How Does an Arc Flash Study Improve Electrical Safety?
- Stephen Fike
- Dec 4
- 4 min read
Arc flash events are among the most dangerous electrical hazards found in industrial and commercial environments. With temperatures reaching 35,000°F, extreme pressure waves, and molten metal, even a single arc flash can cause life-threatening injuries, equipment destruction, fires, and costly downtime.
To address these risks, OSHA and NFPA 70E require employers to identify electrical hazards and protect workers accordingly — and the most effective way to do that is through a professional arc flash study.
At Assured NDT, we help facilities across the United States complete accurate, compliant arc flash assessments designed to improve electrical safety, reduce liability, and keep teams fully protected. Here's how an arc flash study makes a measurable impact on workplace safety and improves electrical safety.
What Is an Arc Flash Study?
An arc flash study (also called an arc flash risk assessment) evaluates your facility’s electrical distribution system to determine:
How much incident energy workers may be exposed to
The arc flash boundary (safe working distance)
Required PPE levels
Whether overcurrent devices (breakers, fuses, relays) are coordinated properly
How quickly equipment will clear a fault
Where hazardous conditions exist
How to reduce or eliminate those hazards
The final product includes engineered arc flash labels, a compliance-grade report, and recommendations to improve electrical safety.
How an Arc Flash Study Improves Electrical Safety
1. Identifies Hidden Electrical Hazards
Many electrical issues — like mis-coordinated breakers, overloaded panels, or deteriorating equipment — remain invisible during routine inspections.
An arc flash study uncovers hazards such as:
Excessive incident energy levels
Improper breaker settings
Failed or aging protective devices
High fault currents
Overloaded conductors
Dangerous work practices
By uncovering these risks early, facilities can fix hazards before someone gets hurt.
2. Determines Accurate PPE Requirements
Without a study, PPE selection becomes guesswork — and using the wrong PPE dramatically increases injury severity.
An arc flash study calculates the exact PPE category needed at each piece of equipment, ensuring workers are properly protected when performing energized tasks.
This reduces the risk of:
Severe burns
Clothing ignition
Eye damage
Blast injuries
PPE is always matched precisely to the risk level.
3. Ensures Compliance with OSHA & NFPA 70E
Both OSHA and NFPA 70E require employers to:
Identify arc flash hazards
Label equipment
Provide proper PPE
Train workers
Maintain documentation
A legally compliant arc flash study helps fulfill all these requirements — protecting your business during audits, injury investigations, or insurance reviews.
4. Optimizes Breaker Settings to Minimize Harm
During an arc flash study, electrical engineers perform short-circuit and coordination analysis to evaluate whether protective devices will operate correctly.
This process:
Lowers incident energy
Reduces arc duration
Prevents large-scale electrical failures
Improves system reliability
Small adjustments to breaker settings can reduce arc flash severity dramatically.
5. Establishes Safe Working Distances (Arc Flash Boundaries)
An arc flash study defines the minimum safe distance workers must maintain to avoid burn injury.
These boundaries:
Reduce exposure
Guide lockout/tagout practices
Improve electrician decision-making
Support safe job planning and permits
When workers know the safe approach distance, they avoid hazardous zones.
6. Provides Clear, Compliant Arc Flash Labels
Accurate labeling is one of the most effective safety tools.
Arc flash labels include:
Incident energy (cal/cm²)
Arc flash boundary
PPE category
Voltage level
Working distance
Hazard and warning symbols
Clear, compliant labels give technicians instant visibility into the risks before opening equipment.
7. Reduces Equipment Damage & Downtime
Arc flash studies improve response time during faults by ensuring the right protection device trips at the right time.
This prevents:
Widespread outages
Damaged switchgear
Destroyed panels
Long production stoppages
A safer system is almost always a more reliable one.
Why Work with Assured NDT?
Assured NDT provides nationwide arc flash studies that meet:
Insurance carrier requirements
We deliver:
Certified electrical engineers
Full system modeling
Short-circuit & coordination studies
Professional arc flash labels
Clear, actionable recommendations
Comprehensive training options
Whether you operate a manufacturing plant, hospital, data center, commercial building, or industrial facility — Assured NDT ensures your electrical system meets the highest safety standards.
Ready to Improve Electrical Safety at Your Facility?
Schedule your arc flash study today with Assured NDT.
📞 Request a quote at assuredndt.com/contact
FAQ: How Does an Arc Flash Study Improve Electrical Safety?
1. What is the main purpose of an arc flash study?
To identify arc flash hazards, determine incident energy levels, and ensure workers have proper protection and safe operating practices.
2. How often should an arc flash study be updated?
NFPA 70E requires updates every 5 years or any time electrical system changes occur (new equipment, breaker updates, renovations, etc.).
3. Do all facilities need an arc flash study?
Any facility with energized electrical equipment over 50 volts must assess arc flash risk under OSHA and NFPA 70E.
4. Who is qualified to perform an arc flash study?
Studies must be performed by experienced electrical engineers or qualified professionals trained in power systems analysis.
5. How long does an arc flash study take?
Typical assessments take 2–8 weeks depending on facility size, data quality, and system complexity.
