Coca-Cola Abu Dhabi: Arc Flash Study for Industrial Bottling Facility
Client: Coca-Cola
120+
Panels Assessed
120+
Arc Flash Labels
4 levels
PPE Categories
4 weeks
Completion Time
IEEE 1584 & IEC 60909
Standards Applied
15+ points
Hazard Reduction
Project Overview
Carelabs was engaged by Coca-Cola's Abu Dhabi bottling facility to perform a comprehensive arc flash hazard analysis across their entire electrical distribution infrastructure. The facility, one of the largest beverage production operations in the UAE, required full compliance with IEEE 1584 and NFPA 70E to protect maintenance workers and meet evolving HSE requirements.
The Challenge
The facility's electrical system included over 120 panels spanning main distribution boards, sub-main distribution boards, motor control centres, and production line electrical infrastructure. Previous arc flash documentation was outdated, and the facility had undergone significant system modifications since the last assessment. Maintenance crews needed current incident energy data and proper PPE assignments to work safely on energised equipment.
Our Approach
Carelabs deployed a team of field engineers using AppSheet-based digital data collection to systematically document every electrical asset. This mobile-first approach ensured accurate, consistent data capture across the sprawling facility. The collected data was used to build a detailed ETAP power system model incorporating all sources, transformers, cables, protective devices, and load characteristics.
Short-circuit analysis was performed per IEC 60909, followed by comprehensive incident energy calculations at every working point per IEEE 1584-2018. We reviewed protective device coordination to identify opportunities for reducing fault clearing times and lowering arc flash hazard levels. The final deliverables included over 120 arc flash labels, a complete hazard analysis report, and PPE requirement matrices for the facility's safety team.
Results and Impact
The study provided Coca-Cola's Abu Dhabi facility with current, standards-compliant arc flash hazard data for their entire electrical system. Maintenance crews received updated PPE assignments and arc flash labels were installed on all assessed equipment. Several high-hazard locations were identified where relay setting adjustments or equipment modifications could significantly reduce incident energy levels, improving worker safety while maintaining system reliability.
Challenge
Coca-Cola's Abu Dhabi industrial bottling facility required a comprehensive arc flash hazard analysis across its entire electrical distribution system. The facility operates multiple production lines with extensive MDB, SMDB, and motor control infrastructure. Regulatory pressure from ADDC and internal HSE requirements mandated a full arc flash study compliant with IEEE 1584 and NFPA 70E to protect maintenance personnel working on energised equipment.
Solution
Carelabs deployed field engineers equipped with AppSheet-based digital data collection tools to systematically survey all electrical equipment across the facility. The team collected nameplate data, protective device settings, cable specifications, and system configurations. Using ETAP software, we built a comprehensive power system model, performed short-circuit analysis per IEC 60909, and calculated incident energy at every working point per IEEE 1584-2018. The study included protective device coordination review to optimise fault clearing times and reduce arc flash hazard levels where possible.