Your first arc flash study often comes with a clear safety and compliance pressure: you must protect workers from electrical hazards and be able to prove it to OSHA, corporate EHS, and insurers. At the same time, you cannot shut your facility down for days just to collect data. This article explains what is actually involved in an arc flash study so you can plan, stay compliant, and keep people safe.
We will walk through what happens from the first call through labels, personal protective equipment (PPE), and long-term upkeep. You will see what your team has to provide, what a qualified arc flash consultant does, and what “good” looks like when OSHA, NFPA 70E, and NFPA 70B are part of the conversation.
Your First Arc Flash Study: What Is Really Involved
Many facilities face the same mix of problems: aging switchgear, equipment added over the years, new safety rules, and pressure from audits or insurance. On top of that, production cannot simply stop for a week so someone can gather data.
OSHA expects you to protect workers from electrical hazards. NFPA 70E requires documented arc flash risk assessments. NFPA 70B ties in by expecting a maintenance program that supports safe, reliable equipment. Together, they point to one thing: you need written proof that you understand your arc flash risks and are managing them.
An arc flash consultant helps move you from “we think we are compliant” to “we can show how we are compliant.” That means traceable calculations, labels that match the system, and work practices and PPE that are based on real numbers, not guesses.
Here is what this process typically covers:
- How to Set Clear Safety and Compliance Goals
- What a Qualified Consultant Should Deliver
- How Data Collection and Modeling Really Work
- How Results Turn Into Labels, PPE, and Procedures
- How to Keep the Study Current Over Time
Clarifying Your Compliance and Safety Objectives
Before anyone starts opening panels, you should agree on what you want the study to achieve. OSHA expects you to create an electrically safe work condition whenever possible. NFPA 70E Article 130 explains how to assess shock and arc flash risk before work is done. Your arc flash study is one of the main tools to support that requirement.
You should clearly define the scope, such as:
- Which Sites or Campuses are in scope
- Which Voltage Levels and Distribution Systems are included
- Whether to Include Only Major Gear or also panels and motor control centers (MCCs)
- How Deep to Go on low-risk or rarely used systems
You should also connect the study to NFPA 70B by looking at how maintenance, testing, and inspection records support safe operation. If there is no maintenance history on protective devices, that affects both safety and confidence in the results.
You then set realistic timelines based on:
- Planned Outages and Shutdowns
- Busy Production Seasons and Peak Demand
- Access Limits in Mission-Critical Spaces
What a Qualified Arc Flash Consultant Brings to the Table
NFPA 70E defines a Qualified Person as someone with the skills and knowledge for the task and who has received safety training on the hazards involved. For your arc flash study, that means the consultant should understand electrical power systems, the standard methods for fault and arc flash calculations, and safe work practices.
You should expect clear deliverables, typically including:
- A Detailed Arc Flash Study Report and System Model.
- Updated or New Single-Line Diagrams (simple drawings that show how your electrical system is connected)
- Arc Flash Labels for equipment in scope
- PPE and Work-Practice Guidance based on the study
A good arc flash consultant will coordinate with:
- Safety and environmental, health, and safety (EHS) leaders
- Maintenance and electrical teams
- Operations, production, and facility management
On day one, you can expect questions about: one-line diagrams, recent projects, utility data, maintenance history, lockout/tagout (LOTO) procedures, and any past electrical incidents. Helpful documents to prepare include: drawings, equipment schedules, relay and breaker settings, test reports, and prior studies if they exist.
Site Data Collection, Modeling, and Turning Results Into Practice
Data collection is more than just taking a quick look at a panel. The consultant will need details on:
- Panels, Switchboards, Switchgear, and MCCs
- Breakers, Fuses, Relays, and Settings
- Cables, Conduit Sizes, and Approximate Lengths
- Transformers and Their Ratings and Impedances
- Utility Service Data and Generator or UPS Systems
The consultant then builds an electrical system model and runs short-circuit and arc flash calculations using accepted methods referenced in NFPA 70E and related standards such as IEEE 1584. A Short-Circuit Study calculates the maximum fault current your system may experience so devices can be properly rated and coordinated.
Not every field detail has to be perfect, but some things must be accurate, such as device ratings, settings, transformer data, and system configuration.
Common issues found during fieldwork often line up with NFPA 70B priorities, such as missing covers, unknown settings, damaged labels, evidence of overheating, or equipment that has not been maintained in years. These findings help feed your maintenance plan, not just your arc flash report.
From the study, the consultant produces Incident Energy values and Arc Flash Boundaries for each location. In plain terms:
- Incident Energy is how much thermal energy a worker might be exposed to during an arc flash.
- The Arc Flash Boundary is how close an unprotected worker can safely stand.
- Equipment may fall into different PPE Levels based on those results.
Labels are then developed, checked, and applied to match NFPA 70E requirements. Labels typically include voltage, boundaries, incident energy or PPE category, and any special notes. The results flow into:
- Task-Based PPE Guidance
- Energized Work Permits when de-energizing is not feasible, as defined in NFPA 70E
- Written Procedures that support your electrical safety program
- You can also use the study to:
- Sharpen LOTO procedures
- Target extra training where the risk is higher
Adjust maintenance intervals for equipment that shows higher incident energy or poor protective coordination (whether devices operate in the right order and time to clear faults safely)
Planning for Updates and Long-Term Compliance
NFPA 70E expects arc flash risk assessments to be reviewed on a regular basis and whenever major changes occur. NFPA 70B also expects you to keep your maintenance program aligned with actual equipment condition. That means your study is not a one-time event.
You will want a process to track changes such as: new gear or panels, renovations, utility fault current changes, protective device upgrades, and new generators or large motors. When these happen, the model and labels may need updates.
Many facilities build an Electrical Safety Roadmap that ties together:
- Arc flash and short-circuit studies
- NFPA 70B-based maintenance and testing
- NFPA 70E training and refresher courses
Planning and budgeting ahead helps you avoid a last-minute scramble before a corporate audit or busy season.
Key Takeaways
- Arc Flash Studies Are a Core Compliance Tool OSHA, NFPA 70E, and NFPA 70B all expect you to know your electrical hazards and document how you control them.
- Clear Objectives and Scope Matter Decide which sites, voltage levels, and equipment are in scope, and link the study to your maintenance and safety programs.
- Qualified Consultants Provide Traceable Results Expect a system model, clear report, accurate labels, and guidance for PPE and work practices, grounded in recognized standards.
- Field Data and Modeling Drive Practical Changes The study should lead to better labels, updated procedures, training priorities, and targeted maintenance.
- Plan for Updates, Not a One-Time Project Build a process to review and revise your study as your electrical system and operations change over time.
Frequently Asked Questions
How Long Does a Typical Arc Flash Study Take From Start to Finish?
It varies with facility size, system complexity, how complete your drawings are, and when equipment can be accessed. Small single-site projects can be completed relatively quickly, while large or multi-site systems often take longer because of data collection and outage scheduling.
How Often Do We Need to Update Our Arc Flash Study to Stay Compliant?
NFPA 70E expects risk assessments to be reviewed on a regular basis and when major electrical changes occur. If the review shows that results are no longer accurate, the study and labels need to be updated.
Do We Have to De-Energize Equipment for an Arc Flash Study?
Some checks can be done by visual inspection with covers closed, but many details require opening equipment, so normal electrical safety rules apply. When de-energizing is not possible, work practices and PPE must follow NFPA 70E requirements for energized work.
What Information Should We Have Ready Before the Consultant Arrives?
Helpful items include single-line diagrams, panel schedules, breaker and fuse lists, relay settings, transformer data, previous studies, test reports, and any electrical maintenance records. Access plans and site safety rules are also important.
Can One Arc Flash Study Cover Multiple Buildings or Sites?
Yes, a single project can include multiple buildings or locations, as long as each system is modeled correctly. Separate models are usually created for systems that are not electrically tied together or that are on different utility services.
To discuss your arc flash study needs, call 866-730-6620 or request an assessment and free quote. Our nationally experienced team provides NFPA 70Eand NFPA 70B-based electrical safety services that help you document compliance and protect your workforce.
Protect Your Team With Expert Arc Flash Guidance
If you are ready to strengthen electrical safety and compliance at your facility, our arc flash consultant services can help you move forward with confidence. At Bowtie Engineering, we focus on practical, actionable solutions tailored to your equipment, work practices, and risk profile. Tell us about your project and we will outline the next steps, timelines, and deliverables so you know exactly what to expect. To start the conversation, simply contact us today.