44 & 44A, Jalan Palma Rafis 1,
Taman Dato Chellam,
81800 Ulu Tiram,
Johor, Malaysia.
+607-8660510
+607-8660511
Saturn Pyro Sdn Bhd
44 & 44A, Jalan Palma Rafis 1,
Taman Dato Chellam,
81800 Ulu Tiram,
Johor, Malaysia.
44 & 44A, Jalan Palma Rafis 1,
Taman Dato Chellam,
81800 Ulu Tiram,
Johor, Malaysia.
Saturn Pyro Sdn Bhd
Johor Bahru Office
44 & 44A, Jalan Palma Rafis 1,
Taman Dato Chellam,
81800 Ulu Tiram,
Johor, Malaysia.
+607-8660510
+607-8660511
enquiry@saturnpyro.com
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K03-03-12, Tower 3,
UOA Business Park,
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Penang Office
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Saturnpyro Solutions Pvt. Ltd.
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K03-03-12, Tower 3,
UOA Business Park,
No 1, Jalan
Pengaturcara U1/51A,
Section U1, Kawasan
Perindustrian Temasya,
40150 Shah Alam,
Selangor, Malaysia.
+607-8660510
+607-8660511
Penang Office
Penthouse 1-21-1,
Suntech @ Penang Cybercity
Lintang Mayang Pasir 3,
11950 Bayan Baru,
Penang, Malaysia.
+607-8660510
+607-8660511
desmond@saturnpyro.com
Bangalore Office
Saturnpyro Solutions Pvt. Ltd.
SFS-B-38, 1st Floor, 7th B Main Road,
Yelahanka New Town, Bangalore 560 064.
GSTIN: 29ABCCS4606C1ZK
+91 829 192 0602
+601 7488 7001
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Shiv Vallabh Cross Road,
Ashokvan, Dahisar (E.),
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Mumbai 400068.
+91 22284 84682
+91 98191 56654
Electrical Arc Flash Hazard Analysis
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ETAP-Based Electrical Safety Engineering
Know the Arc Flash Risk Before Your People Open the Panel
A fault lasting only fractions of a second can expose personnel to extreme thermal energy, pressure, molten metal and life-changing injuries. Our ETAP-based Arc Flash Hazard Analysis converts complex electrical-system behaviour into clear incident-energy results, PPE requirements, equipment labels and practical risk-reduction actions.
Delivered by Saturn Pyro Sdn. Bhd. through mysafety.my for industrial plants, commercial buildings, utilities, data centres and critical electrical facilities.
ETAP Power-System Model IEEE 1584 Methodology NFPA 70E Safety Information Incident Energy Arc Flash Boundary PPE Guidance Equipment Labels
The study gives your team clear answers:
✓ How severe could an arc flash be at each assessed location?
✓ What is the calculated incident energy and arc flash boundary?
✓ What PPE information should be communicated to workers?
✓ Which equipment presents the highest priority for risk reduction?
✓ Can protection settings or operating arrangements reduce exposure?
⚠
Arc Flash Risk Cannot Be Reliably Determined by Equipment Appearance Alone
Two similar-looking panels can have significantly different incident-energy levels because arc flash severity depends on available fault current, equipment configuration, working distance and, critically, how quickly the protective device clears the fault.
Why the Assessment Matters
Turn an Invisible Electrical Hazard into Actionable Safety Information
The analysis provides the engineering basis for safer work planning, effective labelling, PPE communication, hazard prioritisation and electrical-system risk reduction.
Quantify Hazard Severity
Calculate the prospective thermal energy to which a worker may be exposed at the selected equipment and working distance.
Support Correct PPE Planning
Communicate calculated incident-energy information so that appropriate electrical work controls and PPE can be planned.
Evaluate Fault-Clearing Time
Identify cases where slow protection operation may significantly increase arc flash incident energy.
Produce Equipment Labels
Prepare equipment-specific label information for switchboards, switchgear, MCCs, distribution panels and other assessed locations.
The ETAP Advantage
More Than a Calculation: An Updateable Electrical-System Model
ETAP enables the short-circuit, protection and arc flash studies to be performed within an integrated power-system model. This improves traceability and allows future changes to be assessed without rebuilding the entire study from the beginning.
01
Integrated Network Modelling
Transformers, cables, buses, generators, motors, utility sources and protective devices are represented within one coordinated electrical model.
02
Traceable Study Inputs
Equipment ratings, cable parameters, fault levels and protection settings can be reviewed against the corresponding study results.
03
Protection and Arc Flash Linkage
Protective-device operating time is evaluated together with available fault current, supporting more meaningful incident-energy calculations.
04
Scenario Evaluation
Alternative operating configurations and proposed protection-setting changes can be reviewed before implementation.
05
Reusable Digital Model
The model can support future short-circuit, coordination, load-flow, motor-starting and arc flash updates when the electrical system changes.
06
Reduced Future Study Effort
New equipment, feeders or protection changes can be incorporated into the established model, reducing duplicated engineering work.
Important advantage: An arc flash study is a snapshot of the electrical system and its protection settings at the time of assessment. Maintaining the ETAP model makes subsequent reviews more efficient whenever transformers, generators, cables, switchgear, protection settings or operating arrangements are changed.
Standards and Engineering References
Study Methodology Based on Recognised Electrical-Safety Practices
The applicable standards and calculation settings are selected according to the system voltage, equipment configuration, study scope and client requirements.
IEEE 1584
Arc Flash Hazard Calculation
Provides calculation models and technical guidance for estimating arcing current, incident energy and arc flash boundary for applicable AC electrical equipment.
NFPA 70E
Electrical Workplace Safety
Supports the communication and application of arc flash risk information, work practices, labelling considerations and PPE-related safety planning.
IEC 60909
Short-Circuit Current Calculation
Used where applicable for calculating prospective short-circuit currents within three-phase AC electrical systems.
IEC 60255
Protection Relay Considerations
Relevant to protection-relay performance and characteristics used within protection and fault-clearing assessments.
IEC 60364
Low-Voltage Electrical Installations
Provides relevant principles for electrical installation design, protection and safety considerations where applicable to the assessed system.
Local Requirements
Malaysia-Specific Considerations
Relevant client procedures, electrical safety rules, statutory requirements and facility standards can be incorporated into the study scope.
The analysis supports electrical-safety risk management and standards-based decision-making. It should form part of a wider electrical safety programme that includes competent personnel, safe isolation, permit-to-work controls, maintenance, training and appropriate work procedures.
Engineering Study Scope
The Calculations Behind a Reliable Arc Flash Assessment
Incident energy should not be calculated in isolation. The quality of the result depends on accurate system data, short-circuit calculations, equipment configuration and protective device clearing time.
Electrical Data Validation
Review SLDs, source data, transformer ratings, cable details, generators, motors, switchgear information and protective-device data.
Short-Circuit Analysis
Determine prospective fault currents at relevant buses and equipment locations under the defined system operating conditions.
Protection Coordination Review
Evaluate relay, breaker and fuse characteristics to establish operating and fault-clearing times used by the arc flash analysis.
Incident-Energy Calculation
Calculate incident energy, arcing current and arc flash boundary for the selected equipment and working distances.
Operating Scenario Review
Evaluate defined system conditions such as normal supply, generator operation, bus coupling or alternative source arrangements where required.
Risk-Reduction Evaluation
Assess practical opportunities such as faster protection operation, maintenance-mode settings, remote operation or operating-procedure changes.
Our Delivery Method
A Structured Process from Electrical Data to Safety Outputs
Each phase establishes traceability between the available system information, the ETAP model, engineering calculations and final safety deliverables.
1
Define Scope and Locations
Confirm system boundaries, operating scenarios, assessed equipment, required outputs and available documentation.
2
Collect and Review Data
Review SLDs, cables, transformers, switchgear, protection devices, utility data, generators and equipment ratings.
3
Build the ETAP Model
Develop the electrical network model and document assumptions, data gaps and selected calculation parameters.
4
Perform Engineering Studies
Complete short-circuit, protective-device and incident-energy calculations for the approved study cases.
5
Evaluate Risk Reduction
Identify high-risk equipment and assess feasible protection, operational and procedural improvement measures.
6
Report and Label
Issue the engineering report, result schedules, arc flash label information and prioritised recommendations.
Study Outputs
Clear Deliverables for Engineering, Safety and Maintenance Teams
Deliverables are tailored to the project scope, available data, electrical-system size and the client’s documentation requirements.
Engineering Study Report
- Executive summary and study objectives
- Applicable methodology and standards
- System operating scenarios
- ETAP modelling basis and assumptions
- Electrical data gaps and limitations
- Short-circuit calculation results
- Protection-device operating-time review
- Arc flash calculation basis and results
Arc Flash Result Schedule
- Equipment or bus identification
- Nominal system voltage
- Available bolted fault current
- Calculated arcing current
- Protective-device clearing time
- Selected working distance
- Calculated incident energy
- Arc flash boundary
Arc Flash Label Information
- Equipment identification
- System voltage
- Incident-energy information
- Arc flash boundary
- Working distance
- PPE-related information as defined by scope
- Study reference or calculation date
- Warning and hazard communication details
Risk-Reduction Recommendations
- High-incident-energy equipment prioritisation
- Protection-setting improvement opportunities
- Faster fault-clearing options
- Maintenance-switch or alternate-setting review
- Remote operation considerations
- Equipment maintenance observations
- Documentation improvement actions
- Recommendations for future study updates
Protection Study Outputs
- Time-current coordination curves where included
- Protective-device settings summary
- Coordination observations
- Device operating-time assessment
- Protection gaps affecting arc flash energy
- Recommended setting changes where feasible
- Selective coordination considerations
- Technical clarification notes
ETAP Electrical-System Model
- Modelled single-line electrical network
- Source, transformer and cable parameters
- Switchgear and protective-device information
- Defined system operating configurations
- Basis for future model updates
- Support for related power-system studies
- Reduced duplication during future assessments
- Improved traceability of engineering changes
Operational Advantages
Benefits Beyond Regulatory and Safety Documentation
A properly developed study can improve electrical maintenance planning, engineering visibility and long-term management of system changes.
Protect Personnel
Give workers and supervisors better visibility of the potential severity associated with electrical equipment.
Prioritise High-Risk Locations
Focus improvement resources on equipment with the highest calculated incident-energy levels or longest clearing times.
Improve Shutdown Planning
Use the study information when planning isolation, switching, troubleshooting and maintenance activities.
Strengthen Safety Training
Provide equipment-specific information that can support electrical safety briefings and work-planning discussions.
Improve Protection Performance
Identify cases where protection coordination or clearing-time improvements may reduce arc flash exposure.
Support Future System Changes
Reuse the ETAP model when adding equipment, revising protection settings or updating the electrical distribution system.
Typical Applications
Suitable for LV, MV and Critical Electrical Systems
The study is particularly valuable wherever personnel perform switching, inspection, testing, troubleshooting, isolation or maintenance near electrical equipment.
Main LV Switchboards Medium-Voltage Switchgear Motor Control Centres Distribution Boards Transformer Incomers Generator Switchboards Bus Couplers Process Electrical Panels Factories and Manufacturing Plants Data Centres Utilities and Infrastructure Hospitals and Critical Facilities Commercial Buildings Oil, Gas and Chemical Facilities
Why Saturn Pyro
Power-System Engineering with a Practical Safety Focus
Saturn Pyro combines ETAP modelling, electrical-system analysis and practical industrial experience to convert study findings into usable safety and engineering actions.
ETAP Power-System Capability
Integrated short-circuit, protection coordination and arc flash studies within a structured electrical-system model.
Industrial Electrical Experience
Familiarity with industrial distribution systems, switchboards, transformers, MCCs, generators and critical electrical installations.
Traceable Engineering Approach
Clear documentation of study inputs, assumptions, scenarios, limitations, calculations and technical recommendations.
Action-Oriented Recommendations
Findings are presented to support prioritisation, protection improvement, maintenance planning and practical risk reduction.
Do Not Wait for an Electrical Incident to Reveal the Risk
Request an ETAP-based Arc Flash Hazard Analysis for your facility. We can assess your electrical network, calculate incident-energy levels, review protective-device clearing times, prepare arc flash label information and identify practical opportunities to reduce worker exposure.
Email: enquiry@saturnpyro.com | Website: www.mysafety.my
