What Happens If You Don’t Have a Valid Arc Flash Study?

4 days ago

3 min read

Many facility owners assume that having arc flash labels, or an old study completed years ago, is sufficient for compliance. Unfortunately, that assumption often proves costly. Operating without a current and valid arc flash study exposes organizations to regulatory penalties, increased liability, and serious safety risks.

This article explains what actually happens when a facility does not have a valid arc flash study and why proactive compliance is critical.

What Is Considered a “Valid” Arc Flash Study?

An arc flash study is considered valid when it:

Is performed in accordance with NFPA 70E and IEEE 1584
Reflects the current electrical system configuration
Accounts for available fault current, protective device settings, and equipment condition
Has been updated within the last five years, or sooner if system changes occurred
Matches field conditions (breaker sizes, relay settings, utility data)

If any of these conditions are not met, the study may be deemed invalid by inspectors, safety auditors, or insurers.

OSHA Enforcement and Regulatory Risk

Although OSHA does not mandate arc flash studies by name, it does enforce them indirectly.

Under:

OSHA 29 CFR 1910.132(d) (Hazard Assessment)
OSHA 29 CFR 1910 Subpart S (Electrical Safety)

Employers are required to:

Identify electrical hazards
Assess risk severity
Provide appropriate PPE and safe work practices

A current arc flash study is the industry-accepted method for meeting these requirements.

What OSHA Can Do Without a Valid Study

Issue citations for failure to assess hazards
Classify violations as serious or willful
Impose fines per violation
Require corrective action under tight timelines

In practice, arc flash deficiencies are often cited after an incident, when penalties are higher and scrutiny is increased.

Increased Liability After an Electrical Incident

If an arc flash event occurs and your facility lacks a valid study:

Liability shifts heavily toward the employer
Insurance carriers may deny or reduce claims
Legal defense becomes significantly weaker
Prior knowledge of non-compliance can worsen outcomes

Investigators routinely ask:

Was an arc flash hazard analysis performed?
Was PPE selected based on calculated incident energy?
Were employees trained using accurate data?

Without a valid study, the answers are often “no.”

Incorrect PPE Selection and Worker Safety Risk

Arc flash studies determine:

Incident energy levels
Arc flash boundaries
Required PPE categories

Without accurate calculations:

PPE may be under-rated, exposing workers to severe injury
PPE may be over-rated, increasing heat stress and reducing productivity
Arc flash boundaries may be incorrect, putting bystanders at risk

Labels alone do not solve this problem if the underlying data is outdated or incorrect.

Insurance, Audits, and Due Diligence Failures

Insurance carriers, third-party auditors, and corporate EH&S teams increasingly require proof of:

A recent arc flash study
Supporting short-circuit and coordination analysis
Field-verified equipment data
Professional engineering oversight

Facilities without valid documentation may face:

Higher premiums
Required corrective action
Delayed approvals
Project funding complications

Common Reasons Arc Flash Studies Become Invalid

Many facilities unknowingly fall out of compliance due to:

Utility fault current changes
Breaker replacements or setting adjustments
Equipment upgrades or motor additions
Generator or ATS installations
Renovations performed without updating the study

Even small changes can materially affect incident energy results.

How Often Should an Arc Flash Study Be Updated?

Per NFPA 70E, arc flash studies must be:

Reviewed at least every five years
Updated immediately after significant system changes

Facilities with frequent modifications may require updates more often.

How PowerSafe Engineering Helps

PowerSafe Engineering provides complete arc flash studies that include:

Field data collection
Short-circuit analysis
Protective device coordination
Arc flash hazard analysis
NFPA 70E-compliant labels
Clear, defensible documentation

Our studies are tailored for:

Manufacturing facilities
Water and wastewater plants
Schools and universities
Hospitals and healthcare facilities
Municipal and utility infrastructure

Final Takeaway

Not having a valid arc flash study is not a minor paperwork issue—it is a significant safety, compliance, and liability risk. The cost of updating a study is minimal compared to the consequences of operating without one.

If you are unsure whether your arc flash study is current or valid, it is time to review it.