What to Do After an Arc Flash Study: Putting the Findings to Work
Quick Answer: What Should You Do After an Arc Flash Study?
Once the report arrives, the work shifts from analysis to action. Install and verify the arc flash labels, update PPE and energized work procedures, review the recommended protective device setting changes, plan mitigation for any high-energy locations, train the people who work on the equipment, keep the equipment maintained so it performs as modeled, and track system changes so the study stays accurate. NFPA 70E calls for the arc flash risk assessment to be reviewed at least every five years and updated after major modifications (ABB).
If you are still planning a study, start with our step-by-step guide to the arc flash study process and our overview of what drives arc flash study cost.
Key Takeaways
A study is a starting point. Labels, procedures, training, and maintenance are what protect workers.
Review recommended breaker and relay setting changes with your engineer before making them, then confirm the model reflects what was changed.
Prioritize locations with the highest incident energy for mitigation, starting with controls that remove or reduce the hazard rather than relying only on PPE.
Poorly maintained protective devices may not clear a fault as quickly as the study assumes, which can make labels inaccurate.
Keep the electronic model file and a change log so updates are faster and less expensive.
Step 1: Install and Verify Arc Flash Labels
Equipment likely to be examined, adjusted, serviced, or maintained while energized must be labeled with at least the nominal system voltage, the arc flash boundary, and information on the PPE required, such as incident energy at a working distance or a PPE category (ABB, NFPA 70E).
Confirm every label matches the equipment ID in the report.
Remove or cover old labels so workers never see conflicting values.
Use durable labels suited to the environment, such as outdoor, washdown, or high-heat areas.
Photograph installed labels and keep the photos with your study records.
Step 2: Update PPE and Energized Work Procedures
The study gives you incident energy and boundary values. Your safety program has to turn those values into decisions.
Confirm your PPE inventory covers the ratings shown on the labels.
Update energized work permits and job briefings to reference the new values.
Flag any locations where no available PPE is adequate, and prohibit energized work there until the hazard is reduced.
OSHA requires employers to assess the workplace for hazards that call for PPE and to document that assessment in a written certification (OSHA 1910.132). A current arc flash study is a key input to that assessment for electrical work.
Step 3: Review Recommended Protective Device Settings
Many studies recommend changes to breaker trip units or relay settings. Faster clearing times can significantly lower incident energy, but every change also affects selective coordination, so outages can spread farther than intended if settings are adjusted without review.
Have the engineer who performed the study confirm each recommended change.
Use qualified personnel to make the changes, and record the as-left settings.
Send the as-left settings back to the engineer so the model and labels reflect what is actually installed.
Step 4: Plan Mitigation for High-Energy Locations
NFPA 70E directs employers to apply a hierarchy of risk controls, in order: elimination, substitution, engineering controls, awareness, administrative controls, and PPE (ABB). In practice, that means looking for ways to reduce the hazard before relying on heavier PPE.
Common options your engineer may evaluate include:
Establishing an electrically safe work condition (de-energizing) whenever possible.
Energy-reducing maintenance switches or zone-selective interlocking.
Current-limiting fuses or faster protective devices.
Remote racking and remote operation so workers can stand outside the arc flash boundary.
Arc-resistant switchgear for new or replacement equipment.
Mitigation is usually budgeted separately from the study, so prioritize by incident energy and how often each location is worked on.
Step 5: Train the People Who Work on the Equipment
Labels only help if workers know how to read them. Training should cover reading labels, approach boundaries, PPE selection and care, and your energized work permit process. NFPA 70E calls for documented safety training, with retraining at intervals not to exceed three years, and sooner when procedures, equipment, or job duties change (ABB).
Include contractors who perform electrical work at your site, and confirm their training records before they start.
Step 6: Maintain Equipment So It Performs as Modeled
An arc flash study assumes protective devices will operate as designed. If a breaker is slow to trip because of contamination, wear, or loose connections, actual incident energy can be higher than the label shows. NFPA 70E requires the arc flash risk assessment to consider the condition of maintenance of the equipment (ABB).
That is why the study and your maintenance program belong together. An NFPA 70B electrical maintenance program with routine infrared thermography helps you find overheating connections and failing components before they compromise device performance. See what changed in NFPA 70B 2026 for current maintenance expectations.
Step 7: Keep the Study Current
Electrical systems change. New equipment, utility upgrades that raise available fault current, transformer replacements, and setting changes can all make a study inaccurate. NFPA 70E calls for the arc flash risk assessment to be reviewed at least every five years and updated after major modifications (ABB).
Keep the electronic model file, not just the PDF report.
Maintain a simple change log of equipment and setting changes.
Notify your engineer of utility changes or major renovations.
Calendar the five-year review now.
Read more about why arc flash studies should be updated every five years, or use our arc flash compliance checklist to see whether your study is due.
A Note on Calculation Methods
Most arc flash studies in the United States calculate incident energy and arc flash boundaries using IEEE 1584-2018, which covers three-phase systems from 208 V to 15 kV (IEEE). IEEE 1584.1-2022 provides guidance on specifying and performing a study under that method (IEEE Standards Association). If your study predates IEEE 1584-2018, ask your engineer whether it should be recalculated at the next review.
Frequently Asked Questions
What should I do first after receiving an arc flash study?
Install and verify the labels, then update PPE requirements and energized work procedures to match the new values. Flag any locations where no available PPE is adequate so energized work is not performed there until the hazard is reduced.
Should I make the protective device setting changes the study recommends?
Usually, but review each change with the engineer first. Setting changes can lower incident energy but also affect coordination, so they should be made by qualified personnel and the as-left settings sent back to update the model.
How do I reduce high incident energy found in a study?
Follow the hierarchy of risk controls. De-energize when possible, then consider engineering options such as maintenance switches, faster or current-limiting devices, remote racking, or arc-resistant equipment before relying on heavier PPE.
Does equipment maintenance affect arc flash study results?
Yes. Studies assume protective devices clear faults as designed. Poorly maintained devices may operate more slowly, which can raise actual incident energy above the labeled value. Routine maintenance and infrared thermography help keep devices performing as modeled.
How often should arc flash training be repeated?
NFPA 70E calls for retraining at intervals not to exceed three years, and sooner when equipment, procedures, or job duties change or when a worker is not following safe practices.
When does an arc flash study need to be updated?
At least every five years, and sooner after major modifications, utility changes that affect available fault current, or significant setting changes.
About the Author
Stephen Fike is the Principal of Assured NDT and Risk Assured, where he leads a team specializing in risk engineering, fire protection, and non-destructive testing for complex facilities across hospitality, healthcare, manufacturing, and real estate. He has more than a decade of experience at firms including PwC, Marsh, Willis Towers Watson, USI, and AIG, and has evaluated properties exceeding $1 billion in value. Stephen holds a degree in Civil and Environmental Engineering from Penn State University.
Put Your Arc Flash Study to Work
Assured NDT helps facility teams connect arc flash studies, infrared thermography, and NFPA 70B maintenance programs so findings turn into safer, better-maintained equipment. Contact Assured NDT to plan your next study, review, or maintenance visit.
Sources
This article is general information, not engineering or legal advice. Requirements depend on your facility, jurisdiction, and the edition of each standard adopted. Consult a qualified engineer before changing protective device settings or equipment.
