Our Arc Flash Study Process Explained: From Data Collection to Equipment Labels
- Herzig Engineering
- Feb 27
- 3 min read
Updated: Mar 4
Electrical systems power nearly every modern facility, but when something goes wrong, the consequences can be severe. That’s why an arc flash study is not just a paperwork exercise for compliance; it is a detailed engineering process that can prevent equipment damage, costly downtime, and save lives.
If you’ve ever wondered what actually goes into a comprehensive arc flash study, you are not alone. Many facility managers and safety professionals understand that they need one, but may not fully know the process behind it. From gathering equipment data to applying safety labels, each step plays a vital role in ensuring accurate results and protecting your personnel. Today, we’ll walk through a complete arc flash study guide explaining exactly what an arc flash study is and how the professionals at Herzig Engineering use it to keep facilities safe, compliant, and properly engineered.
What Is an Arc Flash Study?
An arc-flash hazard study is a detailed engineering analysis used to evaluate potential hazards in an electrical system. Its primary purpose is to calculate how much energy an arc flash could release during a fault and the level of personal protective equipment (PPE) required to keep workers safe. Per OSHA, NFPA 70E, and IEEE 1584 guidelines, arc-flash studies must be performed by a licensed engineer to remain compliant and keep electrical systems operating safely. Using these standards, engineers will calculate:
Available fault current
Arc duration
Incident energy levels
Arc flash boundaries
Required PPE categories
These arc flash analysis calculations are performed in accordance with IEEE 1584 methodologies and current industry standards and are used to produce detailed reports and compliant equipment labels.
Our Step-by-Step Arc Flash Study Process
At Herzig Engineering, our arc-flash studies follow a structured, engineering-driven process to deliver accurate results, regulatory compliance, and practical safety improvements. Most projects include two on-site visits to ensure thorough data collection, validation, and support for implementation from start to finish.
Step 1: Arc Flash Hazard Analysis - Data Collection
This step consists of extensive on-site data collection to obtain electrical data for the Arc Flash Hazard Analysis. This includes:
Gathering one-line drawings and other electrical prints
Obtaining information on conductor sizes and lengths
Collecting distribution equipment types and ratings
Gathering overcurrent protection information
Recording transformer ratings and impedances
Helping the client submit request forms to the electrical utility company to determine the available energy levels entering the facility.
Step 2: Engineering Analysis
After the pertinent information is collected, our certified engineers will then analyze the system using comprehensive modeling software (SKM typically). This analysis includes, but is not limited to:
Electrical System Modeling
Equipment Evaluation
Coordination Study
Execute Arc Flash Evaluation
1-Line Drawings and Preliminary Report
*To remain a neutral third-party, we are committed to not selling any electrical equipment or PPE, so that our reports and suggestions remain unbiased.
Step 3: Labels
After preliminary reports are approved, our team will develop fully NFPA 70E, OSHA, and NEC-compliant arc flash labels for your electrical system. These labels are designed to clearly communicate critical safety information and ensure electrical workers are aware of:
Nominal voltage
PPE level
PPE description
Limited and restricted approach
Incident energy
Arc flash shock boundary
Date of assessment
Location of equipment
Step 4: Final Reports & 1-lines
Finally, our team will prepare and deliver your comprehensive arc flash study report after it has been reviewed by a chief engineer. We will walk through the findings with you, explain key results, and provide clear, practical recommendations for next steps to strengthen safety and compliance.
The following reports and documentation will be included:
Arc Flash Evaluation Reports
Fault Analysis Input Reports
Fault Contribution Reports
Electrical files of One-Line drawings
As part of Herzig’s commitment to electrical safety, every arc-flash study includes a complimentary NFPA 70E training session, either onsite or via virtual video. This ensures your organization not only receives a compliant, engineer-reviewed study but also gains the knowledge and practical guidance needed to maintain a safer, more informed workplace moving forward.
Who Should Perform an Arc Flash Study
Arc-flash studies are complex engineering analyses that require comprehensive modeling, fault current calculations, and protective device coordination. Because of this, these studies typically require a licensed engineer (P.E.) to perform them in the jurisdiction where the project is located.
At Herzig Engineering, we’re the longest standing national arc-flash study provider who offers premium training, audits, and results to help your workers “Go Home Safely”. Our team combines deep technical expertise with practical field experience to deliver accurate studies, clear reporting, and ongoing support that strengthens your overall electrical safety program. Whether you are completing your first study or updating an existing system, we are committed to helping you protect your people, maintain compliance, and reduce operational risk.
Contact the experts at Herzig Engineering today to schedule your arc flash study and ensure your facility is engineered for safety, compliance, and long-term protection.
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