Custom Electrical Panels for Oil and Gas: Enhancing Reliability

In the demanding environments of oil and gas operations, electrical systems must stand up to extreme conditions while supporting complex processes. Custom electrical panels play a critical role in these environments, controlling equipment, providing data insights, and safeguarding both personnel and infrastructure.

At Smith Industries, we take a customer-centered approach to designing custom electrical panels for oil and gas, combining advanced technologies, compliance-driven design, and close collaboration with clients to meet their exact operational needs.

The Importance of Custom Panels in Oil and Gas Operations

Oil and gas facilities, whether upstream, midstream, or downstream, face several electrical challenges. Equipment often operates in hazardous, remote, and high-stress settings.

Standard off-the-shelf panels are rarely suitable for these demanding applications.

Custom electrical panels allow operators to address site-specific requirements, such as:

• Hazardous area classifications (Class I, Division 1 & 2)

• Extreme temperatures and humidity

• High vibration or corrosive atmospheres

• Critical system redundancy

• Remote monitoring and control capabilities

By working with experienced fabricators like Smith Industries, oil and gas companies gain control panels engineered for their precise needs, ensuring operational continuity and workforce safety.

Meeting Industry Standards and Regulations

Compliance is at the heart of every electrical panel built for oil and gas. Custom panels must meet not only company-specific requirements but also national safety codes and industry standards.

Organizations such as the Occupational Safety and Health Administration (OSHA) and the National Fire Protection Association (NFPA) establish requirements that guide the design, fabrication, and installation of electrical panels in hazardous environments. OSHA emphasizes electrical safety in oil and gas operations under 29 CFR 1910 Subpart S, which outlines standards for electrical installations, grounding, and hazard protection.

NFPA 70 (National Electrical Code) provides additional guidelines, including provisions for hazardous locations, explosion-proof equipment, and wiring methods suited for oil and gas settings. By aligning with these and other regulations, Smith Industries delivers panels that protect both people and property.

Our Collaborative Process for Custom Panels

Every custom electrical panel project at Smith Industries starts with a deep understanding of the customer's facility, processes, and risks. Our collaborative process ensures that panels are engineered to fit not only the equipment they support but also the environmental, spatial, and operational realities of the site.

Key Steps in Our Panel Development Process

1. Requirements Gathering

   • Site evaluations, drawings, and stakeholder interviews inform the initial concept.

   • We review existing processes and future expansion plans to build panels that scale with the operation.

2. Design Engineering

   • Our team uses advanced CAD software and modeling tools to develop a panel design that meets the operational, safety, and compliance requirements.

   • Smart technologies, such as PLCs, HMIs, and IoT integration, are incorporated when applicable.

3. Material Selection and Specification

   • Panels are built with materials rated for the environment, including NEMA 4X stainless steel enclosures, explosion-proof components, and corrosion-resistant finishes.

4. Fabrication and Assembly

   • Smith Industries fabricates panels in-house, controlling quality at every step.

   • All wiring, labeling, and assembly follow best practices to promote reliability and maintainability.

5. Factory Acceptance Testing (FAT)

   • Panels undergo rigorous FAT procedures to verify functionality, safety, and compliance before shipping.

6. Installation Support and Commissioning

   • Our team provides field installation assistance and commissioning support, helping operators bring the panels online smoothly.

   
   

The Role of Smart Technologies in Modern Panels

Today's oil and gas facilities demand more than just basic control. Custom electrical panels now support data acquisition, remote operation, and predictive maintenance. Smith Industries integrates smart technologies that allow operators to monitor performance metrics, receive alerts, and even control equipment from centralized control rooms or mobile devices.

This level of visibility drives faster decision-making and allows operators to address issues before they escalate into costly failures.

Built for Harsh and Remote Environments

Oil and gas facilities often operate in some of the most challenging conditions. Whether a panel is destined for a Permian Basin drilling rig, or a Gulf Coast refinery, it must withstand punishing environments.

Our panels are designed with these realities in mind. Features include:

• Explosion-proof enclosures

• NEMA and IP-rated protection against dust, water, and corrosives

• Heavy-duty climate controls for freezing or high-heat areas

• Reinforced cable entries and vibration-resistant mounting systems

By anticipating the environmental hazards, we build panels that deliver reliable performance year after year, reducing maintenance needs and extending system lifecycles.

Supporting Safety Through Thoughtful Design

Electrical hazards remain one of the top safety concerns in oil and gas, accounting for serious injuries and fatalities each year. According to OSHA, arc flash, shock, and electrocution are significant risks when electrical panels are poorly designed or improperly maintained. Industries prioritize safety through:

• Clear labeling and isolation of circuits

• Integrated safety interlocks and ground fault protection

• Ergonomic layouts that promote easy maintenance and troubleshooting

• Compliance with NEC, NFPA 70E, and applicable local codes

Our approach gives operators confidence that their panels are safe to operate, inspect, and maintain.

When to Consider Upgrading Your Electrical Panels

Many oil and gas facilities still operate with legacy panels that no longer meet current safety codes or support modern technologies. Signs that it may be time to consider a custom panel upgrade include:

• Frequent equipment failures tied to panel malfunctions

• Inability to integrate panels into SCADA or DCS systems

• Lack of redundancy or safety features

• Non-compliance with current NEC or OSHA standards

Smith Industries offers upgrade and retrofit services that allow facilities to modernize their panels without costly shutdowns.

Conclusion: Custom Panels as Part of Operational Excellence

For oil and gas operators looking to improve safety, efficiency, and control, custom electrical panels provide a high-return investment. Smith Industries works closely with clients to develop panels that go beyond basic control functions, helping to safeguard operations, reduce downtime, and support long-term performance goals.

Through our collaborative process, in-house capabilities, and commitment to quality, Smith Industries delivers custom electrical panels for oil and gas that support your mission-critical operations with confidence.