers read nameplates and relay settings from outside enclosures in the right PPE, and records fill many gaps. Only the few items that need a cover removed wait for a planned outage or turnaround. The model and report are ready before units come down.
Does management of change apply to the arc flash study?
Yes, it can. Under OSHA process safety management, electrical changes in a covered process go through management of change. A new transformer or new relay settings should trigger a review of the arc flash values, and the study gives your MOC team the numbers to sign off.
Can you work under our contractor safety program?
Yes. Our field engineers complete your site orientation, follow your permit and lockout procedures, and carry the PPE your rules require. Send your contractor requirements with the quote request and we confirm compliance in the proposal, before anyone arrives at the gate.
How do you handle classified areas?
We plan around them. Equipment in classified areas is surveyed from outside wherever possible; anything that must be opened is scheduled with operations under your gas testing and hot work rules. Labels are chosen to suit the chemical exposure and cleaning regime in each area.
What does a refinery study cost?
Cost depends on the number of buses, the medium voltage scope and how much of the system needs verification in the field. Send your one-line diagram and unit list and we return a fixed written price within 24 hours, with a field plan matched to your turnaround window.
Do you include the cogeneration plant?
Yes, if it connects to the plant system. Generators contribute fault current and change incident energy across the site, so leaving them out understates the hazard. We model each operating mode that matters, such as islanded and grid-tied, and report the worst case at each bus.
Get your arc flash study quoted
Tell us about your facility. An engineer replies within one business day with scope, timeline and price.
- IEEE 1584-2018 and NFPA 70E-2027, PE-reviewed
- Labels and training in the same scope
- Field engineers travel to any US state