Why Arc Flash Studies Should Be Updated Every 5 Years — Not Longer
- Stephen Fike
- Jan 24
- 4 min read
Arc flash hazards remain one of the most serious — and most underestimated — electrical risks in commercial and industrial facilities. While many organizations complete an arc flash study once and consider the box checked, allowing that study to age beyond five years creates significant safety, compliance, and legal exposure.
That is why NFPA 70E clearly defines arc flash study frequency requirements, and why best-in-class facilities treat five years as a hard limit — not a suggestion.
At Assured NDT, we conduct arc flash studies and updates nationwide, helping facilities remain compliant, protect workers, and reduce operational risk. Below, we explain why arc flash studies should be updated every 5 years — and why waiting longer is dangerous.
What Is an Arc Flash Study?
An arc flash study is a detailed engineering analysis of an electrical system that determines:
Available fault current
Incident energy levels (cal/cm²)
Arc flash boundaries
Required PPE levels
Proper protective device coordination
Equipment labeling requirements
The results directly influence:
Worker safety procedures
PPE selection
Electrical maintenance practices
OSHA compliance
Insurance underwriting
If the data behind the study becomes outdated, the protection it provides becomes unreliable.
What NFPA 70E Says About Arc Flash Study Frequency
NFPA 70E establishes a clear requirement regarding arc flash study updates:
Arc flash risk assessments shall be reviewed for accuracy at intervals not to exceed five years, or when major system changes occur.
This means five years is the maximum allowable interval, not a recommended target.
Why the 5-Year Limit Matters
Electrical systems are not static. Over time, changes accumulate — often without being documented.
1. Electrical Loads Increase Gradually
Facilities add:
New equipment
EV chargers
Data infrastructure
Process expansions
Each increase changes available fault current and incident energy levels.
2. Protective Device Settings Drift or Change
Breakers, relays, and fuses may be:
Replaced
Reset
Adjusted
Re-coordinated
Even small setting changes can drastically affect arc flash energy.
3. Utility Fault Current Changes
Utility providers routinely upgrade transformers and distribution systems. These upstream changes can significantly alter fault current, without notice to the facility.
4. Equipment Ages and Degrades
As electrical equipment ages:
Clearing times increase
Mechanical wear impacts performance
Failure modes change
An old arc flash study does not reflect real-world conditions.
5. PPE and Labels Become Inaccurate
Outdated studies often result in:
Under-rated PPE
Incorrect arc flash boundaries
Labels that no longer reflect actual risk
This creates direct worker exposure and serious liability.
Why Waiting Longer Than 5 Years Is a Serious Risk
Allowing an arc flash study to exceed the five-year limit exposes facilities to:
OSHA citations following incidents
Increased liability in injury investigations
Insurance claim challenges or denials
Unsafe energized work practices
Non-compliant labeling
Elevated arc flash injury severity
In many investigations, outdated arc flash studies are treated the same as having no study at all.
When Arc Flash Studies Must Be Updated Sooner
NFPA 70E also requires immediate updates when major system changes occur, including:
New switchgear or panels
Transformer replacement or upgrades
Load increases
Facility expansions
Generator or UPS additions
Utility service changes
Protection device setting modifications
If any of these have occurred, waiting until the five-year mark is not acceptable.
How Updated Arc Flash Studies Improve Safety
Keeping arc flash studies current allows facilities to:
Accurately define safe work boundaries
Select correct PPE
Reduce incident energy through coordination improvements
Improve maintenance planning
Support energized work permits
Protect electricians, contractors, and technicians
An updated study is a living safety document, not a one-time deliverable.
Arc Flash Study Frequency and Insurance Expectations
Insurance carriers increasingly request:
Arc flash study dates
Confirmation of 5-year compliance
Evidence of updates after system changes
Outdated studies often trigger:
Higher premiums
Policy exclusions
Required corrective action plans
Maintaining proper arc flash study frequency strengthens insurability.
Why Facilities Trust Assured NDT
Assured NDT provides arc flash studies and updates for facilities across the U.S., delivering:
Licensed professional engineers
NFPA 70E & IEEE 1584-compliant analysis
Clear, readable reports
Accurate, durable labeling
Coordination with infrared thermography and NFPA 70B programs
Support during OSHA or insurance audits
We help facilities stay compliant — not just once, but continuously.
Don’t Let an Outdated Arc Flash Study Put People at Risk
If your arc flash study is approaching five years — or if your electrical system has changed — now is the time to act.
📞 Contact Assured NDT to review or update your arc flash study👉 https://www.assuredndt.com/contact
FAQs: Arc Flash Study Frequency
1. How often must an arc flash study be updated?
NFPA 70E requires arc flash studies to be reviewed and updated at least every five years.
2. Can an arc flash study be valid for longer than five years?
No. Five years is the maximum allowable interval unless system changes require an earlier update.
3. What events require an arc flash study update before five years?
System changes such as load increases, equipment replacement, utility changes, or protection setting adjustments require immediate updates.
4. What happens if an arc flash study is outdated?
Outdated studies can lead to inaccurate PPE requirements, OSHA citations, increased liability, and elevated injury risk.
5. Who is qualified to update an arc flash study?
Arc flash studies must be updated by qualified electrical engineers or professional firms experienced in NFPA 70E and IEEE 1584 analysis.
