Visual Inspection

What is the first step in PAT testing?

• AVisual inspection✓
• BLabelling the equipment
• CElectrical testing with the PAT tester
• DRecording the result on the label

Answer: Visual inspection should always be the first step in PAT testing. If serious faults are found visually, electrical testing may not proceed.

What should you check when visually inspecting the plug?

• AThe plug's colour, brand and the year printed on its base
• BThe manufacturer's warranty card and the original packaging
• CDamage, cracks, discolouration, bent pins, missing earth pin✓
• DThe appliance's energy rating sticker and its purchase receipt

Answer: Visual inspection of the plug should include checking for cracks, damage, discolouration (indicating overheating), bent pins, and the presence of an earth pin if required.

What does a dark or burnt-looking plug indicate?

• AThat the equipment is simply very old and near the end of its life
• BSimply cosmetic staining, as plugs always darken with normal use
• CPossible overheating from loose connections or overload✓
• DNothing more than normal wear and tear

Answer: Discolouration and burnt appearance on plugs indicate overheating, which could be from loose connections, overload, or internal faults. This equipment should fail inspection.

What should you look for on the cable insulation during visual inspection?

• AWhether the cable is long enough to reach the nearest socket
• BThe colour of the outer sheath, which shows the cable's age
• CCuts, abrasion, burns, exposure of core wires, brittleness✓
• DThe printed cable size, which shows whether the insulation is sound

Answer: Cable insulation should be checked for cuts, abrasion, burns, cracks, and signs of brittleness or damage that could expose live wires.

What is the danger of exposed copper wires on a cable?

• AIt reduces the flexibility of the cable when coiled
• BIt makes the cable look old and untidy to the user
• CIt creates a direct shock hazard if touched✓
• DThere is no danger, because copper is safe to touch

Answer: Exposed copper wires represent a serious shock hazard. Equipment with exposed conductors should immediately fail inspection.

How should the cable be attached to the equipment casing?

• AAttachment doesn't matter
• BWith tape
• CIt can be left loose, provided the conductors have not actually pulled out
• DSecurely with proper strain relief to prevent wires being pulled out✓

Answer: Cable entry must be secure with proper strain relief. Poor cable attachment can lead to internal wiring damage and shock hazards.

What does the term 'strain relief' mean?

• AMaking sure the cable isn't under tension
• BStretching the cable regularly
• CA type of rubber coating that is applied over the whole of the cable
• DA mechanical device that protects the cable entry and prevents stress on internal connections✓

Answer: Strain relief is a mechanical feature (usually a grommet or boot) at the cable entry that protects the vulnerable junction between cable and equipment.

What should you check for on the casing of the equipment?

• ACracks, breaks, missing parts, sharp edges, signs of repair✓
• BThe serial number, which is checked against the purchase invoice
• CThe energy efficiency rating and the date of purchase
• DThe weight of the item, compared with the figure in its manual

Answer: The casing should be checked for cracks, breaks, missing panels or screws, sharp edges, signs of damage or poor repair that could create a shock hazard.

Why is checking for missing screws on the casing important?

• AThe appliance simply looks untidy when screws are missing from it
• BMissing screws could allow access to live components✓
• CIt is a minor point, as the casing is held on by clips as well
• DMissing screws reduce the overall weight of the appliance slightly

Answer: Missing screws can allow the casing to come apart, exposing live electrical components to accidental contact.

What should you do if you find liquid damage on equipment during visual inspection?

• ATest it anyway to see if it works
• BDry the equipment out thoroughly and then continue with the tests
• CFail the equipment; liquid damage compromises insulation✓
• DIgnore the damage provided the equipment still switches on and works

Answer: Liquid damage (corrosion, salt deposits, moisture) compromises insulation and creates short-circuit risks. Such equipment should always fail.

How should the earth pin be positioned on a UK plug?

• AAt the top, above the live and neutral pins✓
• BAt the bottom of the plug, below the live and neutral pins
• CTo the left of the live pin, level with the neutral
• DThe position varies from one manufacturer to another

Answer: In a UK 3-pin plug (BS 1363), the earth pin is the single pin at the top, above the two horizontal live/neutral pins. It is also the longest pin, so it engages first and disengages last for safety.

What is a 'user check'?

• AA simple visual inspection by the equipment user to spot obvious damage✓
• BA test done annually
• CAn electrical test using instruments
• DA full formal PAT test that is carried out by a competent person using instruments

Answer: A user check is a simple, frequent visual inspection performed by equipment users between formal PAT tests to identify obvious faults.

What condition would warrant an immediate fail during visual inspection?

• AEvery fault found can simply be repaired, so an immediate fail is unnecessary
• BOnly a burnt plug top, since every other defect may be passed
• COnly a cut in the outer cable sheath, and nothing else at all
• DAny visible damage to insulation exposing conductors✓

Answer: Exposed conductors from insulation damage are a serious shock hazard and warrant immediate failure. Such equipment should not proceed to electrical testing.

How often should formal visual inspection be performed on portable appliances?

• AOnce, when the equipment is first bought and put into service
• BSet by risk assessment; HSE suggests 2-4 years for office IT✓
• CAt ten-yearly intervals, whatever the equipment type or its use
• DWhen a piece of equipment has stopped working, and not before

Answer: HSE's HSG107 leaves the frequency of formal visual inspection to the dutyholder's risk assessment. Its suggested starting intervals range from weekly for 230V construction equipment, through 6 months to 1 year for earthed or hand-held equipment, to 2-4 years for rarely moved office IT such as desktop computers. These are not legal requirements and are adjusted in light of what inspections find.

What does 'brittle insulation' on a cable indicate?

• AThat the cable is made from a particularly high quality material
• BThat the cable is brand new
• CA harmless change, as all cables stiffen a little in use
• DAge-related deterioration of the insulation material✓

Answer: Brittle insulation indicates the cable's insulation material has deteriorated with age and no longer provides adequate protection. Such equipment should fail.

What should be checked on the rating label of equipment?

• ANothing, as the label may be ignored
• BThe brand name, the colour and the country in which it was made
• CThe purchase price and the date on which the item was bought
• DVoltage, current rating, frequency, and equipment class✓

Answer: The rating label should clearly show voltage, current rating, frequency, and equipment class. Missing or illegible labels can indicate poor maintenance.

Why is checking for modifications to the equipment important?

• AModified equipment looks better
• BIt's not important
• CModifications will always improve the safety of the original equipment design
• DUnauthorised modifications could compromise safety and void warranties✓

Answer: Unauthorised modifications (like cutting off earth pins or adding unauthorised components) compromise safety and should result in equipment failure.

What should you look for in the cable at the point where it enters the plug?

• AThe fuse rating printed on the side of the plug body
• BThe brand of plug and whether it matches the appliance maker
• CWhether the cable has been wound neatly around the appliance
• DProper strain relief and no signs of damage or fraying✓

Answer: The cable entry to the plug is vulnerable. Check for proper strain relief, no pulling/stress, and no signs of internal wire exposure.

What does a 'makeshift repair' look like in equipment inspection?

• AProfessional repairs
• BOnly obvious breaks
• CTape covering damaged insulation, mismatched replacement parts, poor quality repairs✓
• DRepairs that were carried out at the manufacturer's factory

Answer: Makeshift repairs (tape over insulation, mismatched parts, poor workmanship) indicate the equipment hasn't been properly maintained and should fail.

What is a 'formal visual inspection'?

• ASystematic detailed examination of visible components for faults✓
• BTesting the plug and nothing else
• CLooking only at the rating label and recording whatever is printed on it
• DA quick glance at the equipment as it is handed over to you by the user

Answer: Formal visual inspection is a systematic, documented examination of the equipment's visible components including cable, plug, casing, and connections.

Should equipment proceed to electrical testing if serious faults are found during visual inspection?

• AYes, proceed to the electrical testing to confirm what the visual result shows
• BYes, if the equipment owner asks for the test to go ahead
• CNo, fail it immediately and don't proceed to electrical testing✓
• DIt depends on the class of equipment, with Class II items tested regardless

Answer: If serious faults are found visually (exposed wires, major damage), the equipment should immediately fail and NOT proceed to electrical testing.

What is the importance of checking for 'double-pole' switches on Class I equipment?

• AIt's not important
• BIt improves the electrical performance of the appliance while it is in service
• CIt ensures both live and neutral are switched together for added safety✓
• DIt reduces cost

Answer: Double-pole switches disconnect both live and neutral simultaneously, providing additional safety for the user.

What visual signs might indicate that an extension lead has been overloaded?

• AThe lead feels unusually heavy
• BMelted insulation, discolouration, burnt smell, scorch marks✓
• CThe lead is longer than the maximum length stated by the manufacturer
• DThere are never any visible signs at all after an overload has occurred

Answer: Overloaded extension leads show visible damage from overheating: melted insulation, discolouration, and burnt marks.

What should be checked regarding cable length in portable appliances?

• ALonger cables reduce the earth continuity reading, so they pass more easily
• BThe length of the cable does not affect the earth continuity or insulation readings
• CVery long cables can create tripping hazards and should be coiled properly when not needed✓
• DCables over 10 m are exempt from the earth continuity test

Answer: Very long cables create practical hazards. They should be stored properly when not in use to prevent tripping hazards.

What visual defects would make a PAT test fail immediately?

• AExposed live conductors, cracked plugs with exposed pins, liquid damage✓
• BA missing manufacturer's rating label on an appliance that is otherwise undamaged
• CEquipment is old
• DSlight discolouration

Answer: Critical visual defects that warrant immediate failure include exposed conductors, severely damaged plugs, and liquid damage.