Why Fire‑Resistant Cables Are Important in Indonesian Oil Refineries: Pertamina Case Studies and Technical Guide

Introduction

In the midst of rapid growth in the Indonesian oil & gas industry, Pertamina‑operated oil refineries have become the backbone of national energy resilience. However, refinery operational environments are filled with constant fire and explosion hazards due to the presence of highly flammable hydrocarbons, high pressures, and extreme temperatures. This is where fire‑resistant cables play a crucial role as an integral part of modern safety systems.

This article is designed specifically for cable dealers, procurement decision makers, technicians, and engineers in the oil & gas sector. You will gain a deep understanding of the definition of fire‑resistant cables, real applications at Pertamina facilities, why ordinary cables are insufficient from a technical perspective, international standard requirements, practical selection guidance, and maintenance tips.

By following this guide, you can minimize downtime risk, protect worker safety, and comply with Indonesian oil & gas safety regulations.

What Is a Fire‑Resistant Cable?

A fire‑resistant cable is a specialized electrical cable designed to maintain electrical circuit integrity when exposed to heat or flame in fire conditions. Unlike ordinary cables that fail quickly as temperatures rise, fire‑resistant cables continue to carry power long enough for safety and control systems to operate.

The difference with heat‑resistant or flame‑retardant cables:

• Heat‑resistant cables tolerate higher operational temperatures but do not ensure circuit functionality in a fire.

• Flame‑retardant cables (IEC 60332) only prevent flame propagation and do not guarantee ongoing electrical function.

• Fire‑resistant cables are tested for circuit integrity under fire (e.g., IEC 60331 and BS 6387).

Key Characteristics of Fire‑Resistant Cables:

• High‑temperature insulation materials: XLPE, EPR, or silicone rubber

• Heat barrier: mica tape or mica‑glass tape that forms a protective ceramic layer during combustion

• Outer jacket: Low Smoke Zero Halogen (LSZH/LS0H) to reduce toxic smoke and corrosive gases

• Tested per circuit integrity standards such as IEC 60331 (750–830 °C for 90–180 min) and BS 6387 (e.g., CWZ: fire at 950 °C for 180 min with water spray and mechanical shock)

In hydrocarbon environments, fires often involve water spray from suppression systems and structural vibration. LSZH jackets prevent poisonous smoke in confined spaces, while circuit integrity ensures fire pumps, alarms, and emergency shutdown valves remain operational—buying critical evacuation and mitigation time.

Case Studies: Pertamina Oil Refineries

As Indonesia’s main refinery operator, Pertamina has adopted fire‑resistant cables in major system upgrades.

In these facilities, fire‑resistant cables have been used for:

• Fire detection & alarm systems: connecting smoke detectors, H₂S/CH₄ gas sensors, and alarm panels to control rooms

• During the Dumai October 2025 incident, reliable detection enabled rapid response

• Emergency fire pump control: power circuits that must stay alive even as fire spreads

• Control room & communication lines: SCADA, PLC, and safety communications

• Critical power & equipment lines: emergency power to ESD (Emergency Shutdown) valves and critical compressors

In another example, the Cilacap February 2025 fire triggered by tank sludge during maintenance highlighted that without fire‑resistant cables, electrical sparks from regular cables can worsen an incident.

High‑quality fire‑resistant cables used in Dumai were designed for refinery conditions with hydrocarbon resistance, multilayer chemical barriers, and fire resistance up to 1050 °C for 6 hours on ultra‑performance variants such as Prysmian Seaflame™.

These applications prove that fire‑resistant cables are not an additional cost but an investment that prevents billions in production losses due to downtime.

Why Are Fire‑Resistant Cables Needed in Oil Refineries?

In refineries processing crude oil into fuels and petrochemicals, fire risks reach extreme levels. Key reasons include:

1. Ensuring Worker Safety
   During a fire, fire‑resistant cables keep emergency lighting, evacuation alarms, and communications online. In Dumai 2025, this enabled safe and rapid evacuation without casualties.

2. Preventing Escalation
   Ordinary cables can melt within 5–10 minutes, causing ESD failure. As a result, valves may remain open, fire pumps shut down, and fire spread to other units. Fire‑resistant cables provide a “golden time” of 90–180 minutes for staggered safe shutdown.

3. Maintaining Critical Production & Control Systems
   SCADA, PLC, and power circuits remain online. In oil & gas industries, one hour of downtime can cause millions in losses. Indonesian Oil & Gas Directorate regulations and API/IEC standards require circuit integrity in high‑risk facilities.

Thus, fire‑resistant cables are a core safety system element supporting continuous operation in Indonesia’s oil & gas sector.

Technical Requirements for Fire‑Resistant Cables

Major International Standards:

• IEC 60331‑21/1/2: fire tests 750–830 °C plus mechanical shock; circuit integrity 90–180 min

• BS 6387 CWZ:

  C: 950 °C fire 180 min

  W: fire + water spray 15 min

  Z: fire + mechanical shock 15 min

• Additional standards: IEC 61034 (low smoke), IEC 60754 (zero halogen), UL 1709 (hydrocarbon pool fire for refineries)

Cable Structure & Materials

• Conductor: Copper (IEC 60228 Class 2)

• Fire barrier: mica glass tape

• Insulation: XLPE/EPR/Silicone rubber

• Inner sheath: LSZH

• Chemical barrier: lead or multilayer composite resistant to oil/hydrocarbons

• Armour: Steel Wire Armour (SWA) for mechanical protection

• Outer sheath: LSZH resistant to UV, hydrocarbons, chemicals, and Indo‑tropical climates (-15 °C to +90 °C)

Additional resilience includes resistance to water spray, mechanical impact, chemical corrosion, and refinery vibrations, with high flexibility for installation in cable trays or trenches. All products must be certified to SNI + IEC/BS and pass Pertamina audits.

Cables Selection Guide (Practical)

Practical steps for selecting fire‑resistant cables:

1. By Function:

   Power cables (0.6/1 kV): fire pumps, critical motors

   Control cables: PLC, valve actuators

   Instrumentation cables (shielded): gas/temperature sensors

2. Rated Voltage & Fire Duration:

   PH 60/PH 120 (60–120 min) for general use; BS 6387 CWZ for refinery high‑risk zones

3. Match Environment:

   High‑risk zones (Zone 1/2): add chemical barrier + SWA

   Indonesian tropics: LSZH + rodent/termite protection

FAQ & Practical Tips

Q: Are fire‑resistant cables the same as heat‑resistant cables?
A: No. Heat‑resistant cables tolerate higher operational temperatures; fire‑resistant cables guarantee circuit integrity in fire conditions (IEC 60331).

Q: How long will fire‑resistant cables function in a fire?
A: 90–180 minutes per IEC/BS standards, or up to 6 hours on ultra variants. In the Dumai 2025 incident, this time was critical for firefighting.

Q: How to maintain cables in oil refinery environments?
A: Annual visual inspection, insulation resistance testing, avoid mechanical impact, use dedicated cable trays, apply ablative coatings when retrofitting. Store cables in dry warehouses away from hydrocarbons.

Additional Tips:

• Always conduct a HAZOP risk assessment before installation

• Integrate with modern fire suppression systems

• Train maintenance teams to identify fire‑resistant cables (often marked “FR” or “Fire Resistant”)

Conclusion

Fire‑resistant cables are no longer optional but a necessity in Pertamina’s oil refineries and throughout Indonesia’s oil & gas industry. The Dumai and Cilacap case studies demonstrate that investing in high‑quality cables per IEC 60331 and BS 6387 standards can save lives, assets, and national production continuity.

For engineers and procurement teams, choose products that meet the highest standards, resist tropical environments, and are supplied by reputable manufacturers such as Prysmian. This ensures not only regulatory compliance but also enhanced competitiveness for Indonesian refineries on the global stage.