Why Arc Flash Updates Still Cost Real Money Every Five Years — And Why They Matter
- Brady Smith & Adam Brooks
- Dec 8
- 6 min read
Updated: a few seconds ago
Every few years, facilities ask us the same question:
“Why isn’t the update a fraction of the original price? Can’t you just rerun the old data?”
It’s a fair question. And the answer is important for leaders, EHS managers, facility teams, and anyone responsible for electrical safety.
Arc flash studies aren’t “one-and-done.” NFPA 70E and NFPA 70B both require a review at least every five years — and the reasons are practical, not bureaucratic. Electrical systems drift, utilities change equipment, and hazard calculations become outdated faster than most people expect.
This article explains:
Why the five-year requirement exists
What actually changes inside facilities (often quietly)
Why updates still require real engineering effort
Where savings are possible — and where they aren’t
Safe interim options when you aren’t ready for a full field recollection
Why NFPA 70E & 70B Require a Five-Year Review
NFPA 70E and 70B do not say you must redo the entire study every five years.
They require that you review the arc flash risk assessment for accuracy, and update it anytime system changes could impact results - whether it's after 5 years have passed, or before.
These rules exist for three straightforward reasons:
1. Electrical systems drift from their original design
More changes happen in five years than most people realize:
Breakers get replaced
Protective device settings get adjusted during troubleshooting
New motors, drives, or MCC buckets get added
Panels are swapped
Contractors make upgrades or repairs
Renewable energy sources get added or modified
Even small changes — like adjusting the setting on a breaker to stop a nuisance trip — can increase clearing time and double or triple the incident energy.
2. Utilities change their equipment and fault current
Service transformers get replaced without notice; taps get adjusted. Fault current increases or decreases as utilities add or remove generation.
Because available fault current is a major input in arc flash calculations, your model can drift even if your facility hasn't changed a thing.
3. Workers rely on the data every day
Labels, PPE choices, shock boundaries, and energized work permits all depend on current information. NFPA 70E treats your arc flash data as living safety information, not a binder on a shelf.
The five-year review gives your facility a chance to catch issues before they turn into hazards.
Real Findings We See During Five-Year Updates
Five-year updates regularly uncover conditions that would make old labels inaccurate — sometimes dangerously so. Here are common examples across manufacturing, healthcare, agriculture, commercial facilities, and data centers:
New equipment with no labels
OSHA’s General Duty Clause requires employers to warn workers when PPE is required. Missing or outdated labels = compliance exposure.
Breaker upgrades that changed clearing time
A switch to electronic trip units can dramatically change downstream incident energy.
Fuse swaps that altered fault current
Different fuse classes, interrupting ratings, or even incorrect replacements (yes, we’ve found pipe) change device behavior.
Added motors or drives in MCCs
Additional load increases fault current, changes coordination, and shifts arc flash boundaries.
Utility transformer replacements
One of the most common — and most impactful — findings.
Mislabeled or incorrectly fed equipment
Panels fed from unexpected sources, mislabeled disconnects, incorrect transformer IDs…the list goes on.
One-line diagrams that no longer match reality
When documentation drifts, workers lose situational awareness — and risks increase.
Even well-managed sites experience undocumented changes. That’s why NFPA 70E emphasizes regular review.
Why the Cost of a 5-Year Update Is Similar to a New Study
Here’s the hard truth:
Most of the work must be repeated, even if the original study was high quality.
Where the cost stays the same
Travel and site access
Field verification and walkdowns
Entering verified changes into the model
Running all short circuit, coordination, and arc flash calculations
Analyzing the results
Updating the one-line diagrams
Producing updated labels
Printing and applying labels onsite
Preparing your updated report
PE review and approval
These steps are unavoidable because every calculation depends on knowing the current system.
Where limited savings may exist
If documentation is excellent
If changes are minimal
If conductor routing and lengths have remained the same
If existing modeling files are accurate and usable
In reality, this is the exception, not the rule.
Inflation Considerations
Electrical labor has increased far faster than general inflation over the past decade.
This affects:
Field technicians
Engineers
PPE
Travel
Labeling materials
Compliance requirements
Comparing today’s pricing to a study from five years ago isn’t apples-to-apples because the labor market has changed substantially.
What a True Five-Year Update Requires
A compliant update is not “rerunning the old software file.” It is a structured validation of your electrical system.
A proper update includes:
Updated utility fault data
Critical because upstream changes alter the entire model.
Identifying changes in distribution equipment
New panels, replaced breakers, added MCC buckets, new transformers, VFDs, new feeders, UPS/generator changes, contractor-installed modifications.
Verifying conductor lengths and routing
Even small alterations change impedance and fault current.
Confirming all protective devices and settings
Settings drift all the time.
Recalculating short circuit, coordination, and incident energy.
Engineers compare old vs. new results to understand the risk changes.
Updating equipment labels
All required fields must be accurate, legible, durable, and applied correctly.
Updating the one-line diagrams
Workers depend on this for situational awareness.
This is why five-year updates are more about hands-on engineering than clerical work.
Why a Site Visit Isn’t Optional
Some companies advertise “desktop-only updates.”
NFPA 70E, NFPA 70B, and industry best practice strongly discourage this for four reasons:
Field verification catches undocumented changes
Less than 1% of facilities document every electrical change accurately.
Protective device settings change frequently
Often without logging or oversight.
Equipment condition affects safety
Loose doors, missing screws, worn conductors, heat damage, faded labels: none of this appears in paperwork.
The model must match reality
Even small mismatches produce big changes in incident energy.
A site visit is not a luxury; it is the foundation of a credible update.
How to Prevent Falling Behind Between Full Five-Year Updates
Don't look for shortcuts between full arc flash updates. There is no substitute for proper documentation, routine maintenance checks, and a five-year review.
If you want to avoid surprises, outdated labels, or large swings in calculated incident energy, the most reliable path is the one NFPA 70B already outlines.
A strong electrical safety program prevents drift by focusing on three things:
1. Assign an Electrical Maintenance Program (EMP) Coordinator
NFPA 70B requires facilities to designate an EMP Coordinator responsible for tracking changes to electrical equipment. This person ensures that every modification — new equipment, breaker swaps, added feeders, updated settings — is documented when it happens, not five years later.
This single step eliminates most of the hidden costs that can significantly affect the final price.
2. Diligently Implement IR Inspection Recommendations
Your required yearly infrared (IR) inspection isn’t just for hotspots — it’s one of the best opportunities to identify:
New equipment
Repaired or replaced components
Settings that don’t match the last study
Physical discrepancies between the one-line and the real system
If your IR contractor or internal team captures these observations and passes them to the EMP Coordinator, your documentation stays current all year long.
3. Complete the NFPA-required Five-Year Review
Even with excellent documentation, a formal arc flash analysis every five years is essential.
It confirms:
All utility data is current
All protective devices and settings are verified
The one-line diagram reflects reality
New calculations align with IEEE 1584
Updated labels match the actual hazard in front of workers
This is the step that pulls everything together and validates that the system remains safe and compliant.
Takeaway: The Five-Year Update Protects People, Production, and Compliance
Electrical systems change quietly — breaker settings drift, utilities swap transformers, maintenance adds equipment, documentation falls behind.
When that happens, your arc flash labels stop reflecting the real hazards in front of your workers.
A proper five-year update:
Protects your people
Reduces compliance risk
Improves audit readiness
Ensures your PPE and boundaries are correct
Helps supervisors make safe decisions
Keeps your documentation grounded in reality
If you’re unsure where your facility stands today, Guidant Power can review your existing study or recommend the right level of update for your situation.
70E®, Standard for Electrical Safety in the Workplace®, NFPA 70®, NEC®, and National Electrical Code® are registered trademarks of the National Fire Protection Association, Quincy, MA. All rights reserved. This informational material is not affiliated with nor has it been reviewed or approved by the NFPA.