Arc Flash Study – Understand the Full Process

By R.W. Hurst, Editor

An arc flash study is essential for ensuring workplace electrical safety and minimizing the risk of serious injury. It combines multiple layers of analysis to identify potential hazards, calculate incident energy levels, and establish the appropriate protective boundaries and personal protective equipment (PPE) requirements.

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To perform a complete assessment, you must first conduct an in-depth arc flash analysis, which includes identifying fault current, arc duration, and working distance. This forms the basis for calculating the incident energy — the thermal energy released during an arc fault — which is crucial for evaluating the risk level and selecting the appropriate level of arc-rated personal protective equipment (PPE).

To perform an electrical risk evaluation that meets compliance standards and protects workers, organizations must follow a structured approach grounded in IEEE 1584-2018. This methodology provides the framework for accurate calculations based on factors such as fault current, working distance, and arc duration. As part of a thorough electrical risk assessment, facilities must evaluate every piece of electrical equipment to determine potential exposure to hazardous energy. One of the key outcomes of this process is identifying the level of arc flash PPE required for each task, ensuring workers are equipped with the proper personal protective equipment (PPE) based on actual incident energy levels.

A full assessment not only enhances worker safety, it also fulfills your legal and regulatory responsibilities under standards like NFPA 70E and CSA Z462. Facilities that proactively manage electrical hazards reduce the risk of downtime, injury, fines, and insurance complications. By investing in this evaluation, you are taking measurable steps toward reducing risk and ensuring compliance.

Key Components of an Arc Flash Study

Short Circuit Study
This step determines available fault current and ensures that all protective devices are properly rated. Fault current levels are a foundation for both incident energy analysis and labeling requirements.

A short circuit study also identifies system weaknesses that could trigger excessive fault conditions, helping engineers properly size and coordinate breakers and fuses. This enhances system reliability and reduces the impact of outages when faults occur.
Protective Device Coordination Study
This analysis ensures that fuses, breakers, and relays operate in a sequence that limits arc energy and reduces equipment damage and personnel exposure.

Proper coordination not only minimizes electrical hazard exposure but also prevents nuisance tripping and partial blackouts. This is especially crucial in critical environments, such as hospitals, data centers, and manufacturing facilities, where operational continuity is paramount.
Arc Flash Risk Assessment
The arc flash risk assessment evaluates the probability of an arc event occurring at each point in the system. It identifies tasks that require mitigation steps and establishes safety protocols that align with NFPA 70E and CSA Z462 standards.

This process extends beyond raw data — it also involves evaluating human factors, maintenance practices, and equipment condition. By considering real-world conditions, the assessment helps you prioritize risk mitigation where it’s needed most.
Arc Flash Hazard Analysis
The arc flash hazard analysis involves calculating incident energy at various locations and establishing boundaries. This determines safe working distances and the level of PPE required.

It’s during this phase that labeling requirements are established, and decisions are made about barriers, remote switching, and alternative work methods. This ensures your team is equipped with actionable data, not just technical jargon.
Equipment Labeling and Documentation
Based on your findings, you will apply labels to the affected equipment. These labels must display boundary distances, fault current, incident energy, and required PPE. For more information on requirements, see our Arc Flash Study Requirements Guide.

Accurate labeling ensures workers instantly understand the hazards present and how to protect themselves. Labels must be durable, legible, and consistently formatted across your facility to ensure maximum clarity and compliance.

Who Should Conduct the Study?

A qualified electrical engineer with experience in system modeling, protective coordination, and electrical hazard analysis should perform the arc energy assessment. Their expertise ensures that your facility’s data is correctly interpreted and your findings are defensible in compliance audits.

Third-party engineering consultants or certified safety professionals often bring the added benefit of neutrality. Their objectivity, combined with advanced software tools, ensures your assessment meets technical standards and provides a trustworthy foundation for worker protection.

Why Do You Need an Arc Flash Study?

Your electrical system is constantly evolving. Equipment upgrades, layout changes, or service additions can shift fault current values or protective device settings. If left unchecked, these changes increase the risk of catastrophic failures.

Without a current assessment, your labelling and PPE requirements may be dangerously outdated. Even minor changes in upstream service capacity or breaker settings can significantly affect incident energy levels and boundary distances. Regular studies ensure that your program evolves in tandem with your system. Calculations should follow the IEEE 1584-2018 standard to ensure accurate results based on fault current, working distance, and system configuration. Selecting the appropriate arc-rated PPE is essential for protecting workers against thermal hazards identified in the electrical risk evaluation.

Beyond calculations, compliance involves meeting strict NFPA 70E label requirements. These labels must display critical safety information, including incident energy values, boundary, and the required protection devices that mitigate risks. Labels help ensure that qualified personnel can make informed decisions before working on or near energized electrical equipment. A comprehensive arc flash study not only supports label accuracy but also aligns with broader goals of safety culture, regulatory compliance, and operational reliability. By integrating all components—risk assessment, arc-rated PPE, calculations, and labeling—a facility significantly reduces the potential for injury and electrical system failure.

How Often Should a Hazard Study Be Performed?

The NFPA 70E standard recommends updating your arc flash study:

At least every five years
Any time system modifications are made
After fault current capacity changes
When safety standards or PPE categories are updated

Failing to update your assessment can expose workers to unexpected hazards and leave your organization liable in the event of an accident. A simple equipment upgrade or renovation can drastically change your system’s dynamics — periodic review is not just a formality, it's essential.

Don't Forget Training

Even the best analysis is useless without qualified workers. Proper training ensures that your staff understands the results of your arc flash study and how to respond. Our arc flash analysis training course prepares your team to interpret assessment data, apply labels, and use PPE effectively.

Training also reinforces a culture of safety. When workers understand the “why” behind PPE, labeling, and procedures, they’re more likely to comply and make safer decisions on the job. Ongoing education supports long-term risk reduction.

Take the Next Step

If you're ready to build or update your arc flash study, our resources can help:

Start with our incident energy analysis guide.
Review how to set safe distances in our arc flash boundary overview.
Learn how OSHA requirements apply on our OSHA Electrical Safety page.

Or get in touch to request a group training quotation tailored to your facility.

An arc flash study is more than just a compliance task—it’s a proactive measure that saves lives and protects infrastructure. The Electricity Forum is here to help you stay safe, informed, and fully prepared.