Arc flash is the electrical hazard that kills people quietly. Ten times more workers are killed each year by arc flash than by electrocution from direct contact. NFPA 70E is the standard everyone gets cited under — and most contractors don't have a written program.
What NFPA 70E Actually Requires
NFPA 70E, Article 110, requires an electrical safety program (ESP) that includes:
- Written policies and procedures for electrical work
- Arc flash risk assessment for each task
- PPE category tables or incident energy analysis
- Qualified worker training and documentation
- Job briefing documentation for energized work
- Auditing of program every 3 years
PPE Category Tables vs Incident Energy Analysis
NFPA 70E gives you two ways to determine PPE requirements:
- Table 130.7(C)(15)(a) or (b) — pre-calculated PPE categories based on task type and voltage. Simpler but conservative.
- Incident energy analysis — engineering study specific to your equipment. More precise, more expensive to develop.
Most contractors use the tables. For 480V and below, that works. Above 480V, or when using PPE Category 4 (40 cal/cm²) frequently, an incident energy analysis often justifies its cost.
What's In The Forbes Arc Flash Program Pack
- Written arc flash safety program — customizable to your facility
- Task-based arc flash risk assessment template
- PPE category selection matrix — pre-filled for common tasks
- Energized work permit template
- Job briefing template for energized work
- Qualified worker training record
- Incident energy analysis worksheet (if using Method 2)
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Frequently Asked Questions
What's the difference between NFPA 70E and OSHA?
OSHA is federal law — mandatory. NFPA 70E is a consensus standard — but OSHA uses it as the industry benchmark for compliance under the General Duty Clause. Citing NFPA 70E in your program isn't optional in practice — OSHA inspectors expect it.
Do I need an arc flash program if I don't do energized work?
Yes. NFPA 70E 110.5(H)(1) requires an electrical safety program regardless of whether you plan to do energized work. If your workers might be exposed to arc flash (during LOTO, cover removal, or testing for voltage), you need the program. Only truly de-energized, verified-dead work is exempt.
What's PPE Category 4 and when do I need it?
PPE Category 4 is the highest arc-rated protection under NFPA 70E — a 40 cal/cm² rated suit. You need it when the incident energy exposure is between 25 and 40 cal/cm². Above 40 cal/cm², you can't work energized period. Most transmission-level work either requires Category 4 or is prohibited without de-energization.
How often do I need to update the arc flash study?
NFPA 70E 130.5 requires the arc flash risk assessment to be reviewed at least every 5 years, OR when a major modification is made to the electrical system. Most utilities and industrial facilities update annually to capture minor changes.
Do I need arc flash labels on my equipment?
Yes. NFPA 70E 130.5(H) and NEC 110.16 require field-marked labels on electrical equipment operating at 50V or more. Labels must include arc flash boundary, incident energy or PPE category, and voltage. Missing labels are a common OSHA citation.
Can workers wear a hardhat under an arc flash hood?
Depends on the hood design. NFPA 70E 130.7(C)(10)(a)(iii) requires head protection — the arc flash suit hood typically covers this. If you wear a hard hat, it must be non-conductive (Class E). Most modern arc suits are designed to fit over a Class E hard hat.