Disclaimer: The information contained in this guide is of a general informational nature. We have used reasonable endeavours to ensure the accuracy and completeness of the contents but the information does not constitute professional advice and must not be relied upon as such. To the extent permitted by law, we do not accept responsibility for any loss which may arise from reliance on the information contained in this guide.
Plant, machinery and equipment inspection guide
Identifying what needs to be inspected and how often for compliance with health and safety law can often be difficult, so we've put together this guide to help you.
Electrical and mechanical
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Why inspect them?
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Alternators
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Control panels
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Engines, motors, pumps and compressors
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Fixed wiring
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Gearboxes
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Generators
Why do electrical and mechanical plant and equipment need to be inspected?
Safety measures
Prevent injuries, such as burns and electrical shocks, by ensuring guards are in place.
Integrity
All parts must be in place and working as expected to avoid malfunctions.
Wear and tear
Signs of damage (i.e. leakages or excessive noise, vibration or heat) can be investigated.
Defects
Detect faults or other problems that might cause a fire or extreme heat that could scald or burn.
Alternators
These machines are used to produce electrical power from a mechanically driven unit such as a diesel engine. They are generally found in industrial locations, however they can also be used for the provision of electrical power in the event of an interruption to the normal supply.
Alternators need to be inspected within a year from the last inspection, i.e. at least once every 12 months, for compliance with the:
12 months
Control panels
These are generally metallic enclosures for the purpose of housing electrical equipment and/or component parts.
Why inspect it?
- To determine the provision, suitability and security of interlocks etc.
- To ascertain the mechanical and electrical integrity of installation.
- To identify any obvious signs of deterioration, damage or wear.
Applicable legislation:
Periodicity of inspection:
24 months
Industries where found:
Engines, motors, pumps and compressors
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Fixed wiring
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Gearboxes
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Generators
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Lift and crane
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Why inspect them?
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Cleaning lifts
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Cranes
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Dock levellers
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Escalators
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Excavators
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Forklift trucks
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Goods lifts
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Lift accessories
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Lifting appliances
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Lifting machines
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Lorry-mounted cranes
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Mobile cranes
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Pallet trucks
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Passenger lifts
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Vehicle lifting tables
Why do lifts and cranes need to be inspected?
Stability
Collapse, freefall or overturning can be caused by assembly errors and overloading.
Safety measures
Guarding and protective devices may prevent injuries due to interventions, accidents or incorrect use.
Integrity
All parts must be in their correct place and in a good condition to avoid mechanical failures.
Wear and tear
Signs of damage and deterioration (i.e. excessive noise, vibration or heat) can be investigated.
Window cleaning and building maintenance equipment
This type of equipment is used in a variety of industrial, commercial and transportation environments. Typically, separate lifting accessories are used for the lifting and lowering of loads in locations such as factories, utility service depots, repair facilities, garages and construction sites. Such equipment comprises of chains or ropes (fibre and ferrous) and load hook assemblies.
Lifting equipment used for window cleaning and building maintenance must be inspected at intervals of no more than six months, for compliance with the:
6 months
Cranes
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Dock levellers
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Escalators
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Excavators and loading shovels
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Forklift trucks
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Goods lifts
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Separate lift accessories
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Lifting appliances
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Lifting machines
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Lorry-mounted cranes
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Mobile cranes
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Pallet trucks
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Passenger lifts
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Motor vehicle lifting tables
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Local exhaust ventilation (LEV)
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Why inspect them?
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Fume cupboards
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LEV systems
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Shot blast cabinets
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Spray booths
Why inspect LEV plant?
Health hazards
LEV plant is essential to prevent exposure to hazardous substances where work activities can create dangerous fumes.
Integrity
The performance of the system needs to be assessed, with a demonstration that the plant is working correctly and effectively.
Fume cupboards
Fume cupboards are partially enclosed units fitted with a sliding front facia which can be adjusted depending on the type of work being carried out.
Fume cupboards need to be inspected within 14 months of the last inspection for compliance with the:
14 months
Local exhaust ventilation (LEV) systems
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Shot blast cabinets
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Spray booths
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Power press
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Why inspect them?
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Guards and protective devices
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Guillotine (metal)
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Guillotine (paper)
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Injection moulding machines
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Power press
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Press brakes
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Wood working machines
Why inspect power press machinery?
Safety measures
Adequate guarding and protective devices must be fitted so that access to danger zones is prevented.
Integrity
Testing the operation of the machinery ensures that it's working correctly and effectively.
Wear and tear
Signs of damage and deterioration (i.e. excessive noise, vibration or heat) can be investigated.
Defects
Faults or other problems that might cause damage and/or health and safety hazards can be detected early.
Guards and protective devices
Guards and protective devices must be fitted wherever there is a risk of injury due to dangerous moving parts so that it's not possible for the operator or third parties to access them accidentally.
Guards and protective devices fixed to power press plant and machines need to be inspected within a year from the last inspection, i.e. at least once every 12 months, for compliance with the:
12 months
Guillotine (metal)
An electro mechanical and/or hydraulic machine designed to cut single layer sheets of steel on a worktable by means of powered blade (knife) passing against a fixed blade.
Guillotine (paper)
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Injection moulding machines
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Power press
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Press brakes
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Wood working machines
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Pressure plant
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Why inspect them?
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Air receivers
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Autoclaves
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Blowdown vessels
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Bulk storage vessels
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Café boilers
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Calorifiers
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Hot water boilers
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Jacketed reactor vessels
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Pressurisation units
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Refrigeration/ air conditioning
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Steam boilers
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Steam vessels
Why inspect pressure plant?
Integrity
Indications of in-service degradation, such as corrosion, can reduce the item's ability to withstand pressure.
Safety measures
There'll be guards and various protective features incorporated in the operating system that must be tested.
Hazard control
Where the vessel contains a hazardous fluid (i.e. toxic or flammable) then a more rigorous approach to plant inspection may be necessary.
Wear and tear
Signs of damage (i.e. leakages or excessive noise, vibration or heat) on mechanical and electrical components can be investigated.
Air receivers
This type of plant is used in a variety of situations and industries. Typically, compressed air is used for production purposes, operation of hand tools and provision of breathing air.
Systems generally comprise of air receiver, cooler, air dryer, pipework and protective devices, such as a safety valve, pressure gauge and high temperature cut-out.
Typically, it would be recommended that air receivers are inspected at least every 26 months:
26 months
Autoclaves
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Blowdown vessels
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Bulk storage vessels
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Café boilers
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Calorifiers
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Hot water boilers
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Jacketed reactor vessels
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Pressurisation units
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Refrigeration/ air conditioning plant
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Steam boilers
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Steam vessels
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Inspections summary
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Electrical and mechanical
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Lift and crane
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LEV plant
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Power press
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Pressure plant
Electrical and mechanical
Lift and crane
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|
Item type
|
Applicable legislation
|
Period
|
|---|---|---|
| Crane | PUWER + LOLER | 12 months |
| Dock levellers | PUWER | 12 months |
| Escalators | Workplace (HSW) Regulations | 6 months |
|
Excavators/ loading shovels |
PUWER | 12 months |
| Forklift trucks | PUWER + LOLER | 12 or 6 months |
| Goods lifts | PUWER + LOLER | 12 months |
| Lifting appliances | PUWER + LOLER | 12 months |
| Lifting machines | PUWER + LOLER | 12 or 6 months |
|
Lorry-mounted cranes |
PUWER + LOLER | 12 months |
| Mobile cranes | PUWER + LOLER | 12 or 6 months |
|
Motor vehicle lifting tables |
PUWER + LOLER | 6 months |
| Pallet trucks | PUWER | 12 months |
| Passenger lifts | PUWER + LOLER | 6 months |
| Separate lifting accessories | PUWER + LOLER | 6 months |
|
Window/ building maintenance equipment |
PUWER + LOLER | 6 months |
Local exhaust ventilation (LEV) plant
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|
Item type
|
Applicable legislation
|
Period
|
|---|---|---|
| Fume cupboard | COSHH | 14 months |
| LEV systems |
COSHH |
14 months |
|
Shot blast cabinets - new casting |
COSHH | 1 month |
|
Shot blast cabinets - abrading metal |
COSHH | 6 months |
|
Shot blast cabinets - all other |
COSHH | 14 months |
| Spray booths | COSHH | 14 months |
Power press
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|
Item type
|
Applicable legislation
|
Period
|
|---|---|---|
| Guards and protective devices | PUWER | 12 months |
| Guillotine (metal) | PUWER | 12 months |
| Guillotine (paper) | PUWER | 6 months |
| Injection moulding machine | PUWER | 12 months |
|
Power press (interlocking/ photoelectric) |
PUWER | 6 months |
| Press brakes | PUWER | 6 months |
| Wood working machines | PUWER | 12 months |
Pressure plant
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|
Item type
|
Applicable legislation
|
Period
|
|---|---|---|
| Air receivers | PUWER + PSSR | Typically 26 months |
| Autoclaves | PSSR | 14 months |
| Blowdown vessels | PSSR | Same as connected boiler |
| Bulk storage vessel | PUWER + PSSR + COMAH | Varies |
| Café boilers | PUWER + PSSR | 14 months |
| Calorifiers | PUWER + PSSR | 26 months |
|
Hot water boilers (below 100˚C) |
PUWER | 24 months |
|
Hot water boilers (above 100˚C) |
PSSR | 14 months |
| Jacket reactor vessel | PUWER + PSSR + COMAH | Varies |
| Pressurisation units | PUWER + PSSR | 60 months |
|
Refrigeration/ air conditioning |
PUWER + PSSR | 48 months |
|
Steam boilers (horizontal multi-tubular/ vertical) |
PSSR | 14 months |
|
Steam boilers (water-tube) |
PSSR | 26 months |
| Steam vessels | PSSR | 26 months |