Arc Flash Hazard Analysis and Risk Assessment
An arc flash hazard analysis is a detailed engineering study of your facility’s electrical system designed to identify the potential arc flash and shock hazards at each exposed energized point in your electrical distribution system. The analysis determines incident energy levels, arc flash boundaries, and the personal protective equipment (PPE) required to keep employees safe when working on or near energized equipment.
Arc Flash Florida provides arc flash hazard analysis and risk assessment services for commercial and industrial facilities throughout the state of Florida. Our analyses are conducted in accordance with NFPA 70E 2024, IEEE 1584-2018, and OSHA electrical safety standards.
Why Arc Flash Hazard Analysis Matters
Arc flash incidents are among the most dangerous electrical hazards in the workplace. An arc flash occurs when electrical current leaves its intended path and travels through the air from one conductor to another or to ground, producing an explosive release of energy. Temperatures at the arc can reach 35,000 degrees Fahrenheit, and the resulting pressure wave, molten metal, and intense light can cause severe burns, blast injuries, hearing damage, and death.
OSHA requires employers to assess workplace electrical hazards and protect employees from arc flash and shock risks. NFPA 70E 2024 provides the framework for meeting these obligations through a formal arc flash risk assessment process that identifies hazards, evaluates risk levels, and determines the appropriate protective measures for each piece of equipment.
What an Arc Flash Hazard Analysis Includes
Shock Hazard Analysis
A shock hazard analysis determines the voltage exposure and approach boundaries for each piece of equipment in your electrical system. This analysis establishes the limited approach boundary, restricted approach boundary, and prohibited approach boundary as defined in NFPA 70E Table 130.4(E)(a) and Table 130.4(E)(b). These boundaries dictate how close qualified and unqualified persons can safely approach energized equipment and what protective measures are required at each distance.
Arc Flash Risk Assessment
The arc flash risk assessment evaluates the potential incident energy exposure at each work location where employees may interact with energized electrical equipment. Using the calculation methods outlined in IEEE 1584-2018 (Guide for Performing Arc-Flash Hazard Calculations), the assessment determines the incident energy in calories per square centimeter (cal/cm²) at the working distance for each piece of equipment. This value directly determines the arc rating required for protective clothing and PPE.
The risk assessment also establishes the arc flash boundary for each location. The arc flash boundary is the distance from the arc source at which incident energy drops to 1.2 cal/cm², the threshold for a second-degree burn. Anyone inside this boundary must wear arc-rated PPE appropriate to the incident energy level at their working distance.
Data Required for the Analysis
To properly perform an arc flash hazard analysis, the following information about your electrical system is typically required:
One-line diagram: A schematic representation of your electrical distribution system showing the relationship between all major electrical components from the utility source through the distribution system.
Available fault current from your utility: The maximum short circuit current that the utility can deliver at your service entrance. This is available from your electric utility provider.
Circuit breaker nameplate data and protective settings: Manufacturer, model, ampere rating, and current trip settings for all protective devices in the system.
Cable types, sizes, count, and lengths: Conductor specifications for all feeders and branch circuits, including material (copper or aluminum), insulation type, size, number of conductors per phase, and run lengths.
Conduit type: Whether conductors are in steel (magnetic) or PVC (non-magnetic) conduit, as this affects impedance calculations.
Equipment types and configurations: Manufacturer data, bus configurations, and physical dimensions for switchboards, panelboards, motor control centers, and other electrical equipment.
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What You Receive After the Analysis
Upon completion of the arc flash hazard analysis, you receive a comprehensive report documenting the findings for your entire electrical system. This report includes:
Incident energy calculations for each piece of equipment evaluated, showing the potential arc flash energy in cal/cm² at the working distance.
Arc flash boundary distances for each equipment location, defining the safe approach limits for unprotected personnel.
PPE category assignments for each work location, specifying the minimum arc rating and type of protective equipment required per NFPA 70E Table 130.7(C)(15)(c).
Arc flash hazard warning labels for each piece of equipment. These labels are required by NFPA 70E and OSHA and must include the nominal system voltage, arc flash boundary, incident energy level or PPE category, minimum required PPE, and the date of the assessment. The 2026 NEC (NFPA 70) Section 110.16 further clarifies the labeling requirements to align with NFPA 70E 2024.
Short circuit and coordination analysis documenting fault current levels throughout the system and verifying that protective devices are properly coordinated to clear faults safely.
Recommendations for reducing incident energy levels where possible, such as adjusting protective device settings, adding current-limiting devices, or implementing zone-selective interlocking.
NFPA 70E 2024 Requirements
NFPA 70E 2024 establishes the following requirements that directly relate to arc flash hazard analysis and risk assessment:
Training requirements for qualified employees (Article 110.2): All employees who work on or near exposed energized electrical conductors or circuit parts must be trained to understand the specific hazards associated with electrical energy. Training must be provided at intervals not exceeding three years.
Employer and contractor responsibility (Article 110.3): The employer is responsible for providing an electrical safety program, conducting risk assessments, and ensuring employees are properly trained and equipped.
Electrical Safety Program (Article 110.5): Employers must implement and document an electrical safety program that directs activity appropriate to the electrical hazards, voltage, energy level, and circuit conditions present in the workplace.
Energized Electrical Work Permit (Article 130.2): When energized work is necessary and justified, an energized electrical work permit must document the justification, risk assessment results, safe work practices to be employed, and the PPE required.
Job briefing (Article 110.7): Before starting each job that involves exposure to electrical hazards, the employee in charge must conduct a job briefing covering hazards, procedures, PPE requirements, and emergency response.
Establishing an electrically safe work condition (Article 120): The standard requires that electrical conductors and circuit parts be placed in an electrically safe work condition through proper lockout tagout procedures before any work is performed, unless energized work has been properly justified and permitted.
The Real Cost of Arc Flash Incidents
Arc flash incidents result in thousands of workplace injuries each year across the United States. Beyond the human cost of severe burns, blast injuries, and fatalities, employers face significant financial consequences including OSHA citations and penalties, workers’ compensation claims, equipment damage and replacement costs, production downtime, and potential litigation. A proactive arc flash hazard analysis identifies these risks before an incident occurs, allowing you to implement the protective measures and training programs that keep your employees safe and your facility in compliance.
Statewide Arc Flash Analysis Across Florida
Arc Flash Florida provides arc flash hazard analysis and risk assessment services for commercial and industrial facilities throughout the state. Our team serves operations in Tampa, Orlando, Jacksonville, Miami, Fort Lauderdale, St. Petersburg, Lakeland, Sarasota, Tallahassee, and communities statewide. Whether your facility needs an initial arc flash study, an update to an existing analysis, or a complete electrical safety program review, contact Arc Flash Florida to discuss your specific requirements.