Stage 1 – The Introduction

A multinational manufacturing client operates over 20 sites across the UK and Europe, each with a unique engineering requirement and different network. Seeking to unify their approach and ensure every site maintains an up-to-date Arc Flash and Fault Level Assessment, they turned to Covol. With a proven track record in multi-site projects, Covol stepped in to deliver a forward-thinking, standardised solution. This document will cover why the client wanted to unify their approach and how Covol was able to deliver our solution.

Stage 2 – The client’s requirements and our initial approach.

• Fragmented Compliance: The client did not have a consistent programme schedule for Arc Flash and Fault Level Assessments. Some sites had recently undertaken assessments, while others had none at all.

• Corporate Engagement: The relationship with Covol was initially at a corporate level, with each site expected to engage with Covol independently based on its specific needs.

• Methodical Approach: Leveraging experience from similar multi-site projects, Covol identified key engineering contacts at each location and mapped out an efficient schedule, ensuring that all sites were included in the compliance calendar.

Stage 3 – The Challenges

• Inconsistent Awareness: With certain sites never having had an assessment, awareness of arc flash hazards varied widely.

• Complex Network: Each facility had different operational parameters, meaning a standard ‘one-size-fits-all’ approach would be ineffective.

• Frequent Updates: Evolving network changes and staff turnover, demanded a reliable and adaptable compliance programme solidified at a corporate level.

Stage 4 – The Solution

By collaborating closely with the client’s central management team, Covol implemented a unified, site-specific strategy that delivered robust Arc Flash and Fault Level Assessments across all locations.

We had been able to engage with key personnel at each site to schedule the assessments and site visits around their current commitments ensuring no site remained unassessed.

The assessment included the following key components:

• Arc Flash and Fault Level Analysis from the site infeed down to equipment rated at or above 100A 3 Phase.

• A Site Survey to gather all pertinent technical data, conducted by one of our expert engineers.

• A comprehensive Assessment Report, renowned for it’s robustness and credibility in HSE evaluations.

• Utilisation of the SKM Power Tools Software, acclaimed in the industry for its efficacy in conducting such assessments.

• The provision of new Single Line Diagrams.

• All necessary self-adhesive warning labels.

Stage 5 - The Results

• Consistent Compliance: Every site now meets its Arc Flash and Fault Level requirements, identifying risk accurately and enhancing safety across the entire network. This is the case for each site and each site now complies with the applicable standards, this includes:

  • NFPA 70E 2024 – Standard for Electrical Safety in the Workplace

  • IEEE 1584 2018 – Guide for Performing Arc Flash Hazard Calculations

  • BS EN 60909 – Short-circuit currents in three-phase ac systems. Calculation of currents.

• Proactive Risk Management: With a schedule for ongoing updates, the client is no longer reactive or concerned about missing future updates as Covol now sends reminders to the individual site, 3 months in advance of a planned updates.

• Cultural Shift: Covol’s involvement fostered a deeper awareness of electrical safety, embedding a proactive stance on hazard identification at each facility.

We take pride in not only meeting but consistently surpassing our client’s expectations. Their ongoing positive feedback reflects both our clear communication and the high standard of our work. Having worked with this particular client for almost a decade, Covol now oversees all Arc Flash and Fault Level responsibilities on their behalf. By taking ownership of these critical processes, we enable the client to remain focused on their other core priorities.

Ready to Embark on a Journey Towards Engineering Excellence?

Choosing the right partner can be the difference between mere survival and outstanding success. By partnering with Covol, industry leaders gain more than electrical engineering services—they acquire a forward-thinking collaborator that propels them and allows them to focus on other critical business requirements.

If you are seeking a partner that understands the gravity of your operation and has the proficiency to meet them, look no further than Covol. Contact us to discover how we can support your path towards heightened safety, compliance, and innovation.