Arc Flash Studies: What They Are and Why You Need One
Every year, electrical workers across the country are injured by arc flash incidents. Sudden, explosive releases of energy that can cause severe burns, hearing loss, and worse. Most of these incidents happen at facilities that had no idea how serious their exposure was until it was too late.
An arc flash study changes that. It gives your facility a clear, documented picture of where the risks are, how serious they are, and what your workers need to stay safe. For industrial facilities across Minnesota and the U.S., it is also becoming a compliance requirement that you cannot afford to overlook.
Here is what an arc flash study actually involves, why the rules around it have changed, and what it means for your operation.
What Is an Arc Flash?
An arc flash is an electrical explosion that occurs when current travels through the air between conductors or from a conductor to ground. The energy released in that fraction of a second can reach temperatures of up to 35,000 degrees Fahrenheit, nearly four times hotter than the surface of the sun.
The results can include:
- Severe burns to exposed skin
- Ignition of clothing and equipment
- Blast pressure injuries
- Hearing damage from the accompanying sound wave
- Vision loss from the intense light
Arc flash incidents do not only happen through negligence. They can occur during routine maintenance, switching operations, equipment inspection, or any time a worker is near energized electrical equipment.
What Is an Arc Flash Study?
An arc flash study is a formal engineering analysis of your facility's electrical system. It identifies the locations where arc flash hazards exist, calculates the potential severity of an incident at each location, and determines what personal protective equipment (PPE) your workers need when working near those systems.
The study typically includes:
- A complete inventory of your electrical equipment and system configuration
- Short circuit and coordination analysis
- Incident energy calculations at each point in the system
- Arc flash hazard labels for your equipment
- PPE requirements for each work location
- Recommendations for reducing risk through system changes or updated work practices
The result is a documented, site-specific record of your electrical hazards -- and a clear roadmap for managing them safely and in compliance with current standards.
What Triggers the Need for an Arc Flash Study?
- New electrical equipment installation
- Utility service upgrades or transformer changes
- Facility expansions or process modifications
- Protective device setting adjustments
- Outdated or missing arc flash labels
Why NFPA 70E and NFPA 70B Make This a Requirement
This is where the urgency comes in for many Midwest facilities right now.
NFPA 70E is the standard that governs electrical safety in the workplace. It has long required arc flash risk assessments as part of a compliant electrical safety program. Many facilities have been aware of NFPA 70E for years.
The 2023 update elevated NFPA 70B from a recommended practice to a standard, increasing its role as a benchmark OSHA may reference when evaluating electrical maintenance programs.
The practical result is that a large number of industrial facilities that considered themselves compliant are no longer meeting current standards. Is your facility one of them?
To be NFPA 70E compliant, your facility needs to confirm:
- One-line drawings are current and accurate
- Arc flash study is up to date
- An electrical safety and energized work program is established
- Training is in place for both qualified and unqualified workers to recognize electrical hazards
- A formal risk assessment has been completed
To be NFPA 70B compliant, your facility needs to:
- Establish an Electrical Preventive Maintenance (EMP) program and follow it
- Test electrical equipment on a documented schedule
- Identify an EMP coordinator
- Confirm that maintenance personnel are qualified
- Verify that one-line drawings are accurate and legible
These are not suggestions. They are requirements, and the gap between where many facilities currently are and where these standards expect them to be is significant.
How Often Does an Arc Flash Study Need to Be Updated?
NFPA 70E recommends reviewing your arc flash study whenever a major change is made to your electrical system and at a minimum every five years. In practice, many facilities go far longer without an update, which means their hazard labels, PPE requirements, and risk assessments no longer reflect the actual state of their system.
If your facility has added equipment, changed system configurations, or simply has not reviewed its arc flash data in several years, the study needs attention before the next time a worker opens an electrical panel.
What KE Brings to Arc Flash Studies
KE offers a comprehensive portfolio of compliance services built specifically for industrial facilities across Minnesota and the U.S. Their arc flash and coordination studies are conducted by experienced engineers who understand both the technical requirements and the operational realities of running a facility.
The full service offering includes:
- Arc Flash and Coordination Studies
- Electrical Preventive Maintenance Programs (EMP)
- Employer training for qualified and unqualified workers
- One-line drawing development and updates
- Risk assessment support
- Ongoing compliance consultation
This expert approach helps facilities:
- Improve worker safety and PPE accuracy
- Reduce unexpected downtime from electrical failures
- Maintain inspection readiness
- Extend equipment lifespan through coordinated maintenance
For more than 30 years, manufacturers and industrial operators across the region have trusted KE to handle the electrical work that keeps their facilities running safely and efficiently.
That same depth of experience applies directly to arc flash compliance, combining engineering expertise with field experience and a genuine commitment to getting it right.
Schedule a Consultation Before Your Next Inspection
Arc flash compliance is not a one-time task; it is an ongoing program. For facilities across Minnesota and the U.S. that have not revisited their electrical safety documentation since the 2023 NFPA 70B updates, now is the time to act.
KE can review your current documentation, identify gaps, and help you prioritize the updates that will have the greatest safety and compliance impact.
Contact our team today to schedule your consultation.
Frequently Asked Questions
Do I need an arc flash study if my facility is small?
The size of your facility does not determine whether you need an arc flash study -- the presence of energized electrical equipment does. If your workers interact with electrical panels, switchgear, or other energized systems, NFPA 70E applies, and an arc flash risk assessment is required.
Who can perform an arc flash study?
Arc flash studies should be performed by qualified electrical engineers with experience in power systems analysis. The calculations involved require specialized software and a thorough understanding of your facility's electrical system. This is not a task for general contractors or unqualified personnel.
What happens if my facility is not compliant?
Failure to address the hazards covered by NFPA 70E and NFPA 70B can increase exposure to OSHA citations, liability, and worker injury, because OSHA may rely on consensus standards as evidence of recognized industry practice.
What information is needed to start an arc flash study?
Most studies begin with existing one-line drawings, equipment nameplate data, and protective device settings. If documentation is incomplete, field data collection may be required.
How long does an arc flash study take?
The timeline varies based on the size and complexity of your electrical system. KE can give you a realistic estimate after an initial consultation and review of your existing documentation.