Arc Flash for Manufacturing Safety: A Compliance and Safety Guide for Plant Managers
- Stephen Fike
- Oct 10
- 4 min read
Arc Flash: The Hidden Threat in Manufacturing Facilities
In high-energy industrial environments, few hazards are as sudden — or as catastrophic — as an arc flash.
With temperatures exceeding 35,000°F (hotter than the surface of the sun) and explosive pressure waves strong enough to melt metal, an arc flash event can devastate equipment, injure personnel, and halt operations in seconds.
For plant managers overseeing complex electrical systems, understanding and mitigating arc flash risk isn’t just a best practice — it’s a legal and ethical obligation.
At Assured NDT, we conduct arc flash studies that help manufacturing plants comply with OSHA and NFPA 70E standards while ensuring your workforce has the knowledge, labeling, and protection required to stay safe.
What Is an Arc Flash — and Why Does It Happen?
An arc flash is a sudden release of electrical energy caused by a fault that allows current to travel through the air rather than its intended path.
Common causes include:
Loose or corroded electrical connections
Faulty or aging switchgear
Inadequate PPE or unsafe work practices
Accidental contact during energized maintenance
The consequences can be severe:
Severe burns or fatalities
Equipment and facility damage
Fire or explosion risk
Costly downtime and OSHA investigations
Arc flashes aren’t rare — they’re preventable. The key is to identify risk factors before they lead to failure.
Why Arc Flash Safety Matters in Manufacturing
Manufacturing facilities typically run medium- to high-voltage electrical systems, operate around the clock, and depend heavily on uptime. This makes them especially vulnerable to the consequences of electrical failures.
Regulatory standards like OSHA 29 CFR 1910 Subpart S and NFPA 70E require employers to:
Identify arc flash hazards and calculate incident energy
Label equipment with appropriate warnings and PPE categories
Train workers on safe work practices and PPE selection
Failure to comply can lead to:
OSHA fines and regulatory penalties
Equipment loss and production interruptions
Worker injuries or fatalities
Legal liability and reputational harm
A professional arc flash study from Assured NDT ensures compliance, improves safety, and strengthens your facility’s risk management posture. Arc Flash studies for manufacturing safety is critical.
Step-by-Step: The Arc Flash Study Process
Here’s how Assured NDT delivers comprehensive, NFPA 70E-compliant arc flash studies:
Data Collection
Our engineers begin with an on-site review of your electrical distribution system, collecting data such as:
Transformer ratings and panel schedules
Breaker and fuse settings
One-line diagrams and system voltages
We verify drawings, labels, and configurations to ensure every component is accurately represented.
Short Circuit & Coordination Analysis
Using specialized power system modeling software, we calculate the available fault current at each point in your system and analyze coordination between breakers and fuses.
Goal: Ensure protective devices isolate faults quickly and selectively — reducing arc energy and preventing system-wide outages.
Incident Energy Calculations
Based on IEEE 1584 standards, we calculate the potential energy release at each piece of equipment and determine:
Arc flash boundary distance
Minimum PPE category
Safe working distances
These results form the foundation for your plant’s PPE requirements and electrical safety training.
Arc Flash Labeling
We produce and install custom, NFPA 70E-compliant warning labels for all relevant equipment. Each label clearly displays:
Voltage and incident energy (cal/cm²)
Arc flash boundary
PPE category and working distance
Proper labeling gives workers immediate, critical safety information at the point of risk.
Final Report & Compliance Recommendations
AssuredNDT provides a detailed report that includes:
System models and analysis results
Arc flash boundaries and PPE recommendations
Coordination and fault analysis summaries
Compliance deficiencies and corrective actions
We also provide training sessions to help your personnel understand labeling, safe work practices, and regulatory responsibilities.
Why Partner with AssuredNDT for Arc Flash Studies
Our difference lies in precision, professionalism, and purpose.
Certified Electrical Engineers – experienced in manufacturing and heavy industry
Turnkey Compliance Solutions – from data collection to labeling
NFPA 70E & OSHA Alignment – audit-ready reports and documentation
Budget-Minded PPE Recommendations – safety without overspending
Fast Turnaround – so you can act quickly on critical findings
Our clients include manufacturers across the U.S. — from automotive to pharmaceuticals — who trust Assured NDT to make electrical safety practical, affordable, and effective.
The Bottom Line: Don’t Wait for a Flashpoint
An arc flash isn’t just an electrical event — it’s a life-altering incident that can shut down production and devastate your workforce.
By performing a professional arc flash study, you can:
Don’t leave safety to chance.Schedule an arc flash risk assessment with Assured NDT and bring clarity — and compliance — to your electrical safety program.
Frequently Asked Questions About Arc Flash Safety in Manufacturing
1. What is the purpose of an arc flash study?
An arc flash study evaluates your electrical system to determine potential incident energy levels, PPE requirements, and labeling needs. It ensures compliance with NFPA 70E and OSHA 1910 Subpart S, helping protect workers and equipment.
2. How often should arc flash studies be updated?
Arc flash studies should be reviewed at least every 5 years, or sooner if major electrical system changes occur — such as new equipment installations, breaker upgrades, or distribution redesigns.
3. What standards govern arc flash compliance?
The key standards include:
NFPA 70E – Electrical Safety in the Workplace
OSHA 29 CFR 1910 Subpart S – Electrical Safety Requirements
IEEE 1584 – Arc Flash Calculation Methodology
These ensure your facility identifies hazards, labels equipment, and provides proper PPE.
4. What information is needed to perform an arc flash study?
You’ll need:
Up-to-date one-line diagrams
Breaker and fuse settings
Transformer data
Panel schedules and system voltages
Assured NDT collects and verifies this data as part of every study.
5. How does an arc flash study improve plant safety?
By calculating incident energy and arc flash boundaries, a study ensures your team uses the correct PPE and safe work practices. This drastically reduces the chance of electrical injuries or fatalities.
6. What are common causes of arc flash incidents?
Common causes include dust buildup, corroded connections, human error during energized work, or aged equipment. Regular maintenance and updated labeling reduce these risks significantly.
7. How can Assured NDT help with arc flash compliance?
Assured NDT provides turnkey arc flash studies, system modeling, labeling, PPE recommendations, and staff training — ensuring full compliance with OSHA and NFPA 70E while minimizing downtime and cost.
Contact Assured NDT to schedule your arc flash compliance study:
