From arc flash risk assessments to preventive maintenance and worker training, facilities can reduce electrical hazards and improve reliability by treating electrical safety as an ongoing program, not a one-time project.

• By Shawn Gregg
• Aug 06, 2026

In industrial environments, electrical infrastructure directly impacts uptime, equipment reliability and the strength of an organization’s overall safety culture. Safety officers play a critical role in ensuring that power distribution and control systems are safe to operate, maintain and expand. And the stakes are incredibly high.

According to OSHA, arc flash incidents remain among the most serious electrical hazards in industrial settings. Electrical hazards are consistently cited in OSHA’s top workplace violations, and arc flash events can reach temperatures of up to 35,000°F (hotter than the surface of the sun) resulting in severe burns and injuries – even death. Structured safety programs, timely assessments and strategic maintenance practices can help mitigate these risks across the plant floor.

Here are four best practices to help facilities protect personnel, safeguard power and control systems, and maintain reliable operations.

To improve electrical safety you must first understand the risks. An arc flash audit or assessment provides the foundation for safe work practices, personal protective equipment (PPE) requirements and proper labeling across power and control systems. Without current analysis, facilities may be relying on outdated assumptions about available fault current, clearing times or protective device coordination.

Standards such as NFPA 70E require that arc flash risk assessments be reviewed at least every 5 years—or sooner if significant system changes occur. That includes adding new production lines, expanding facilities, upgrading switchgear or modifying electrical distribution. Any change that affects available fault current or protective device settings can alter arc flash incident energy levels.

A comprehensive assessment should lead to:

• Updated arc flash and shock hazard labels on panels, switchgear, MCCs and control systems
• Defined PPE requirements for each piece of equipment
• Documented approach boundaries and safe work distances
• Coordination with lockout/tagout procedures
• Updated single-line diagrams and system documentation

One area that often flies under the radar is proper labeling. When equipment lacks voltage markings, energy data or PPE guidance, electricians are forced to make assumptions and that introduces unnecessary risk. Clear labeling ensures technicians can quickly identify hazards before opening enclosures or performing maintenance.

This article originally appeared in the July/August 2026 issue of Occupational Health & Safety.

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