Arc Flash Study in Europe: INFOCOM's Approach, Results and Lessons Learned

Arc flash is one of the most serious hazards associated with industrial electrical systems. Within a very short time, an arc fault can generate extreme thermal energy, pressure and extensive equipment damage.

For an industrial company, an Arc Flash Study should therefore be viewed as much more than a calculation performed for compliance purposes.

It is a comprehensive assessment of the electrical power system that can identify weaknesses, verify protection performance and define measures to reduce risks to personnel and equipment.

INFOCOM has performed Arc Flash studies at more than 15 industrial facilities across Europe, covering electrical network analysis, short-circuit calculations, protection assessment and the development of practical technical recommendations.

What is an Arc Flash Study?

An Arc Flash Study evaluates the potential energy released during an electrical arc event.

Its purpose is to determine:

• where hazardous locations exist,
• the potential incident energy at individual equipment,
• which protective measures may be required,
• whether existing protection operates quickly enough,
• how the risk can be reduced technically.

The final result is therefore not simply a calculated value.

A well-executed study provides the facility with a clear understanding of the condition of its electrical system and actionable recommendations for improving safety.

Step one: understand the actual electrical network

Every project begins with collecting and verifying technical information.

Existing documentation does not always accurately represent the current configuration of a facility.

Over the years, plants may change:

• transformers,
• switchboards,
• cables,
• production technologies,
• motors,
• circuit breakers,
• protective relay settings.

For this reason, an Arc Flash Study should not rely solely on old drawings.

INFOCOM analyses the network topology and, depending on the project scope, verifies the technical information required to create an accurate electrical model.

Building the electrical network model

The collected information is used to create a calculation model of the electrical system.

This allows engineers to simulate the behaviour of the network under different operating and fault conditions.

The model may include:

• utility or local power sources,
• transformers,
• generators,
• cables,
• busbars,
• motors,
• circuit breakers,
• fuses,
• protective relays.

The quality of the results depends heavily on the accuracy of the input data.

Short-circuit calculations

Short-circuit analysis is one of the fundamental parts of the project.

It determines the potential fault-current levels at different points within the electrical distribution system.

The results can be used to verify:

• whether switchgear has sufficient short-circuit withstand capability,
• whether circuit breakers and fuses are correctly rated,
• how the system will behave during a fault,
• which locations may require additional attention.

Short-circuit conditions also directly influence Arc Flash calculations.

Protection must operate correctly — and quickly

During an arc fault, clearing time is critical.

The longer the arc remains active, the greater the potential incident energy.

INFOCOM therefore analyses the operation and settings of protective devices.

This may include reviewing:

• clearing times,
• circuit breaker settings,
• protective relay settings,
• coordination between protection levels,
• system selectivity.

Incorrect protection settings can cause a fault to remain active longer than necessary.

Properly coordinated protection can significantly reduce the consequences.

Selectivity: one fault should not shut down the entire plant

A well-designed protection system should not simply disconnect a fault.

Where technically possible, it should isolate the fault as close as possible to its source.

A problem affecting one machine should not unnecessarily shut down an entire production area or facility.

Selectivity analysis verifies whether protective devices will operate in the correct sequence.

This can contribute to:

• smaller outage areas,
• faster restoration of production,
• higher system availability,
• lower operational impact of electrical faults.

Calculating Arc Flash incident energy

Once the electrical model, short-circuit calculations and protection analysis are complete, potential Arc Flash incident energy can be calculated.

The results help determine the risk associated with individual pieces of equipment.

They may be used to define:

• equipment hazard labelling,
• personal protective equipment requirements,
• safe working procedures,
• technical risk-reduction measures.

However, classification itself is not the ultimate objective.

The priority should be to determine whether the hazard can be reduced through engineering measures before relying on PPE alone.

How can Arc Flash risk be reduced?

The appropriate solution depends on the electrical system.

Recommendations may include:

• modifying protective relay settings,
• changing circuit breaker settings,
• improving selectivity,
• upgrading protection devices,
• reducing fault clearing times,
• changing system configuration,
• modifying switchgear,
• updating operating or maintenance procedures.

Not every improvement requires a major capital investment.

In some cases, optimisation of existing protection settings can significantly improve safety.

What does the facility gain?

The value of an Arc Flash Study goes beyond technical documentation.

A properly executed project can provide several practical benefits.

Improved personnel safety

Identifying hazardous locations allows suitable procedures and protective measures to be implemented.

Reduced risk of major equipment damage

Correct and faster fault clearing can limit the extent of an electrical incident.

Better protection coordination

The analysis can reveal settings that do not provide the intended protection performance.

Reduced outage impact

Selective isolation can prevent a local fault from unnecessarily interrupting a much larger part of the facility.

Technical input for future modernisation

The study provides valuable data for planning upgrades and electrical infrastructure investments.

Experience from more than 15 European plants

INFOCOM’s experience from more than 15 industrial facilities across Europe demonstrates that no two electrical systems are exactly the same.

Facilities differ in:

• equipment age,
• network topology,
• production technology,
• protection systems,
• operating modes,
• quality and accuracy of available documentation.

For this reason, there is no universal Arc Flash calculation that can simply be applied to every plant.

Each study must reflect the actual electrical system.

The real value comes from implementing the recommendations

An Arc Flash Study creates the greatest value when its conclusions are converted into practical action.

Identified risks should not remain only in a technical report.

INFOCOM therefore approaches the work as a complete process:

data collection → electrical model → short-circuit analysis → protection assessment → Arc Flash calculation → recommendations → corrective measures.

This connects personnel safety with the reliability of the electrical infrastructure.

Electrical safety begins with understanding the real system

Industrial electrical networks change over time.

New technologies are connected, power sources change, protection settings are modified and operating configurations evolve.

It is therefore important to verify periodically whether existing calculations and settings still correspond to actual site conditions.

An Arc Flash Study enables companies to identify electrical risks and make modernisation decisions based on engineering data.

The objective is not simply to calculate the hazard. It is to create a safer and more reliable electrical system.