1. Keep Your Arc Flash Study Up to Date
An arc flash event can be catastrophic, not just for your equipment, but for anyone nearby. That's why NFPA 70E requires a current arc flash study. If it's been more than five years since your last one, or if you've made system changes, you're due for an update.
A solid arc flash study gives you accurate PPE requirements, hazard labels, and boundaries, so your team knows exactly what they're dealing with. Not sure what's involved or what it costs? Here's a breakdown of why an arc flash study pays for itself.
2. Don't Cut Corners on Labeling
Labels matter. Every panel, switchboard, and disconnect should be clearly marked with the right hazard information. It's not enough to throw a generic sticker on and call it good.
Labels should reflect the actual data from your arc flash analysis: incident energy levels, required PPE, approach boundaries, and more. This is one of the simplest ways to keep your crew safe and avoid fines.
The 2026 NEC makes this even more critical, with detailed labeling now enforceable by local electrical inspectors.
3. Train (and Re-Train) Your Electrical Workers
Even the best safety program falls apart without trained people behind it. OSHA expects that anyone working near electrical hazards is properly trained, not just once, but on a regular basis.
That means understanding arc flash and shock risks, knowing how to work around energized gear safely, and following lockout/tagout procedures to the letter. Make sure you're documenting training and keeping it current. It's often the first thing OSHA will ask about.
4. Have a Written Electrical Safety Program
If you're relying on tribal knowledge or word-of-mouth for safety procedures, it's time to put things in writing. A clear, practical electrical safety program helps everyone stay on the same page and proves that you take compliance seriously.
Your program should include steps for risk assessments, how energized work is justified (when absolutely necessary), and what to do in an emergency. It's also worth reviewing at least once a year to make sure it still reflects your actual practices.
5. Revisit Power System Studies Periodically
Power systems change. Equipment gets added, loads shift, and suddenly your breakers aren't coordinating like they used to. That's why it's smart to review your short circuit, coordination, and load studies every few years.
Doing so helps catch underrated gear, prevent nuisance trips, and ensure your system can support future expansion without surprise issues. Think of it as a health checkup for your plant's electrical infrastructure.
Here's a real example of code violations found during a recent arc flash study that wouldn't have been caught without a full system analysis.
Wrapping Up
Staying compliant with electrical safety standards isn't just about avoiding penalties. It's about keeping your people safe and your operations reliable. A proactive approach goes a long way in minimizing risk and avoiding disruptions.
Need Help With Electrical Safety Compliance?
At Zech Engineering, we specialize in helping manufacturers build safer, more efficient operations, one system at a time.