How to Prepare for an Arc Flash Study: A Step-by-Step Guide

Aug 12

3 min read

If you manage an industrial plant, commercial facility, or utility system, an arc flash study isn’t just a compliance checkbox—it’s a critical step in protecting your personnel and your equipment. The better you prepare for the study, the more accurate and valuable your results will be.

At PowerSafe Engineering, we’ve performed countless studies across manufacturing, healthcare, wastewater, and energy sectors. Here’s our step-by-step guide to ensure your arc flash study is smooth, efficient, and delivers actionable results.

Step 1 – Understand Why You Need the Study

Arc flash studies are required under NFPA 70E, OSHA, and industry best practices. They determine the incident energy levels at various points in your electrical system and help define the PPE requirements, arc flash boundaries, and labeling needed to keep your team safe. Preparation starts with knowing the goal—to protect workers, comply with standards, and reduce the likelihood and severity of arc flash events.

Step 2 – Gather Electrical Documentation

Accurate, up-to-date documentation is the backbone of a reliable study. Before your engineering team arrives, compile:

One-line diagrams of your electrical system
Panel schedules and switchgear layouts
Transformer nameplate data
Breaker and fuse information (make, model, and settings)
Cable sizes, types, and lengths
Motor horsepower and load data

If this information is incomplete, don’t worry—our engineers can gather it during the site visit, but having it ahead of time speeds the process.

Step 3 – Coordinate a Site Visit

The field assessment allows us to verify your documentation, capture missing details, and note real-world conditions that drawings may not reflect. This includes:

Checking for equipment upgrades or changes since your last study
Measuring conductor lengths and routing
Documenting protective device settings
Identifying any safety hazards in the electrical rooms

Pro tip: Arrange for escort access to all electrical rooms and ensure that panels are unlocked and available for inspection.

Step 4 – Involve the Right People

An arc flash study isn’t just for engineers—it’s a team effort. Key personnel to include are:

Maintenance staff who know the electrical system inside and out
Safety officers responsible for compliance
Facility managers who schedule downtime and coordinate operations

Having the right people available during data collection avoids repeat visits and ensures nothing is overlooked.

Step 5 – Plan for Operational Impacts

Most of the data collection is non-invasive and can be done without shutting down your facility. However, in some cases, breaker or relay settings may need to be verified, which might require brief outages. Work with your engineering team to schedule these during low-impact periods.

Step 6 – Review Preliminary Findings

Once the modeling and calculations are complete, we’ll provide a draft report showing:

Incident energy values at each bus or piece of equipment
Recommended PPE categories
Arc flash boundaries
Coordination adjustments to reduce hazard levels

Reviewing this draft allows you to provide feedback before finalizing the report and printing arc flash labels.

Step 7 – Implement Recommendations

An arc flash study is only as effective as its follow-up. Implementation may include:

Applying new arc flash labels
Updating your electrical safety program
Adjusting protective device settings for better coordination and hazard reduction
Training your team on new PPE and work procedures

Final Thoughts

Preparation is the key to getting the most value from your arc flash study. The more organized your data and team are, the faster we can deliver accurate results that improve safety and compliance.

If your facility is due for a study—or it’s been more than five years since your last one—contact PowerSafe Engineering today. We’ll guide you through the entire process, from preparation to implementation, ensuring your people and equipment are protected.

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