Electrical Testing Procedures

GK Batchelor Laboratory
Department of Applied Mathematics and Theoretical Physics

UNIVERSITY OF CAMBRIDGE
Electrical Safety:
Policy and Procedures
Contents
1 Scope .......................................................................................................................... 5
2 Use of Equipment....................................................................................................... 5
2.1 Policy................................................................................................................... 5
2.1.1 Offices .......................................................................................................... 5
2.1.2 Laboratory .................................................................................................... 5
2.1.3 Laptops ......................................................................................................... 5
2.1.4 Home office.................................................................................................. 6
2.2 Testing................................................................................................................. 6
2.3 Auditing............................................................................................................... 7
2.4 Rig Risk Assessment ........................................................................................... 7
2.5 Elemental Risk Assessment ................................................................................ 8
2.6 Operating Procedures .......................................................................................... 8
2.7 Standard Procedures............................................................................................ 9
2.7.1 Positioning of Equipment............................................................................. 9
2.7.2 RCD Protection ............................................................................................ 9
2.7.3 Switching...................................................................................................... 9
2.7.4 Extension leads and plug boards ................................................................ 10
2.7.5 Earth bonding ............................................................................................. 10
2.7.6 Submersible equipment .............................................................................. 10
2.8 Faults ................................................................................................................. 11
2.9 Disposal............................................................................................................. 11
2.10 People .............................................................................................................. 11
2.10.1 User .......................................................................................................... 11
2.10.2 Electrical Safety Assessor ........................................................................ 11
3 Tests ......................................................................................................................... 11
3.1 Brand New Equipment ...................................................................................... 11
3.2 Equipment from Other Sources......................................................................... 12
3.3 Standard Tests ................................................................................................... 12
3.3.1 Cable damage ............................................................................................. 12
3.3.2 Casing damage and condition .................................................................... 12
3.3.3 Fuse rating .................................................................................................. 12
3.3.4 Earth bond .................................................................................................. 12
3.3.5 Insulation.................................................................................................... 13
3.3.6 Operational ................................................................................................. 13
3.3.7 Earth leakage .............................................................................................. 13
3.4 Flash Tests......................................................................................................... 13
3.5 Supplementary Tests ......................................................................................... 13
4 Documentation ......................................................................................................... 14
1
Electrical testing: Intervals and procedures
DAMTP
4.1 Record Sheet ..................................................................................................... 14

4.2 Test Sticker........................................................................................................ 14
4.3 Database ............................................................................................................ 14
5 Office Equipment ..................................................................................................... 15
5.1 Office Appliances.............................................................................................. 15
5.1.1 Desk lamps ................................................................................................. 15
5.1.2 Fans ............................................................................................................ 15
5.1.3 Heaters........................................................................................................ 15
5.2 Kitche and Cleaning .......................................................................................... 16
5.2.1 Kettles......................................................................................................... 16
5.2.2 Microwaves ................................................................................................ 16
5.2.3 Vacuum cleaners ........................................................................................ 16
5.3 IT Equipment..................................................................................................... 17
5.3.1 Computers .................................................................................................. 17
5.3.2 Computer monitors..................................................................................... 17
5.3.3 Laptops ....................................................................................................... 18
5.3.4 Printers ....................................................................................................... 18
5.3.5 Data hubs.................................................................................................... 18
5.4 Communication Equipment............................................................................... 19
5.4.1 Answerphones and dictation machines ...................................................... 19
5.4.2 Fax machines.............................................................................................. 19
5.5 Reproduction Equipment................................................................................... 19
5.5.1 Photocopiers ............................................................................................... 19
5.5.2 Binders ....................................................................................................... 19
5.6 Projection Equipment ........................................................................................ 20
5.6.1 Slide projectors........................................................................................... 20
5.6.2 Overhead projectors ................................................................................... 20
5.6.3 Data projectors ........................................................................................... 20
Video tape recorders............................................................................................ 21
6 General Equipment................................................................................................... 21
6.1 Catering Equipment........................................................................................... 21
6.2 Plant................................................................................................................... 21
6.3 Lighting and Sockets......................................................................................... 21
7 Laboratory Equipment.............................................................................................. 21
7.1 Office Appliances.............................................................................................. 21
7.1.1 Desk lamps ................................................................................................. 21
7.1.2 Fans ............................................................................................................ 22
7.1.3 Vacuum cleaners ........................................................................................ 22
7.2 Laboratory Appliances ...................................................................................... 22
7.2.1 Densitometer .............................................................................................. 22
7.2.2 Refrigerator ................................................................................................ 23
7.2.3 Freezer........................................................................................................ 23
7.3 IT Equipment..................................................................................................... 23
7.3.1 Computers .................................................................................................. 23
7.3.2 Computer monitors..................................................................................... 24
7.3.3 Printers ....................................................................................................... 24
7.3.4 Data hubs.................................................................................................... 24
7.3.5 Portable equipment..................................................................................... 25
7.4 Video Equipment and Cameras......................................................................... 25
7.4.1 Video tape recorders................................................................................... 25
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7.4.2 Video monitors........................................................................................... 25

7.4.3 Video timers ............................................................................................... 26
7.4.4 High-speed cine camera ............................................................................. 26
7.4.5 Video cameras ............................................................................................ 26
7.4.6 Camera power supplies .............................................................................. 27
7.5 Light Sources..................................................................................................... 27
7.5.1 Projectors.................................................................................................... 27
7.5.2 Photographic lamps .................................................................................... 28
7.5.3 Turntable lamps.......................................................................................... 28
7.5.4 Fluorescent lamps....................................................................................... 29
7.5.5 Light boxes................................................................................................. 30
7.5.6 Arc lamps ................................................................................................... 30
7.5.7 Strobe lights ............................................................................................... 31
7.6 Lasers ................................................................................................................ 31
7.7 Power Supplies.................................................................................................. 31
7.7.1 Bench supplies ........................................................................................... 31
7.7.2 Plug-in adapters.......................................................................................... 32
7.7.3 High voltage supplies ................................................................................. 32
7.8 Laboratory Instrumentation............................................................................... 33
7.8.1 Amplifiers................................................................................................... 33
7.8.2 Bridge circuits ............................................................................................ 34
7.8.3 Multimeters ................................................................................................ 34
7.8.4 Oscilloscopes.............................................................................................. 34
7.8.5 High voltage equipment ............................................................................. 35
7.9 Motors and Controllers...................................................................................... 36
7.9.1 Servo motor controllers.............................................................................. 36
7.9.2 Servo motors .............................................................................................. 36
7.9.3 AC motors .................................................................................................. 36
7.10 Pumps .............................................................................................................. 37
7.10.1 Integrated pumps ...................................................................................... 37
7.10.2 Peristaltic pumps ...................................................................................... 37
7.10.3 Submersible pumps .................................................................................. 38
7.10.4 Vacuum pumps......................................................................................... 38
7.10.5 Double-bucket pumps .............................................................................. 38
7.10.6 Variable speed pumps .............................................................................. 39
7.11 Turntables........................................................................................................ 39
7.11.1 Turntables................................................................................................. 39
7.12 Laboratory Equipment..................................................................................... 40
7.12.1 Heat baths................................................................................................. 40
7.12.2 Stirrers ...................................................................................................... 40
7.12.3 Scales........................................................................................................ 41
7.12.4 Immersion heaters .................................................................................... 41
7.13 Frameworks and Tanks ................................................................................... 41
7.13.1 Metalwork ................................................................................................ 41
7.14 Power Cords .................................................................................................... 42
7.14.1 Standard cords (IEC)................................................................................ 42
7.14.2 Non-standard cords .................................................................................. 43
7.14.3 Cords with RCD ....................................................................................... 43
7.15 Plug-boards and Extension Leads ................................................................... 43
7.15.1 Plug-boards............................................................................................... 43
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7.15.2 Integrated plug-boards.............................................................................. 44

7.15.3 Extension Leads ....................................................................................... 44
7.16 RCDs ............................................................................................................... 45
7.16.1 RCD adapters ........................................................................................... 45
7.16.2 RCD plugs ................................................................................................ 45
7.16.3 RCD sockets............................................................................................. 45
7.17 Fixed Installations ........................................................................................... 45
7.17.1 Hand driers ............................................................................................... 45
7.17.2 Heaters...................................................................................................... 46
7.18 Three-phase Installations................................................................................. 46
7.18.1 Wind tunnels ............................................................................................ 46
7.18.2 Flumes ...................................................................................................... 46
7.18.3 Sump pump .............................................................................................. 46
7.18.4 Ventilation equipment .............................................................................. 47
8 Workshop ................................................................................................................. 47
8.1 Hand Tools ........................................................................................................ 47
8.1.1 Drills........................................................................................................... 47
8.1.2 Grinders...................................................................................................... 47
8.1.3 Saws ........................................................................................................... 48
8.1.4 Routers ....................................................................................................... 48
8.1.5 Heat guns.................................................................................................... 49
8.1.6 Soldering irons ........................................................................................... 49
8.2 Fixed Tools........................................................................................................ 49
Three Years ......................................................................................................... 49
8.3 Three-phase Installations................................................................................... 50
8.3.1 Milling machines........................................................................................ 50
8.3.2 Lathes ......................................................................................................... 50
8.3.3 Drilling machines ....................................................................................... 50
8.3.4 Compressor ................................................................................................ 50
8.3.5 Abrasion tools ............................................................................................ 51
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1 Scope
This document outlines the various procedures, responsibilities, and risks
associated with the use of mains-operated electrical equipment in the Fluid
Dynamics Laboratory. The document provides guidance for the development of
Risk Assessments, and describes the various test procedures and hazards
associated with the main classes of equipment used in the Laboratory and
Workshop.
NOTE: A replacement for this document is under preparation. A draft of the
new CMS Site Policy may be found at
http://www.damtp.cam.ac.uk/lab/safety/ElectricalDraftPolicy.pdf
2 Use of Equipment
2.1 POLICY
2.1.1 Offices
No mains-operated electrical or electronic equipment may be used unless it has a
valid test sticker issued by the Department. Test stickers from other sources are
not acceptable alternatives. This requirement applies to all office equipment and
domestic appliances, including computers and even if they are brand new. Any
equipment that has been modified or is not standard equipment must be subject to
the procedures and standards outlined for laboratory equipment.
The user must be familiar with the manufacturers instructions for the equipment
and use it in accordance with these.
Failure to observe these procedures may result in sanctions or disciplinary action
against the offender.
2.1.2 Laboratory
No mains-operated electrical or electronic equipment may be used unless it has a
valid test sticker issued by the Department and a Risk Assessment has been
carried out. Test stickers from other sources are not acceptable alternatives, and
stickers are required even for brand new equipment. The user must have read and
be familiar with the Operational Procedures for the equipment. The user must also
be familiar with and adhere to the general guidance and procedures given in the
Laboratory Safety Guidelines and the specific procedures outlined below.
Failure to observe these procedures may result in sanctions or disciplinary action
against the offender.
2.1.3 Laptops
All laptops purchased or owned by the Department must be tested in accordance
with this policy, even if the laptop is never used within the Department itself.
Testing should include inspection of any multi-standard mains adapter that may
be used with the laptop.
When outside the Department, users should only connect to the mains if they are
confident that the electrical outlet is safe and that their laptop is not damaged.
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Visitors from outside the Department are requested not to connect their laptops
unless they have been tested to a level comparable to that outlined in this
document. The Department is happy to test laptops for long-term visitors. It is
recommended that short-term visitors run their laptops from batteries. The
Department does not condone the use of laptops that have not been tested and
cannot be held liable for any injury, damage or other consequence of failing to
observe this guideline.
2.1.4 Home office

Some members of staff have equipment (primarily IT equipment) in their own
homes where this equipment is purchased out of departmental or research funds.
The responsibility for ensuring that this equipment is tested regularly (typically
every three years) falls solely on the user of such equipment. The Department will
test such equipment if the user brings it into the Department for testing. The
Department will also test other equipment that is used predominantly for work at
home, even when it is not owned by the Department, provided it is brought into
the Department for testing.
Users should adhere to the same level of standards in both the home office and
Departmental contexts. This includes but is not limited to Electrical Safety and the
Universitys guidelines for the use of VDU screen equipment.
The Department cannot be held responsible for loss or injury resulting from
failure to adhere to this guideline or from failure to ensure the equipment is tested
regularly.
2.2 TESTING
Prior to 2000, the test stickers on items of equipment indicated only the date the
equipment was last tested. From July 2000 onwards, the stickers indicate both the
date tested, and the date the next test is due. With the older type of stickers, the
user should seek verification that the equipment is still safe to use for any
equipment where the date is more than two years before the present. For the
newer style of sticker, equipment must not be used beyond the next test due
date.
For equipment where the mains power cable is not integral, both the cable and the
equipment itself should have a valid test sticker.
Brand new items, and equipment sourced from elsewhere must also be issued with
test stickers. The equipment must not be used until this has been completed. The
level of testing required for this is detailed elsewhere in this document.
In the Risk Assessment for a laboratory experiment, the user must list all electrical
equipment and record the next test due date for each item. It is the responsibility
of the user to react accordingly when this due date is approaching. It is
recommended that a re-test is requested four weeks before the due date. Note that
failure to request testing at least three weeks in advance of the due date may lead
to delays in the experimental programme while awaiting for a test to be
undertaken.
The user should also complete a visual inspection of all equipment on a regular
basis. Any defective, damaged or otherwise unsafe equipment should be
disconnected immediately and the reason for the disconnection indicated on the
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equipment. Notices for indicating faults are available from the Electronics
Technician. The defect should also be reported to the Electronics Technician.
Not all equipment will be subject automatically to regular testing. The testing of
items that have not been used for a long time, or are only used infrequently, may
be allowed to lapse to avoid unnecessary testing. It is the responsibility of the
user to check that the testing is up to date before connecting the equipment.
2.3 AUDITING
All equipment in active use will be audited on a regular basis. For equipment in
the Laboratory and Workshop, this auditing will occur every six months. For
equipment in the offices, this auditing will occur annually.
Typically, an audit will involve inspecting a subset of equipment to ensure the
relevant procedures have been adhered to.
During an audit (or at any other time), any equipment found not to have a valid
test sticker, found not to meet standard practices, or found to have an obvious
defect, must be disconnected immediately. Such equipment must not be
reconnected until it has been tested and any problems have been rectified. The
Safety Officer must be informed of all such equipment. In most cases, failure
during an audit will trigger a more detailed examination of any associated
equipment.
2.4 RIG RISK ASSESSMENT

A Risk Assessment must always be undertaken for an experimental rig. This Rig
Risk Assessment is normally developed by the user or potential user of the rig,
often in consultation with previous users or other Laboratory personnel. The Rig
Risk Assessment may draw upon details contained in the Risk Assessment for
other similar rigs; when this occurs, this link should be spelt out explicitly in the
assessment.
The scope of this Rig Risk Assessment is not limited to electrical equipment, but
must include the full range of mechanical, chemical, light and other potential
hazards.
This Rig Risk Assessment must list each of the items of electrical equipment used
in the rig, and the date at which they are next due to be tested must be recorded.
The Rig Risk Assessment should highlight all potential risks, safe operating
procedures, safe methods in which the rig may be shutdown, and the risk posed
through any equipment connected via signal or data cables. The Rig Risk
Assessment must be completed before the experimental rig is first used, and
reviewed or revised whenever there is any material change in the set-up. The
adequacy of the Rig Risk Assessment and the overall safety of the experimental
rig must be reviewed by an Electrical Safety Assessor prior to any work being
undertaken.
The Rig Risk Assessment must also contain a copy of or explicit reference to the
Risk Assessment for any individual component that requires a separate Elemental
Risk Assessment, and any limitations of use or recommended practice contained
in such a separate assessment must be observed.
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Such separate Elemental Risk Assessments are required for all discrete electrical
components that are custom-built, modified in any way, or used in a manner or for
a purpose differing from that envisaged by the manufacturer.
All queries concerning electrical safety should be directed to the Director of the
Laboratory or the Electronics Technician. The Electronics Technician will
normally undertake any electrical tests required.
2.5 ELEMENTAL RISK ASSESSMENT

An Elemental Risk Assessment should be completed for every custom-made or
modified item of equipment. Elemental Risk Assessments are also required for
standard items of equipment when such an item is to be operated in am manner
not envisioned by the manufacturer, although such assessments may be derived
from the manufacturers documentation.
The Elemental Risk Assessment should indicate the potential hazards associated
with the equipment, its intended use, the tests to which the equipment should be
subject, the interval for testing, and verification that the Operating Procedures are
valid and appropriate. Generic Elemental Risk Assessments are permitted for
standard laboratory items (e.g. conductivity bridges) even when there may be
some small differences between each individual example.
Elemental Risk Assessments for custom equipment should be reviewed at an
interval of two years, or twice the test interval, whichever is longer. A review is
also required whenever the equipment is modified, or it is to be used in a
substantially different manner.
These Elemental Risk Assessments do not replace the need for a Rig Risk
Assessment.
2.6 OPERATING PROCEDURES

All users should consult the Operating Procedures for an item of equipment before
using the equipment. Moreover, if the Operating Procedures or Risk Assessment
specifies that training is required, the use must seek and obtain this training.
For standard commercial equipment, the manufacturers operating procedures are
all that is required, provided the equipment is to be used for the purpose envisaged
by the manufacturer. Any deviation to this requires supplementary Operating
Procedures to be developed and, potentially, an Elemental Risk Assessment.
All custom-made equipment requires Operating Procedures to be written. These
procedures may be developed during the first six months following
commissioning, provided the Laboratory Safety Officer deems the user
competent. In such cases, the user will be responsible for developing the
Operating Procedures and will be required to submit a first draft of these
procedures to the Laboratory Safety Officer within two months of the equipment
being commissioned.
Items that are identical or similar to items for which Operating Procedures already
exist may refer to the existing procedures only after those procedures have been
reviewed.
Where possible, all operating procedures should be provided in both electronic
and hard copy. Where the source documentation is electronic, both the source file
(TEX, Word or plain text) and a PostScript or Acrobat version must be logged
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with the Laboratory Safety Officer. Electronic copy in Acrobat format may be
created from hardcopy by the use of a suitable scanner.
2.7 STANDARD PROCEDURES

This section lists various standard procedures that must be adhered to for the
majority of equipment. If any of these procedures is to be waived, the reasons for
doing so and the associated risks must be discussed explicitly in the Rig Risk
Assessment.
Spills of water are inevitable in the laboratory. If such spills occur over or close to
electrical or electronic equipment then this represents a serious risk of
electrocution. The standard procedures listed here will help reduce the risk to an
acceptable level.
2.7.1 Positioning of Equipment

Mains operated equipment must be positioned where it is not subject to splashes,
chemicals spills, or other potentially hazardous contamination.
When located above water (or any other fluid), it must be fastened in such a way
to prevent any chance of it falling into the fluid. Where possible, avoid mounting
any item below a source of water. If this is unavoidable (e.g. some electric motors
or pumps) careful consideration must be given to minimise the chance of the
water reaching live connections.
The equipment must not be located where it is likely to fall or otherwise suffer
mechanical damage. Where necessary, the technicians will make special brackets
to hold the equipment securely.
2.7.2 RCD Protection

All equipment should be connected to the mains only through a Residual Current
Device (RCD). These devices are designed to immediately cut the supply as soon
as any imbalance occurs between the live and neutral wires, or when any current
is detected in the earth wire. Note that this does not completely remove the chance
of electrocution, but does decrease it significantly.
The RCD should be installed as the first component when connecting to the
mains. Where possible, wall-mounted RCD sockets should be employed. If this is
not possible, RCD plugs or RCD adapters (in that order of preference) should be
used. There is no harm (but also no advantage) in having more than one RCD in
the circuit to a given item of electrical equipment.
RCDs should be checked at least once a month using their integrated test
facility.
Computer equipment may be connected without an RCD unless there is a chance
that it may be exposed to splashes. As a rule, computer equipment should always
be located where there is no chance of such exposure. Note, however, that if the
computer is in any way connected to a probe or control circuit, then an RCD is
required.
2.7.3 Switching
Never turn off, connect or disconnect equipment when your hands are wet, or
when standing on a wet floor.
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Similarly, do not operate equipment with wet hands or when you are in contact
with water unless the equipment has been designed to allow safe operation when
wet. In such cases, the need for such operation and the risks involved must be
assess in the Risk Assessment.
Ensure the power to the equipment may be safely shut off in the event of an
accident. This should be marked clearly as it may be necessary for someone
unfamiliar with the equipment or rig to do so.
Any cut-out switch should be of a type that may be operated safely with wet
hands. Operation of the cut-out switch should be tested at six-month intervals.
2.7.4 Extension leads and plug boards

Extension leads and plug boards may be used to provide a suitable number and
location of electrical sockets.
No more than one additional plug board may be connected to a plug board.
The total electrical load on the plug board must not exceed the rating of the plug
board, and the total electrical load on a given double socket must not exceed 20A.
Plug boards must be positioned where there is no danger of them being splashed,
stood on, or likely to be immersed in the event of an accidental spillage.
Cables leading both too and from the plug board must be kept tidy and routed to
ensure they do not represent a risk of entanglement. Cables must not be under
strain, and nor should they be of excessive length.
Double adapters must never be used.
2.7.5 Earth bonding

All permanent and substantial equipment containing exposed metalwork must be
earth bonded. Earth bonding consists of providing wires, straps or other direct
electrical connection between each piece of metal, and connecting this into a good
earth.
The Electrical Safety Assessor will check the integrity of these connections.
2.7.6 Submersible equipment

Submersible equipment such as pumps and immersion heaters must only should
preferably be used in tanks where a suitable route to earth is provided. This route
to earth may be provided by an earth connection on the submersible unit, by earth
bonding of metal work exposed to the water, or by the insertion of an earth
electrode into the tank.
If the earth connection is provided by a separate electrode, then this electrode
should be positioned so that it has at least 200mm2 contact with the working fluid
when the fluid is at the lowest level likely to be encountered.
The earth electrode must be kept clean and free from corrosion. It is
recommended that the electrode be constructed from stainless steel and is located
at the bottom of a tank side wall (location on the tank floor may allow an
insulating layer of particles to form on top of the electrode).
The earth electrode must be connected to a suitable earth. For fixed installations,
this should be a permanent route to earth. For moveable equipment, it is
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recommended that the connection be made through the same RCD-protected

circuit as the electrical equipment used with the tank. This connection may be
through a dedicated earth terminal on the electrical equipment, or using an
adapted earth-only mains plug inserted into a socket.
2.7.6.1 Faults
Any instances of blown fuses either in the plugs or in the equipment must be
reported to the Electronics Technician. The equipment must be inspected by the
Technician to ascertain the cause prior to the fuse being replaced.
Any instances of the local RCD tripping must be reported to the Electronics
Technician. All the equipment on the circuit that tripped, or any other equipment
connected to this through signal cables, must be inspected by the Technician to
ascertain the cause prior to any of the equipment on the tripped circuit being used
again.
Any instances of thermal cut-outs operating must be reported to the Electronics
Technician. The equipment must be inspected by the Technician to ascertain the
cause prior to any of the equipment being used again.
2.8 DISPOSAL
If an item of equipment is sold, given away or otherwise disposed of, the
equipment must be marked with a sticker stating that it has not been electrically
tested and that it is the recipients responsibility to ensure the electrical safety
before use. In the case of any equipment disposed of through the rubbish, the plug
must be cut off.
2.9 PEOPLE
2.9.1 User
For the purposes of this document, the User is the person or group of people who
will make direct use of the equipment. In the case of a group, every member must
understand any limits or procedures imposed by the Risk Assessment or
Operational Procedures.
2.9.2 Electrical Safety Assessor

The Electrical Safety Assessor is required to assess the safety (or otherwise) of an
experimental rig as a whole. The Director of the Fluid Dynamics Laboratory will
appoint appropriate Assessors once he is satisfied of their competence to
undertake this task.
The Electronics Technician is an Electrical Safety Assessor.
3 Tests
This section outlines the various standard tests that may be performed on
electrical and electronic equipment. Additional tests for certain categories of
equipment are detailed under the documentation for that equipment.
3.1 BRAND NEW EQUIPMENT

Brand new equipment must be tested or, if it carries the appropriate certification
(e.g. a CE mark), may be deemed safe based that certification, provided the level
of testing required for that certification is at lease comparable with the procedures
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laid out in this document. If the equipment is deemed safe based on the
manufacturers testing then the test sticker should be completed with New in
place of the date tested, and with an appropriate date entered for the date the next
test is due. All equipment processed in this manner must be logged and the record
sheet must indicate that no tests were undertaken.
3.2 EQUIPMENT FROM OTHER SOURCES

Equipment that has been tested by another source (e.g. another department in the
University) should be inspected by someone authorised to undertake electrical
testing. If such equipment appears to be in good order and the tester is satisfied
that the test procedures the equipment has been subjected to previously are
adequate, then the equipment may be handled in a manner similar to that for brand
new equipment. The date for the next test should be calculated based on the
information contained on the existing sticker. If this produces a different date for
the next test than is indicated on the existing sticker, then the earlier of the two
dates must be selected. All equipment processed in this manner must be logged
and the record sheet must indicate that no tests were undertaken.
3.3 STANDARD TESTS

3.3.1 Cable damage
Visual inspection.
Any cuts, abrasions, distortions or bad kinks in the cable, or damage to the
connectors, are to be rectified by replacing the cable. This work must be carried
out before proceeding with any of the other tests.
The integrity of the cable clamps should be confirmed at both ends of the cable.
Any fault or inadequacy found is to be rectified.
3.3.2 Casing damage and condition

Visual inspection.
Any damage to the equipment case should be mended and a risk assessment
undertaken on the adequacy of the repair. When the casing cannot be repaired to
an acceptable standard, the casing must be replaced or the equipment
decommissioned.
Ventilation slots, heat sinks and fans must be clear of obstruction.
Any build-up of dust or grease must be removed.
3.3.3 Fuse rating

Visual inspection.
The rating of the fuse in the plug must not exceed the rating of the associated
cable.
The type and rating of any user-replaceable fuse in the equipment must be in
accordance with the manufacturers specification.
3.3.4 Earth bond

If not double-insulated.
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The electrical resistance between all exposed metal parts and the earth terminal on
the connector should not exceed 0.1. Circumstances where the resistance
exceeds this value should be investigated and, when there is an acceptable reason
for higher values, this should be noted on the test sheet. A resistance exceeding
0.1 must either lead to the equipment being repaired or decommissioned, or lead
to a full Risk Assessment being undertaken.
If an earlier test or Risk Assessment has recorded a resistance more than 20%
lower than the new figure, the reasons for this must be explained and assessed.
3.3.5 Insulation
This test applies 500V DC between the power conductors and a nominal earth.
This test should not be performed on electronic equipment.
This test is different if earthed or double-insulated equipment. For earthed
equipment, the test is between the combined live/neutral pins and the earth pin.
For double-insulated equipment, the test is between the combined live/neutral pins
and a probe applied to the outside of the case. For submersible double-insulated
equipment, the second probe may be applied to the liquid surrounding the
submersed item; this will provide a check for any cracks in the insulation through
which the liquid may penetrate.
If the insulation is found to be less than 2M, then the equipment must be
repaired or decommissioned.
3.3.6 Operational
Check that current within specified limits.
The equipment should be run in accordance with the standard operational
procedures and the current drain measured. This current should be within 20% of
the value specified by the manufacturer (or in any Risk Assessment).
The source of any unexpected noise should be investigated.
Any evidence of sparking (except if as an intended part of the equipment design)
must be investigated.
Failure of this test must either lead to the equipment being repaired or
decommissioned, or lead to a full Risk Assessment being undertaken.
3.3.7 Earth leakage

Should be less than 3mA.
This leakage should include all routes to earth, not just any earth connection the
equipment might have.
3.4 FLASH TESTS

Due to the possibility of damage to the associated equipment and insulation, this
test is not to be performed..
3.5 SUPPLEMENTARY TESTS

The standard tests outlined above in 3.3 apply to all equipment. For some
categories of Laboratory equipment, additional tests are desirable. These
supplementary tests include, for example, tests for submersible pumps whilst
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actually submersed, and confirmation of earth terminals and routes to earth for
probes. Recommended supplementary tests for each category of equipment are
listed in 7.
4 Documentation
4.1 RECORD SHEET
The test record sheet for every item should be completed. If an item fails, this
should be recorded, along with details of the cause of failure. Details of the
remedy should also be recorded.
Any item that deviates from the expected performance (e.g. the operational
current), must be noted along with the conditions under which the deviation was
found. Future tests should always include assessing whether this level of deviation
has changed.
When a record sheet is changed, it must be moved to the Updated folder. At
regular intervals, the details in this folder will be added to the database and the
corresponding sheets returned to the main folder.
If an item is disposed of, the record sheet should be removed from the main series
and transferred into the Decommissioned folder. The reason for
decommissioning should be recorded.
4.2 TEST STICKER

Every item passing the test procedures should be marked with an appropriate test
sticker indicating the initials of the person responsible for the test, the date tested,
and the date the next test is due.
Cables and equipment must both have test stickers attached, unless the cable is an
integral (non-removable) part of the equipment. For the cable, the test sticker
should be located close to the mains plug. For the equipment, the test sticker
should be located in such a position that it is obvious to anyone attempting to
operate the equipment.
An item failing the test should be immediately removed from service and a
Failed Electrical Test Do Not Use notice attached to the plug and over the face
of the item.
4.3 DATABASE
The database should reflect the contents of the Record Sheets and tie this
information in with the main equipment inventory, operation manuals and risk
assessments.
The database should be updated at regular intervals (at least quarterly) from the
Record Sheets contained in the Updated folder. Once the details contained by an
updated Record Sheet has been transferred to the database, the sheet should be
marked and returned to the main folder.
Once a quarter, the database should be used to generate a list of equipment for
which a test is over due, and a list of tests due in the coming quarter.
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5 Office Equipment
5.1 OFFICE APPLIANCES
5.1.1 Desk lamps
Elements of risk assessment
Location.
Proximity to combustible material.
Routing of cable.
Test interval
Three years.
Tests required
Standard tests.
Switch.
5.1.2 Fans
Location.
Routing of cable.
Stability.
Test interval
Three years.
Tests required
Standard tests.
Finger guards.
5.1.3 Heaters
Location.
Routing of cable.
Stability.
Proximity to flammable materials.
Test interval
Three years.
Tests required
Standard tests.
Finger guards.
Tilt switch.
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5.2 KITCHE AND CLEANING

5.2.1 Kettles
Manual kettles are not permissible.

Location.
Routing and length of cable.
Stability.
Test interval
Three years.
Tests required
Standard tests.
Automatic turn off.
5.2.2 Microwaves
Manual kettles are not permissible.

Location.
Routing and length of cable.
Operator instructions.
Suitable cooking implements.
Cleanness.
Test interval
Three years.
Tests required
Standard tests.
Timer.
5.2.3 Vacuum cleaners

Dry or wet and dry usage.
Period of operation.
Storage location.
Dust filtering.
Use with toner spillages.
Test interval
One year.
Tests required
Standard tests.
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RCD plug (if wet and dry ability).
5.3 IT EQUIPMENT
5.3.1 Computers
Location.
Ergonomics.
Routing of cables.
Power and data.
Interchangeable power cables.
These must be designated explicitly to the associated IT item and not
interchanged with any other cable. The 13A mains plug must be clearly
marked as to which item it belongs to. It is recommended that the IEC
connector is also marked. The cable must carry a test sticker and be re-tested
at the same time as the computer. If either the cable or the computer has a test
sticker that is out of date, then both must be re-tested.
Test interval
Three years.
Tests required
Standard tests.
Cable.
Dust.
Fan operational.
Obstruction of ventilation.
Internal operational temperatures (where motherboard/BIOS provide these).
5.3.2 Computer monitors

Routing of cables.
Adequacy of ventilation.
Refresh rate and interference.
Stability and crispness of picture.
Ambient illumination.
Ergonomics.
at the same time as the monitor. If either the cable or the monitor has a test
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Test interval
Three years.
Tests required
Standard tests.
5.3.3 Laptops
Damage due to transportation.
Especially of power cables and power supplies.
Connection to other standards.
Any adapters should be tested.
Test interval
One year.
Tests required
Standard tests.
Cable.
Adapter.
5.3.4 Printers
Toner spillage.
at the same time as the printer. If either the cable or the printer has a test
Test interval
Three years.
Tests required
Standard tests.
Cable.
Filters.
Internal dust and toner.
5.3.5 Data hubs
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Routing of cables.
Test interval
Three years.
Tests required
Standard tests.
5.4 COMMUNICATION EQUIPMENT

5.4.1 Answerphones and dictation machines
Location.
Ergonomics.
Routing of cables.
Test interval
Three years.
Tests required
Standard tests.
5.4.2 Fax machines

Location.
Ergonomics.
Routing of cables.
Test interval
Three years.
Tests required
Standard tests.
5.5 REPRODUCTION EQUIPMENT

5.5.1 Photocopiers
The testing of this equipment is part of the Service Contract for this equipment.

Toner spillage.
Test interval
As recommended in Service Contract.
Tests required
As recommended in Service Contract.
5.5.2 Binders
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Location.
Test interval
Three years.
Tests required
Standard tests.
Finger guards.
5.6 PROJECTION EQUIPMENT

5.6.1 Slide projectors
Routing of cables.
Dazzle of lecturer.
Test interval
Three years.
Tests required
Standard tests.
Fan & ventilation slots.
Procedure for replacing bulb.
5.6.2 Overhead projectors

Routing of cables.
Dazzle of lecturer.
Test interval
One year.
Tests required
Standard tests.
5.6.3 Data projectors

Routing of cables.
Dazzle of lecturer.
Test interval
Three years.
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Tests required
Standard tests.
Video tape recorders

Location
Ergonomics.
Routing of cables.
Potential blockage of ventilation slots.
The flat top of a VTR is an attractive place for paper, books, tapes, etc. This
may lead to a blockage of the ventilation slots.
Test interval
Three years.
Tests required
Standard tests.
6 General Equipment
6.1 CATERING EQUIPMENT
All catering equipment in the Pavilion A kitchen is the responsibility of the
University Catering Service. Members of the Department do not have access to
this equipment. All testing and servicing of this equipment will be arranged by
the University Catering Service.
6.2 PLANT
All plant, including machinery located in the Plant Room, wall-mounted or
under-bench water heaters, hand driers, extract equipment and other fixed
equipment is the Responsibility of Estate Management and Building Services.
Members of the Department have a responsibility to report any faults, but
EMBS will arrange for any tests necessary.
6.3 LIGHTING AND SOCKETS

The testing of all fixed lighting, fixed sockets, emergency lighting, etc., is the
responsibility of Estate Management and Building Services.
7 Laboratory Equipment
7.1 OFFICE APPLIANCES
7.1.1 Desk lamps
Location.
Proximity to combustible material.
Protection for luminary.
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Availability of low-voltage alternative.
Test interval
Three years if in Office.
Two years if in Laboratory.
Tests required
Standard tests.
Switch.
7.1.2 Fans
Location.
Stability.
Test interval
Three years if in Office.
Two years if in Laboratory.
Tests required
Standard tests.
Finger guards.
7.1.3 Vacuum cleaners

Dry or wet and dry usage.
Use in wet environment.
Period of operation.
Unattended operation.
Test interval
One year.
Tests required
Standard tests.
RCD plug (wet and dry).
7.2 LABORATORY APPLIANCES

7.2.1 Densitometer
Frequency of relocation.
Test interval
Three years.
Tests required
Standard tests.
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Dust in heater/cooler unit.

Leaks.
7.2.2 Refrigerator
Nature of contents.
Location of electrics in event of leakage.
Test interval
Three years.
Tests required
Standard tests.
Dust on condenser & compressor.
Corrosion damage.
Warning notices.
7.2.3 Freezer
Nature of contents.
Use: storage or experiment.
Risk of damage from experiments.
Location of electrics in event of leakage.
Test interval
Two years.
Tests required
Standard tests.
Dust on condenser & compressor.
Corrosion damage.
Warning notices.
Temperature within acceptable range.
7.3 IT EQUIPMENT
7.3.1 Computers
Office or Laboratory location.
Location relative to experiments.
Risk of splashing.
Connection to control or measurement circuits.
Connection to data ports and other computer peripherals.
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Test interval
Three years.
Tests required
Standard tests.
Dust.
Fan operational.
Internal operational temperatures (where motherboard/BIOS provide these).
7.3.2 Computer monitors

Risk of splashing.
Refresh rate and interference.
Ambient illumination.
Ergonomics.
Test interval
Three years.
Tests required
Standard tests.
7.3.3 Printers
Risk of splashing.
Test interval
Three years.
Tests required
Standard tests.
Filters.
Internal dust and toner.
7.3.4 Data hubs
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Risk of splashing.
Risk due to faults in attached equipment.
Test interval
Three years.
Tests required
Standard tests.
7.3.5 Portable equipment

Location.
Use of multi-standard adapters.
Test interval
One year.
Tests required
Standard tests.
7.4 VIDEO EQUIPMENT AND CAMERAS

7.4.1 Video tape recorders
Risk of splashing.
Risk of contamination through ventilation slots.
Unlike computers, ventilation slots tend to be located in the top of the VTR.
Contamination may cause either an electrical or a mechanical problem.
Potential blockage of ventilation slots.
The flat top of a VTR is an attractive place for paper, books, tapes, etc. This
may lead to a blockage of the ventilation slots.
Connection to computers or controllers.
Connection to data ports and other computer peripherals.
Test interval
Three years.
Tests required
Standard tests.
7.4.2 Video monitors

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Risk of splashing.
Equipment stacks.
Video monitors are often positioned directly on top of VTRs. While this
practice is acceptable, it is not acceptable to subsequently position any further
equipment or items on top of the video monitor.
Test interval
Three years.
Tests required
Standard tests.
7.4.3 Video timers

Risk of splashing.
Test interval
Three years.
Tests required
Standard tests.
7.4.4 High-speed cine camera

Risk of splashing.
Trip hazard from stand.
Test interval
Three years.
Tests required
Standard tests.
7.4.5 Video cameras

Most video cameras operate on a low voltage, using either batteries or an
external power supply. The present section deals only with those cameras
having a direct connection to the mains supply.

Risk of splashing.
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Adequacy of mounting arrangements.
Test interval
Two years.
Tests required
Standard tests.
7.4.6 Camera power supplies

Risk of splashing or leaks.
Risk of mechanical damage.
Adequacy of physical attachment.
This is particularly relevant on turntables.
Test interval
Two years.
Tests required
Standard tests.
Damage to low voltage cable.
7.5 LIGHT SOURCES

7.5.1 Projectors
This is particularly relevant on turntables, tripods and when light sources are
mounted in any orientation other than sitting on a bench.
Control of stray light.
Even the relatively low intensities from a standard slide projector represent a
hazard, both directly to the eyes, and through dazzling laboratory users.
Measures must be taken to ensure no light causes a risk or inconvenience to
other Laboratory users.
Test interval
Two years.
Tests required
Standard tests.
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Operation of fan.
Integrity of tripod plate or other mounting system.
7.5.2 Photographic lamps

Risk to user of casing temperature.
These lamps run very hot. The case is fitted with a thermal cut-out to switch
the lamp off if the case temperature exceeds 150oC, but this temperature is still
sufficiently high to burn a user trapped against the lamp.
These lamps should not have their fans or ventilation slots hindered in any
way.
The high intensities from these lamps represent a serious hazard, both directly
to the eyes, and through dazzling laboratory users. Measures must be taken to
ensure no light causes a risk or inconvenience to other Laboratory users. Noncombustible materials must be used for any shielding closer to the lamp than
500mm. All shielding must be secured firmly and designed to prevent any
hindrance to the air flow through the lamp.
Can low voltage lamps or light sources in other locations be used instead?
The typical location of these turntable lamps exposes the user to greater risk
than would be the case if the lighting was provided by low voltage lamps or
provided from a remotely mounted lamp.
Test interval
Two years.
Tests required
Standard tests.
Case temperature.
7.5.3 Turntable lamps

Risk of injuring entangling user.
These lamps are intended for mounting on a turntable. As such, they will
normally be in motion relative to the user, introducing additional potential
hazards.
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Even the relatively low intensities from a standard slide projector represent a
hazard, both directly to the eyes, and through dazzling laboratory users.
Measures must be taken to ensure no light causes a risk or inconvenience to
other Laboratory users.
Test interval
Two years.
Tests required
Standard tests.
7.5.4 Fluorescent lamps

The fluorescent tubes are particularly susceptible to breakage. Moreover, if
broken, they represent a greater hazard due to the cocktail of fluorescent
materials they contain.
Fluorescent lamps run relatively cool and may safety be used much closer to
flammable materials than most other light sources. However, it is important
that adequate ventilation be maintained when doing so.
It is sometimes necessary to locate these lamps below an experimental
apparatus, thus exposing the lamps to a significantly increased risk from leaks
and splashes. The possibility of using low voltage lamps or other remote
sources of light should be considered.
Test interval
Two years.
Tests required
Standard tests.
Diffusers and end caps.
The diffuser and end caps provide part of the protection to the tube and
electrics within the lamp. The diffuser and end caps, or a suitable alternative
arrangement, must be secure and intact.
Temperature.
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The operational temperature, when the lamp has been left on for a number of
hours, should be checked if air flow around the lamp is hindered in any way.
7.5.5 Light boxes

Test interval
Two years.
Tests required
Standard tests
7.5.6 Arc lamps

The xenon arc lamps consist of a separate power supply and lamp unit. The
power supply generates both very high voltages (30kV) for striking the arc,
and high currents (at relatively low voltages) for maintaining the arc. For
most of the units, the power supply and lamp unit are permanently wired
together, but for one it is possible to disconnect the two.

The relatively short length of the cables connecting the lamp unit to the power
supply can cause difficulty. It is important to ensure that this cable is not put
under any significant strain, and that both the lamp and the power supply are
mounted in a secure fashion in a safe location.
These lamps use very high voltages (30kV) to strike the ark. Any splashes or
moisture may lead to the user being exposed to these voltages.
The cables and terminals connecting the lamps and power supplies are
particularly vulnerable. Due to the high voltages associated with striking the
ark, it is extremely important that the insulation remains intact.
The collimated or focused light produced by the arc lamps is potentially
extremely hot and capable of igniting most flammable materials if placed
within 500mm of the lamp. The use of a cold mirror or cold window to filter
the heat from the light reaching an experiment is strongly recommended.
These lamps and their power supplies must not have their fans or ventilation
slots hindered in any way.
Both the power supply and lamp unit need to be attached securely.
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DAMTP
ensure no light causes a risk or inconvenience to other Laboratory users. Noncombustible materials must be used for any shielding closer to the lamp than
500mm. All shielding must be secured firmly and designed to prevent any
hindrance to the air flow through the lamp.
Test interval
One year.
This short test interval is required due to the presence of the high voltages
associated with striking the arc.
Tests required
Standard tests.
Obstruction of ventilation of power supply.
Obstruction of ventilation of lamp.
Check cable to lamp.
Check and clean cable terminals/connectors.
7.5.7 Strobe lights

ensure no light causes a risk or inconvenience to other Laboratory users.
Test interval
Two years.
Tests required
Standard tests.
7.6 LASERS
Not currently in use. Secured under lock and key.
7.7 POWER SUPPLIES

7.7.1 Bench supplies
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It is often possible and desirable to locate the power supplies well clear of the
experiment, bringing only low-voltage connections through to the experiment.
When the supply is integrated into an experimental rig such as a rotating table,
it is essential that it is firmly attached.
Low-voltage route to earth.
Under most circumstances the low voltage side of the power supply should be
earth-referenced. This will ensure that, in the event of power supply failure,
the equipment will remain safe. This earth referencing is most conveniently
achieved at the power supply itself; often power supplies have an earth
terminal and a removable strap between this and either the positive or
negative side. If connection to earth is not possible or not desirable (e.g. to
avoid earth loops), then an earth point should still be provided somewhere in
the equipment.
Test interval
Two years.
Tests required
Standard tests.
Earth terminal.
7.7.2 Plug-in adapters

It is often possible and desirable to locate the power supplies well clear of the
experiment, bringing only low-voltage connections through to the experiment.
Free movement of air around the adapter must be maintained. As most
adapters have internal temperature fuses, failure to observe this is likely to
lead to the adapter ceasing to function. Note that under normal circumstances
the Laboratory will not attempt to repair any plug-in adapters following
failure of this fuse.
Test interval
Two years.
Tests required
Standard tests.
Low voltage cable insulation.
7.7.3 High voltage supplies

This category of equipment is for power supplies generating voltages in excess
of mains voltages. Where at all possible, alternative solutions not requiring
such voltages should be employed.
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The presence of high voltages, the generation of interference and the need to
keep cables relatively short complicate the location of high voltage supplies. It
is critical that the high voltage cables are not put under strain and do not run
through an area where they are likely to suffer damage or be exposed to
electrolytes.
Any splashes or moisture may lead to the user being exposed to these voltages.
The high voltage cables are especially sensitive and prone to damage. Where
these cables must be exposed, they should be provided with some for of
covering or armouring. The cables and terminals connecting the lamps and
power supplies are particularly vulnerable. Due to the high voltages
associated with striking the ark, it is extremely important that the insulation
remains intact.
The power supply, cables and any associated equipment need to be attached
securely.
Can low voltage equipment be used instead?
Where possible, low voltage equipment should be used instead. Where only
high-voltage equipment is feasible, the reasons behind this must be given
explicitly in the Risk Assessment.
Test interval
One year.
Tests required
Standard tests.
Check HV insulation.
7.8 LABORATORY INSTRUMENTATION

7.8.1 Amplifiers
Earth for probes.
Probe casings should normally be earthed. If this is not possible, or not
desirable (e.g. due to the formation of earth loops), a separate earth
electrode must be incorporated into the design of the apparatus.
Risk to/from attached equipment.
What risks might the user be exposed to if any attached equipment fails? Does
failure of this equipment have other vectors with potential risk (e.g. probes).
Test interval
Two years.
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Tests required
Standard tests.
Input/output isolation.
7.8.2 Bridge circuits

Earth for probes.
Probe casings should normally be earthed. If this is not possible, or not
desirable (e.g. due to the formation of earth loops), a separate earth
electrode must be incorporated into the design of the apparatus.
Risk to/from attached equipment.
What risks might the user be exposed to if any attached equipment fails? Does
failure of this equipment have other vectors with potential risk (e.g. probes).
Test interval
Two years.
Tests required
Standard tests.
Probe isolation.
7.8.3 Multimeters
Battery-powered multimeters should also be tested.

Probe insulation.
This must be adequate to withstand the maximum voltage present on the
experimental rig, not just the voltage that is to be measured.
Test interval
Two years.
Tests required
Standard tests.
Probe isolation.
7.8.4 Oscilloscopes
By use of probe cables of a suitable length, the location of the oscilloscope
need not be close to the experiment.
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Probe insulation.
This must be adequate to withstand the maximum voltage present on the
experimental rig, not just the voltage that is to be measured.
Test interval
Two years.
Tests required
Standard tests.
Probe isolation.
7.8.5 High voltage equipment

This category of equipment is for equipment utilising voltages in excess of
mains voltages. Where at all possible, alternative solutions not requiring such
voltages should be employed.

The presence of high voltages, the generation of interference and the need to
keep cables relatively short complicate the location of high voltage supplies. It
is critical that the high voltage cables are not put under strain and do not run
through an area where they are likely to suffer damage or be exposed to
electrolytes.
Any splashes or moisture may lead to the user being exposed to these voltages.
This will occur at much lower levels of contamination than for standard
voltage equipment.
The high voltage cables are especially sensitive and prone to damage. Where
these cables must be exposed, they should be provided with some for of
covering or armouring. The cables and terminals connecting the lamps and
power supplies are particularly vulnerable. Due to the high voltages
associated with striking the ark, it is extremely important that the insulation
remains intact.
The power supply, cables and any associated equipment need to be attached
securely.
Can low voltage equipment be used instead?
Where possible, low voltage equipment should be used instead. Where only
high-voltage equipment is feasible, the reasons behind this must be given
explicitly in the Risk Assessment.
Test interval
One year.
Tests required
Standard tests.
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Check HV insulation.
7.9 MOTORS AND CONTROLLERS

7.9.1 Servo motor controllers
Earth-referencing.
Should the motor be earth referenced, or is it safer to have it floating? Earthreferencing in combination with a suitable fuse, circuit breaker or RCD may
reduce the risk associated with higher voltage servo motors.
Test interval
Two years.
Tests required
Standard tests.
Output isolation.
7.9.2 Servo motors

Risk of entanglement or injury.
Are guards required? Have all sharp corners been removed?
Earth-referencing.
Should the motor be earth referenced, or is it safer to have it floating? Earthreferencing in combination with a suitable fuse, circuit breaker or RCD may
reduce the risk associated with higher voltage servo motors.
Test interval
Two years.
Tests required
Standard tests.
Output isolation.
7.9.3 AC motors
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Are guards required? Have all sharp corners been removed?

Low voltage alternatives.
Is it possible to use a low voltage motor instead?
Test interval
Two years.
Tests required
Standard tests.
7.10 PUMPS
7.10.1 Integrated pumps
Location within experimental rig.
What additional risks will occur if the pump leaks risks both due to the pump,
and due to anything that may be contaminated as the result of the pump
leaking?
Cable routing.
Does this take the best route available? Is it protected from mechanical
damage? Is it possible to inspect the cable for damage?
Switching and control.
How is the pump to be controlled? Can it be shut off safely in the result of a
leak or a detached hose?
Guards.
Some integrated pumps are not self-contained units. In such cases, the
question of whether guards are necessary should be addressed.
Test interval
Two years.
Tests required
Standard tests.
Check for leaks.
7.10.2 Peristaltic pumps

Location relative to experimental rig.
leaking?
Test interval
Two years.
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Tests required
Standard tests.
Check for leaks.
7.10.3 Submersible pumps

Route to earth.
If the pump or cable insulation fails, the water may become live. It is desirable
that a suitable route to earth must always be is provided, either through earthbonding of metal parts of the apparatus exposed to the water, or by the
provision of an additional earth electrode of at least 200mm2 area, as outlined
in 2.7.6 of the standard procedures.
RCD on mains cable.
The mains cable of the submersible pump should normally be fitted with an
RCD plug, even if this will be plugged into circuits with other RCD protection.
Test interval
One year.
Tests required
Standard tests.
Optional: check insulation and/or leakage current when submerged.
RCD required.
7.10.4 Vacuum pumps

Test interval
Two years.
Tests required
Standard tests.
7.10.5 Double-bucket pumps

Route to earth.
All metal work on the double buckets must be earth-bonded via the earth
provided on the pump.
RCD on mains cable.
The mains cable of the submersible pump should normally be fitted with an
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Test interval
One year.
Tests required
Standard tests.
Speed control.
RCD required.
Check for leaks.
Check shielding from water.
7.10.6 Variable speed pumps

leaking?
Route to earth.
All metal work on the double buckets must be earth-bonded via the earth
provided on the pump.
Test interval
One year.
Tests required
Standard tests.
Speed control.
RCD required.
7.11 TURNTABLES
7.11.1 Turntables
Location of controller.
Can this be operated safely while the table is rotating?
Is the controller located well clear of any splashes or leaks? Are the turntable
motor and mains outlets adequately protected?
Are all items on the turntable adequately secured?
Are there sharp corners on the turntable or equipment mounted on it?
Trip hazard.
The routine of the cables between controller and turntable. Also any other
potential hazards around the turntable base.
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Emergency shut-off.
Are the provisions for stopping the turntable in an emergency adequate? Will
this also cut the power to the mains sockets?
Maximum speed.
Is there a limit on the maximum speed of the turntable? Is this limit safe? Who
has the ability to change or over-ride this limit? What will happen if this limit
is exceeded?
Test interval
Two years.
Tests required
Standard tests.
RCD required.
Shut-off switch.
Speed limiter.
Verify that turntable cannot be rotated faster than the maximum allowable
speed.
7.12 LABORATORY EQUIPMENT

7.12.1 Heat baths
What additional risks will occur if the bath or associated tubing leaks risks
both due to the bath, and due to anything that may be contaminated as the
result of the bath leaking?
Temperature control.
What is the effect of the temperature control circuit failing (or user error),
resulting in temperatures either much higher or much lower than intended?
Test interval
Two years.
Tests required
Standard tests.
Check for leaks.
Check earth leakage current when full.
7.12.2 Stirrers
What additional risks will occur if the bath or associated tubing leaks risks
both due to the bath, and due to anything that may be contaminated as the
result of the bath leaking?
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Test interval
Two years.
Tests required
Standard tests.
7.12.3 Scales
Location.
Contamination by chemicals.
Test interval
Two years.
Tests required
Standard tests.
7.12.4 Immersion heaters

Risk of drying out.
What will happen if the heater does not remain immersed?
Route to earth.
If the insulation fails, the water may become live. A suitable route to earth
must always be provided. In most cases this will be through the metal case of
the immersion heater. If this route is not possible, the route to earth may either
be through earth-bonding of metal parts of the apparatus exposed to the water,
or through the provision of an additional earth electrode of at least 200mm2
area, as outlined in 2.7.6 of the standard procedures.
RCD on mains cable.
The mains cable of the immersion heater should normally be fitted with an
Test interval
Two years.
Tests required
Standard tests.
Check for leaks.
Check leakage current when immersed.
RCD required.
7.13 FRAMEWORKS AND TANKS

7.13.1 Metalwork
Live metalwork.
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DAMTP
The metalwork of tanks may become live due to the failure of equipment, the
incorrect connection of equipment, or as a result of stray electromagnetic
fields. To prevent this happening, all metalwork must be connected to earth as
described by the wiring regulations BS7671.
A conductor with cross-section not less than 6mm2 must connect all fixed
frames to a suitable earth. Water supply pipe work may be used as the earth
only once its continuity to earth has been adequately verified to have a
resistance of less than 0.1.
Moveable frameworks and tanks must be provided with a suitable earth
terminal and lead. This earth lead must be connected to a suitable earth
whenever the framework or tank is used in conjunction with any electrical
equipment. It is recommended that the connection be made through the same
RCD-protected circuit as the electrical equipment used with the framework or
tank. This connection may be through a dedicated earth terminal on the
electrical equipment, or using an adapted earth-only mains plug inserted into
a socket.
Each electrically separate but mechanically integrated part of the metalwork
must be connected with an earth strap of at least 2.5mm2 cross-section (4mm2
if not sheathed or mechanically protected). This earth strap may be omitted
only when a reliable earth with a resistance of less than 0.1 is formed as an
inherent part of the design of the framework or tank.
Test interval
Three years.
Tests required
Test earth bonding of all exposed metal work on frames and tanks.
7.14 POWER CORDS

7.14.1 Standard cords (IEC)
Routing.
Trip hazard.
Location.
In Office or Laboratory?
Use.
For computer or laboratory equipment?
Test interval
Three years.
Tests required
Visual inspection.
Earth continuity.
Fuse.
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DAMTP
7.14.2 Non-standard cords

Routing.
Trip hazard.
Location.
Use.
Test interval
Two years.
Tests required
Visual inspection.
Earth continuity.
Fuse.
7.14.3 Cords with RCD

Routing.
Trip hazard.
Location.
Use.
Test interval
One year.
Tests required
Visual inspection.
Earth continuity.
Fuse.
RCD.
7.15 PLUG-BOARDS AND EXTENSION LEADS

7.15.1 Plug-boards
Plug-boards that are not integrated permanently into an experimental set-up.

Routing of cable.
Length of cable.
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DAMTP
Excess cable should be avoided, within reason. Cable may only be coiled if the
total load on the plug board is less than 50% of the rated load of the cable,
and even then only coiled loosely (diameter of coil greater than 250mm).
Similarly, cables should not be stretched taut.
Trip hazard.
Standing.
The plug board must not be located where it may be accidentally kicked or
stood on.
Total electrical load.
Cascading
No plug board should have more than one further plug board connected to it
either directly or indirectly,
Test interval
One year.
Tests required
Standard tests.
7.15.2 Integrated plug-boards

Plug-boards that are integrated permanently into an experimental set-up.

Routing of cable.
Length of cable.
Trip hazard.
Standing.
The plug board must not be located where it may be accidentally kicked or
stood on.
Cascading
No plug board should have more than one further plug board connected to it
either directly or indirectly,
Test interval
Two years.
One year if not integrated into apparatus.
Tests required
Standard tests.
7.15.3 Extension Leads
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DAMTP

Routing of cable.
Length of cable.
Alternatives.
Extension leads should generally be avoided except as a temporary measure.
The alternatives (e.g. power from a different source) should be explored in
advance.
Trip hazard.
Test interval
One year.
One year if not integrated into apparatus.
Tests required
Standard tests.
7.16 RCDS
7.16.1 RCD adapters
Test interval
Six months.
Tests required
Visual inspection
Check trip current
7.16.2 RCD plugs

Visual inspection
Check trip current
7.16.3 RCD sockets

Visual inspection
Check trip current
7.17 FIXED INSTALLATIONS

7.17.1 Hand driers
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DAMTP

Cable routing.
Proximity of combustible material.
Test interval
Three years.
Tests required
Standard tests.
7.17.2 Heaters
Cable routing.
Proximity of combustible material.
Test interval
Three years.
Tests required
Standard tests.
7.18 THREE-PHASE INSTALLATIONS

7.18.1 Wind tunnels
Test interval
Three years.
Tests required
Standard tests.
Isolator.
Cut-out switch.
Operating procedures.
7.18.2 Flumes
Test interval
Two years.
Tests required
Standard tests.
Isolator.
Cut-out switch.
7.18.3 Sump pump
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DAMTP

Test interval
Two years.
Tests required
Standard tests.
Isolator.
Cut-out switch.
7.18.4 Ventilation equipment

Test interval
Three years.
Tests required
Standard tests.
Isolator.
Cut-out switch.
8 Workshop
8.1 HAND TOOLS
8.1.1 Drills
Damage to cable.
Indirect mechanical damage due to regular use and exposure to potentially
abrasive or sharp obstacles.
Contact with live circuits when drilling.
Always check that nearby circuits are isolated before drilling.
RCD protection.
The drill should normally be connected to the mains through a RCD plug
permanently wired to its cable.
Eye protection.
Ear protection.
Test interval
Two years.
Tests required
Standard tests.
8.1.2 Grinders
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DAMTP

Damage to cable.
There are two principal sources of cable damage: indirect mechanical damage
to the cable (from sharp or abrasive obstacles), and direct damage to the cable
through it contacting with the grinding surface.
Contact with live circuits when grinding.
Always check that nearby circuits are isolated before grinding.
RCD protection.
The grinder should normally be connected to the mains through a RCD plug
Eye protection.
Ear protection.
Test interval
One year.
Tests required
Standard tests.
RCD required.
8.1.3 Saws
Damage to cable.
through it contacting with the saw blade.
Contact with live circuits when grinding.
Always check that nearby circuits are isolated before cutting.
RCD protection.
The saw should normally be connected to the mains through a RCD plug
Eye protection.
Ear protection.
Test interval
One year.
Tests required
Standard tests.
RCD required.
8.1.4 Routers
Damage to cable.
through it contacting with the router cutter.
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DAMTP
RCD protection.
The router should normally be connected to the mains through a RCD plug
Eye protection.
Ear protection.
Test interval
One year.
Tests required
Standard tests.
RCD required.
8.1.5 Heat guns

Damage to cable.
to the cable (from sharp or abrasive obstacles), and heat damage.
Test interval
Two years.
Tests required
Standard tests.
8.1.6 Soldering irons

Damage to cable.
to the cable (from sharp or abrasive obstacles), and heat damage.
Test interval
Two years.
Tests required
Standard tests.
8.2 FIXED TOOLS

Three Years
Eye protection.
Ear protection.
Test interval
Three years.
Tests required
Standard tests
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DAMTP
8.3 THREE-PHASE INSTALLATIONS

8.3.1 Milling machines
Test interval
Three years.
Tests required
Standard tests
Isolator
Cut-out switch
8.3.2 Lathes
Test interval
Three years.
Tests required
Standard tests
Isolator
Cut-out switch
8.3.3 Drilling machines

Test interval
Three years.
Tests required
Standard tests
Isolator
Cut-out switch
8.3.4 Compressor
Test interval
Three years.
Tests required
Standard tests
Isolator
Cut-out switch
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DAMTP
8.3.5 Abrasion tools

Test interval
Three years.
Tests required
Standard tests
Isolator
Cut-out switch
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51

Electrical Testing Procedures

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Electrical Testing Procedures

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GK Batchelor Laboratory

Department of Applied Mathematics and Theoretical Physics

Electrical testing: Intervals and procedures

4.1 Record Sheet ..................................................................................................... 14

Electrical testing: Intervals and procedures

7.4.2 Video monitors........................................................................................... 25

Electrical testing: Intervals and procedures

7.15.2 Integrated plug-boards.............................................................................. 44

Electrical testing: Intervals and procedures

Electrical testing: Intervals and procedures

2.1.4 Home office

Electrical testing: Intervals and procedures

2.4 RIG RISK ASSESSMENT

Electrical testing: Intervals and procedures

2.5 ELEMENTAL RISK ASSESSMENT

2.6 OPERATING PROCEDURES

Electrical testing: Intervals and procedures

2.7 STANDARD PROCEDURES

2.7.1 Positioning of Equipment

2.7.2 RCD Protection

Electrical testing: Intervals and procedures

2.7.4 Extension leads and plug boards

2.7.5 Earth bonding

2.7.6 Submersible equipment

Electrical testing: Intervals and procedures

recommended that the connection be made through the same RCD-protected

2.9.2 Electrical Safety Assessor

3.1 BRAND NEW EQUIPMENT

Electrical testing: Intervals and procedures

3.2 EQUIPMENT FROM OTHER SOURCES

3.3 STANDARD TESTS

3.3.2 Casing damage and condition

3.3.3 Fuse rating

3.3.4 Earth bond

Electrical testing: Intervals and procedures

3.3.7 Earth leakage

3.4 FLASH TESTS

3.5 SUPPLEMENTARY TESTS

Electrical testing: Intervals and procedures

4.2 TEST STICKER

Electrical testing: Intervals and procedures

Electrical testing: Intervals and procedures

5.2 KITCHE AND CLEANING

Elements of risk assessment

Elements of risk assessment

5.2.3 Vacuum cleaners

Electrical testing: Intervals and procedures

RCD plug (if wet and dry ability).

5.3.2 Computer monitors

Electrical testing: Intervals and procedures

5.3.5 Data hubs

Electrical testing: Intervals and procedures

Elements of risk assessment

5.4 COMMUNICATION EQUIPMENT

5.4.2 Fax machines

5.5 REPRODUCTION EQUIPMENT

Elements of risk assessment

Electrical testing: Intervals and procedures

Elements of risk assessment

5.6 PROJECTION EQUIPMENT

5.6.2 Overhead projectors

5.6.3 Data projectors

Electrical testing: Intervals and procedures

Video tape recorders