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Arc Flash Study

Identify arc flash hazard levels, determine required PPE categories, establish protection boundaries, and ensure your electrical installations comply with arc flash safety standards.

An arc flash study identifies the amount of incident energy released during an electrical arc fault at each point in your system. This determines the hazard level, required personal protective equipment (PPE), and safe working distances — saving lives and ensuring regulatory compliance.

Arc Flash Study - H-Infinity

01What is an Arc Flash Study

An arc flash is an unexpected release of electrical energy through the air, caused by insulation breakdown between conductive surfaces of different potential. It is one of the most dangerous events that can occur in any electrical system — temperatures can exceed 19,000°C (35,000°F), creating an explosive plasma ball that projects molten metal, intense heat, and a destructive pressure wave in every direction.

An arc flash study quantifies this danger by calculating the incident energy (measured in cal/cm²) at every piece of equipment throughout your installation. These calculations determine the arc flash boundary — the distance within which a worker would receive a second-degree burn — and the corresponding PPE category required for safe entry.

02What Causes Arc Flash

Arc flash incidents can be triggered by a variety of conditions and events:

  • Dropped tools or equipment — Metal objects bridging the gap between phase conductors or between phase and earth.
  • Corrosion and insulation deterioration — Gradual degradation of insulation systems reducing dielectric strength over time.
  • Pollution and contamination — Dust, moisture, conductive particles bridging insulation gaps.
  • Accidental contact — Personnel or animals inadvertently touching energised components.
  • Voltage transients — Switching surges or lightning strikes exceeding insulation capability.

03Consequences of Arc Flash

Personnel Hazards

  • • Severe burns (often fatal at incident energies above 40 cal/cm²)
  • • Electric shock from step and touch potentials
  • • Pressure wave trauma (barotrauma to ears, lungs, brain)
  • • Blindness from intense ultraviolet radiation
  • • Toxic gas inhalation from vaporised materials
  • • Flying shrapnel and molten metal projections

Equipment Damage

  • • Explosive equipment damage and enclosure rupture
  • • Melting and vaporisation of conductors
  • • Structural fire and secondary damage
  • • Carbon deposits degrading insulation on adjacent equipment
  • • Long-term reliability reduction even if not destroyed
  • • Production loss and business interruption

04How We Conduct the Study

1. Data Collection & Site Survey

Collect complete electrical system data — utility source, transformer ratings and impedances, cable lengths and sizes, protective device settings, and operating conditions. Validate with a thorough site survey.

2. Fault Level Calculation

Calculate the available fault current at each piece of equipment, considering the contribution from all sources including the utility, on-site generation, and motors.

3. Incident Energy Analysis

Apply IEEE 1584 equations to calculate the incident energy at each point, factoring fault current, arc duration (determined by protective device clearing time), working distance, and arc type.

4. Labelling & PPE Selection

Assign arc flash PPE categories, establish protection boundaries, and produce compliant arc flash labels for every piece of equipment per NFPA 70E requirements.

05Standards & Compliance

IEEE 1584 — Arc Flash Calculation Guide
NFPA 70E — Electrical Safety in the Workplace
IEC 60364-4-41 — Protection for Safety
BS 7671 — Requirement for Earthing & Bonding

06Why H-Infinity

H‑Infinity provides thorough arc flash studies backed by decades of field experience. Our approach combines detailed simulation modelling with practical site assessment to deliver results you can act on immediately.

We don't just hand you a report — we provide clear, colour-coded arc flash labels ready for application, comprehensive training materials for your electrical teams, and a prioritised action plan to reduce arc flash energy where feasible through protective device adjustments and system modifications.

Ready to discuss your project?

Our team of power systems engineers is ready to provide expert guidance, detailed studies, and robust solutions tailored to your specific requirements.