Arc flash incidents are among the most dangerous electrical hazards in the workplace, capable of causing severe injuries, equipment damage, and costly downtime. An arc flash occurs when electrical current deviates from its intended path, creating an intense burst of heat and pressure. Temperatures can reach up to 35,000°F—hotter than the surface of the sun—posing a serious risk to personnel working near electrical equipment.
To mitigate these risks, facilities must conduct an Arc Flash Hazard Analysis, also known as an Incident Energy Analysis. This assessment identifies potential arc flash hazards, determines the severity of incident energy exposure, and establishes the necessary protective measures, including Personal Protective Equipment (PPE) requirements. Compliance with NFPA 70E and OSHA regulations ensures a safer work environment and minimizes liability for businesses.
What is an Arc Flash Hazard Analysis?
An Arc Flash Hazard Analysis is an engineering study that evaluates the electrical system within a facility to determine the potential severity of an arc flash event. It helps assess the incident energy levels at different equipment points, define arc flash boundaries, and ensure proper labeling and safety precautions are in place.
Key Objectives of an Arc Flash Study:
- Identify locations in the electrical system with high arc flash risks.
- Determine incident energy levels (cal/cm²) at different working distances.
- Define arc flash boundaries to establish safe working distances.
- Specify the minimum PPE requirements for workers.
- Ensure compliance with NFPA 70E and OSHA regulations.
By conducting an Arc Flash Hazard Analysis, businesses can significantly reduce the risks associated with electrical work, improve safety protocols, and ensure their facility remains compliant with workplace safety standards.
Why is Arc Flash Analysis Important?
1. Protects Workers from Life-Threatening Injuries
An arc flash can result in severe burns, hearing loss, blindness, or even fatalities. Workers exposed to an arc flash without proper protection are at high risk of suffering from life-altering injuries. A hazard analysis ensures employees are equipped with the right PPE and follow safe working procedures.
2. Ensures Compliance with NFPA 70E & OSHA
Employers are required by OSHA (29 CFR 1910 Subpart S) to assess workplace electrical hazards and implement protective measures. NFPA 70E provides guidelines on conducting an arc flash risk assessment, specifying PPE, and implementing labeling and safety protocols to protect workers.
3. Reduces Downtime and Equipment Damage
An arc flash can destroy electrical components, leading to costly repairs and downtime. By identifying and mitigating arc flash risks in advance, facilities can prevent unexpected failures, ensure continuous operations, and protect valuable equipment.
4. Avoids Legal Liabilities & Financial Losses
Failure to conduct an arc flash analysis can expose businesses to lawsuits, OSHA citations, and hefty fines. Implementing a proper hazard assessment demonstrates due diligence and reduces liability risks.
Key Components of an Arc Flash Study
1. Data Collection
- Gather electrical system documentation, including one-line diagrams, equipment specifications, and breaker settings.
- Conduct an on-site survey to verify existing conditions.
2. Short Circuit Analysis
- Determine the available fault current at different points in the electrical system.
- Ensure equipment can handle expected fault currents without failure.
3. Protective Device Coordination
- Evaluate how circuit breakers, fuses, and relays operate during a fault.
- Ensure protective devices trip in the correct sequence to minimize equipment damage and worker exposure.
4. Incident Energy Calculation
- Determine the heat energy (cal/cm²) a worker would be exposed to during an arc flash.
- Define arc flash boundaries to establish safe working distances.
5. Arc Flash Labeling
- Equipment must be labeled with NFPA 70E-compliant arc flash warning signs.
- Labels should include incident energy levels, PPE requirements, and approach boundaries.
How to Conduct an Arc Flash Hazard Analysis (Step-by-Step)
- Plan the Study – Define scope, gather system documentation, and establish assessment objectives.
- Perform a Field Survey – Verify system components, protective devices, and load conditions.
- Model the Electrical System – Create a one-line diagram to visualize the power distribution network.
- Conduct Short Circuit Analysis – Calculate the available fault current at key equipment locations.
- Evaluate Protective Device Clearing Times – Determine how long breakers and relays take to trip.
- Compute Incident Energy Levels – Identify areas with high arc flash hazards and required PPE levels.
- Generate Arc Flash Labels – Apply clear warning labels on electrical equipment as per NFPA 70E guidelines.
- Implement Safety Measures – Train workers, establish PPE requirements, and develop electrical safety protocols.
As OSHA continuously updates its safety regulations, it’s crucial for businesses to stay informed about new recommendations concerning Arc Flash Hazard Protection. Our latest blog post, ‘Understanding OSHA’s New Recommendations for Arc Flash Hazard Protection’, explores recent updates and how they impact workplace safety.
At C&H Electric, we specialize in Electrical Maintenance Services including conducting Arc Flash Hazard Analysis to help businesses:
- Improve workplace safety & compliance.
- Reduce risks of electrical hazards & injuries.
- Ensure accurate arc flash labeling & PPE determination.
- Provide ongoing support & training for electrical safety programs.
