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Electrical systems power everything in your facility — but they can also present hidden dangers. One of the most serious risks is an arc flash , a sudden and explosive release of electrical energy that can cause burns, injuries, and even fatalities. To keep workers safe and stay compliant with regulations, facilities are required to perform an arc flash study . What Is an Arc Flash Study? An arc flash study is an engineering analysis of your electrical system that: Identifies potential arc flash hazards. Calculates the amount of energy that could be released in an event. Determines the level of personal protective equipment (PPE)  workers need. Provides clear labels and documentation  for equipment. Why It Matters: Worker Safety:  Arc flashes can reach temperatures of 35,000°F — hotter than the surface of the sun. A study helps reduce these risks. Regulatory Compliance:  OSHA requires employers to protect workers from electrical hazards. NFPA 70E provides the standard framework. Cost Avoidance:  Fines, lawsuits, and downtime from an incident can be devastating. A study is far less expensive than the consequences of not having one. Clarity for Workers:  Proper labeling and PPE requirements take the guesswork out of electrical safety. When Do You Need One? New facility construction. Major electrical system upgrades. Every 5 years (per NFPA 70E), or sooner if system changes occur. Arc Defense Engineering Solutions specializes in helping facilities of all sizes perform accurate, affordable arc flash studies . Protect your team and stay compliant — contact us today .

An arc flash study isn’t a one-and-done project. Electrical systems change over time — and those changes can make your original study inaccurate. The question many safety managers ask is: “How often do we need to update our arc flash study?” The NFPA 70E Requirement: According to NFPA 70E, arc flash studies must be reviewed and updated at least every 5 years . But that’s the minimum. In many cases, you’ll need to update sooner. When to Update Your Study Sooner: System Upgrades:  Adding new machinery, panels, or breakers. Service Changes:  Utility feed adjustments or transformer replacements. Protection Device Settings Changed:  Even minor changes in breakers, fuses, or device settings can alter results. That dial you adjusted to eliminate the nuisance trip just invalidated your arc flash label. Accidents or Near Misses:  Any electrical event should trigger a review. Why Updates Are Important: Accuracy = Safety:  Outdated studies can leave workers under-protected. Compliance:  OSHA can cite companies if their arc flash data is outdated. Insurance Requirements:  Some insurers require up-to-date electrical safety studies. Tip: Even if no major changes occur, scheduling a review every 3–5 years  keeps your program aligned with best practices. Arc Defense can help you determine if your study needs updating — and provide a plan that fits your budget. Schedule your review today .

Arc flash studies are only useful if their results are communicated clearly — and that’s where equipment labeling comes in. Unfortunately, many facilities make labeling mistakes that put workers at risk and create compliance gaps. Here are the top 5 mistakes to avoid. 1. Missing Labels Altogether It’s shocking how often equipment goes unlabeled. Every piece of electrical equipment likely to require servicing while energized must have a label. 2. Outdated Labels Labels from an old study may not match current system conditions. This gives workers false confidence and creates serious risk. 3. Generic “Warning” Labels OSHA requires more than just a warning sign. Labels must include incident energy levels, arc flash boundaries, and required PPE. 4. Labels That Are Hard to Read If a worker can’t read the label quickly, it defeats the purpose. Small fonts, poor color contrast, or fading stickers are common problems. 5. Inconsistent Labeling Across the Facility Mixing different formats or data points confuses workers. Standardization ensures clarity and compliance. Best Practice: Use durable, standardized, and compliant labels placed consistently on all equipment. Pair them with worker training to ensure the message gets through. Arc Defense Engineering Solutions provides compliant arc flash labeling and clear reporting that makes safety simple. Contact us  to learn more.