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Arc Flash Analysis

An Arc Flash Analysis helps identify issues that may lead to an arc flash or blast. An arc flash or blast can release dangerous levels of heat energy, fire, molten materials, vaporized solids that can be inhaled, flying shrapnel and trigger the rapid expansion of air, all capable of causing severe and sometimes fatal injuries. To help reduce the risk of an arc flash or blast, and the associated injuries, a Rockwell Automation Arc Flash Analysis includes:

  • Electrical Power Systems Analysis
  • Recommended Arc Flash Safety Training
  • Short Circuit Current Analysis
  • Overcurrent Protective Device Coordination Analysis
  • Hazard Analysis

Rockwell Automation can perform problem remediation and updates to one-line diagrams following the assessment.


The foundation to any successful machine safety program is a risk assessment. Leading safety organizations including TUV, IEC, NFPA, ANSI and ASSE have recognized and promoted the benefits associated with performing risk assessments based on industry published methodologies. Today, safety-related standards and industry guidelines are being updated to reflect the need for conducting risk assessments. Your Rockwell Automation Risk Assessment will provide:

  • A repeatable process that can help improve machine safeguarding and act as a guide towards achieving regulatory compliance
  • Clarification of safeguarding requirements and definition of the appropriate control circuit architecture and safety performance level needed for compliance
  • Documented evidence of intent to produce a safer product or workplace
  • A baseline that can be referenced during periodic inspections of the machine to help assure all safeguards are still implemented and working properly. As production dictates changes in machine operations, previous risk assessments can be quickly updated to reflect any new hazards and mitigation plans associated with the modification
  • Identification of potentially hazardous situations that may be missed by using any other method of risk assessment (Rockwell Automation utilizes a task-based methodology)
  • The framework to create a positive staff attitude around machine safety. By involving technicians in the safeguarding process, the technicians can better understand why a machine needs to be guarded in a particular manner and; therefore, may be more likely to accept the new safeguard


These exception-based assessments are a quick and inexpensive way to audit a machine /work cell to determine the obvious points of operation and power transmission hazards. The result of the hazard assessment is a concise report that identifies the location of each observed hazard and provides a rough budgetary estimate for safeguarding. The hazard assessment will also provide:

  • General recommendations on how to guard a machine/work cell
  • A prioritization plan for your machine safeguarding project when many unique machines need to be evaluated and upgraded
  • The unbiased, third party opinion of a machine safety consultant with the required knowledge of relevant safety standards, best practices and current safeguarding technology


This assessment helps identify lockout/tagout issues that could lead to the unexpected release of hazardous energy during service and maintenance work. The LOTO Assessment includes training and hardware recommendations to improve your LOTO process. Improvements can be realized in risk reduction and overall LOTO time reduction.

ESC Services, Inc., a Leading Lockout-Tagout Service Provider

Rockwell Automation, Inc. has acquired ESC Services, Inc., a global hazardous energy control provider of lockout-tagout services and solutions.

ESC Services develops and installs equipment-specific lockout-tagout procedures featuring custom graphics and safety workflows.

Stop Time

Stop time measurements evaluate compliance of light curtain and area guarding device installations. These services also help to determine ergonomic and operational advantages of safeguarding options.

Safety Circuit

A Safety Circuit Analysis will help you meet your safety standards. Rockwell Automation will verify the safety circuit design per the applicable standards specified by you. These standards may include EN-954 Category B,1,2,3, or 4, ANSI B11, TR3 Control Reliable, Single Channel w/ monitoring, Single Channel, or others. During the Circuit Analysis we will:

  • Assure compliancy of system architectures and designs
  • Evaluate the safety circuit integrity
  • Provide you a third-party evaluation

Process Safety

Functional Safety Consultancy