Arc Flash Studies: What Are They and Why Do You Need One?

When working with three-phase (3ø) electrical equipment, there’s always the risk of a short circuit or other malfunctions that could cause a sudden release of energy through the air. This “arc flash” is not only hazardous to the equipment but could cause injuries and even fatalities to personnel working in the area. Arc flash studies are aimed at minimizing these risks by assessing potential hazards and recommending proactive steps, such as PPE, safe work practices, and potential equipment modifications, to keep everyone safe. Whether you’re running a manufacturing facility, data center, or large office building, getting an arc flash study can help keep you compliant with NFPA 70E requirements and help ensure workplace safety. Below, we will be diving into the importance of arc flash studies, and why having one performed by licensed engineers and electricians, such as with Herzig Engineering, is an essential part of your operations. 

What is an Arc Flash Study?

An arc flash study is an in-depth assessment performed by a qualified engineer to assess a facility’s overall risk of arc flash events. These events occur when an electrical current deviates from its intended path, instead traveling through the air between conductors or to the ground, resulting in intense heat and light. At Herzig Engineering, our arc flash studies help calculate the potential severity of these incidents between various points of the electrical system by analyzing several factors, including electrical current, system configuration, and protective device settings. By the end of the study, you will have a comprehensive assessment of current risks, recommendations of PPE tailored to each panel, and NFPA 70E-compliant hazard labels.

Why are Arc Flash Studies Important

Arc flash studies are much more than just another checkbox for meeting regulatory compliance; they're an essential step in ensuring that your workers go home safely every day. According to estimates, arc flashes account for over 400 deaths and 2,000 hospitalizations every single year. While each case is unique in terms of how well the technician followed protocols and the condition of the equipment, the sad truth is that most of these incidents are preventable. In addition, arc flash accidents can be extremely costly due to company liabilities, operational downtime, and employee medical expenses, often exceeding $5 million (see "How Much Do Arc Flash Incidents Typically Cost? A Breakdown"). Without arc flash studies and proper assessment of risk, businesses could risk equipment damage, costly fines, and putting their workers in potentially dangerous working conditions. 

NFPA 70E Arc Flash Study Requirements

Arc flash studies are essential for proper compliance and ensuring the safety of your workers. Per NFPA 70E Article 130.5 guidelines, an arc flash hazard analysis should be performed by a licensed professional engineer for any of the following circumstances:

New Installations -  A new facility should meet all NFPA 70E arc flash requirements before any energized work, troubleshooting, or inspections are performed.

System Modifications - Any significant modification made to the system, such as upgrades, replacements, or alterations, should have a new arc flash study performed.

Periodic Reviews: NFPA 70E standards require that the arc flash analysis interval not exceed five years. This allows us to account for any new industry standards or potential changes in the equipment. 

In addition to performing an in-depth analysis and issuing a report, NFPA 70E requires proper equipment labeling and guidance on the selection of personal protective equipment (PPE). If you have any questions about staying compliant with NFPA 70E standards, contact our Herzig Engineering team online today.

Our Arc Flash Study Process at Herzig Engineering

Our arc flash studies include comprehensive analysis, calculations, and documentation to ensure complete accuracy and compliance. Below is a summary of what a typical arc flash study from Herzig Engineering includes:

Data Collection

This process involves gathering all the necessary information for each electrical system. This will include proper equipment evaluations and ratings (such as breakers, fuses, and transformers), one-line diagrams, system voltages, and fault levels. 

Short Circuit Analysis

This analysis helps determine the maximum available fault current at various points throughout the system and is crucial for performing accurate arc flash and coordination studies. 

Protective Device Coordination

Protective device coordination ensures that installed protective devices, such as circuit breakers and fuses, all trip as expected to minimize equipment damage and outage areas.

Arc Flash Hazard Calculations

Our arc flash hazard calculations determine the amount of incident energy (measured in cal/cm²) and help define the arc flash boundaries at electrical panels and equipment. This is useful for identifying the appropriate amount of PPE to protect workers. 

Labeling

Labeling involves placing arc flash warning and danger labels on electrical equipment displaying incident energy levels, arc flash boundaries, and required PPE categories. This ensures workers are aware of potential hazards and can take proper precautions. 

Documentation & Recommendations

Our documentation includes a comprehensive report outlining the arc flash analysis results. Additionally, we include recommended mitigation strategies, such as reducing fault current, enhancing device coordination, or installing arc flash relays. 

Overall, arc flash studies help ensure your facility is compliant and adequately equipped with the knowledge and tools to protect your workers from electrical safety hazards. 

Schedule Your Arc Flash Study with Herzig Engineering

For more than 25 years, and as the longest-standing Arc Flash company in the United States, Herzig Engineering has been “Helping Workers Go Home Safely” through our extensive arc flash studies and training. We’re proud to be trusted by safety leaders nationwide as the preferred electrical safety partner. If your facility is due for an arc flash analysis, contact our team today for a same-day quote at 816-734-8300 or fill out the form here.