Arc Flash Compliance Checklist: Do You Need a Study Right Now?

Most facility managers know that electrical safety regulations like NFPA 70E and OSHA require employers to identify and manage arc flash hazards, but they may not know whether their electrical systems meet current arc flash study requirements or overall arc flash compliance standards. In many cases, companies that completed an arc flash study years ago or installed warning labels during construction may assume that everything is still up to date.

The reality is that electrical systems change frequently over the years. Equipment upgrades, facility expansions, and modifications can all impact arc flash incident risks and energy levels. When these changes happen, an outdated study or labeling system may put your equipment and personnel at risk. 

Today, we will present several arc flash compliance checklist items to help facility managers, safety professionals, and plant engineers determine whether their electrical safety program may require a new or updated study.

Arc Flash Compliance Checklist for Facilities

Arc flash compliance involves more than simply installing labels or completing a study once. This checklist can help you quickly evaluate whether your facility’s arc flash study and safety program needs review or an update.

Arc Flash Compliance Checklist:

• Has your facility completed an arc flash study for all applicable electrical equipment?

• Has the study been reviewed or updated within the past five years?

• Are arc flash warning labels installed on switchgear, panels, and motor control centers, etc?

• Do arc flash labels clearly identify incident energy or PPE requirements?

• Are accurate one-line diagrams available for your electrical distribution system?

• Have protective devices been evaluated and coordinated as part of the study?

• Have employees been trained on arc flash hazards and electrical safety procedures?

• Are the required PPE levels clearly identified for energized work tasks?

• Are electrical safety procedures documented and accessible to workers?

• Has your electrical system changed since the last arc flash study was performed?

Proper labeling is a key part of arc flash labeling requirements and helps workers quickly understand hazard levels, required PPE, and arc flash boundary requirements when working near energized equipment.

If you answered no or are unsure about any of these questions,  contact our team for assistance on next steps.

Situations That Typically Trigger the Need for a New Arc Flash Study

Both OSHA regulations and NFPA 70E arc flash requirements require employers to identify electrical hazards and ensure workers are protected when working with energized equipment. If system modifications occur, an outdated arc flash assessment may no longer accurately reflect current risks.

NFPA 70E recommends that an arc flash risk assessment or analysis be reviewed at intervals not to exceed 5 years, or whenever major changes to the electrical system occur. Because of this, the following situations are common triggers that may require a new arc flash study to be performed:

• Installation of new electrical equipment, such as switchgear, panels, or motor control centers.

• Transformer upgrades or replacements that increase or decrease the available fault current.

• Changes to electrical distribution equipment, including panelboards or switchgear.

• Facility expansions or added production lines that increase electrical load or alter system configuration.

• Adjustments to breaker or relay settings that affect protective device coordination.

• Major electrical system upgrades or redesigns.

Even relatively small electrical system changes can impact arc flash incident energy calculations. Reviewing your arc flash study after these types of modifications helps ensure that safety labels, PPE requirements, and electrical safety procedures remain accurate and compliant.

If you are unsure when an arc flash study is required or how often an arc flash study should be updated, reviewing your facility’s electrical system with experienced engineers can help ensure your safety program remains accurate and compliant.

Not Sure If Your Facility Needs an Arc Flash Study?

Determining whether your current arc flash documentation is still valid isn't always straightforward. Electrical systems evolve over time, and what was compliant five years ago may no longer reflect the actual hazard levels your workers face today.

At Herzig Engineering, we specialize in arc flash hazard assessments and electrical safety compliance for manufacturing plants, commercial facilities, and industrial operations nationwide. If you're unsure whether your facility's safety program is still current, our engineers can evaluate your electrical system and provide a clear, honest answer. No unnecessary upsells, just accurate assessments and practical next steps.

Contact us today to schedule a free consultation.

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