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“A new compressor can still need a Written Scheme of Examination before you switch it on.”

Buying a new air compressor does not automatically make the complete installation ready for use under the Pressure Systems Safety Regulations 2000 (PSSR).

The compressor may arrive with a manual, a data plate and manufacturer documentation. The business using it still needs to establish whether the pressure system requires a Written Scheme of Examination (WSE), what parts it covers and what examination is required before operation.

This guide gives you a practical way to check a new compressor or air receiver before it enters service.

Explore Velocity Safety’s PSSR examinations and Written Scheme of Examination support.

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What Must Happen Before a New Compressor Is Used?

Start by identifying the complete pressure system. A compressor package may include an air receiver, protective devices and associated pipework. It may also connect to an existing receiver or fixed air distribution system.

For a qualifying system, HSE states that a suitable WSE must be in place before operation. The scheme must be drawn up or certified as suitable by a competent person. It specifies what needs examination and, where appropriate, provides for an examination before the system is used for the first time.

Before putting the system into service:

1. Identify the receivers and system connections. Include existing vessels and pipework connected to the new equipment.
2. Check the vessel details. Obtain the internal volume and relevant pressure information from the data plate and manufacturer documentation.
3. Check whether the small-system exception applies. Consider each pressure vessel and any other relevant PSSR provisions or exceptions.
4. Arrange a suitable WSE if required. A competent person must draw it up or certify it.
5. Complete any examination required before first use. The scheme and competent person establish what is needed for the particular system.
6. Keep the documentation. Retain the WSE, examination report and information about the system’s safe operating limits.

For the wider rules applying to pressure systems, see our PSSR Written Scheme of Examination guide.

How Does the 250 Bar Litre Check Work?

For a compressed air receiver, multiply its relevant pressure in bar by its internal volume in litres:

Pressure (bar) × internal vessel volume (litres) = bar litres

The PSSR exception from the written-scheme and examination provisions applies to a non-steam pressure system only when the pressure-volume product of each pressure vessel is less than 250 bar litres. A result of exactly 250 is not less than 250.

These examples use an assumed pressure solely to illustrate the calculation:

Use the appropriate pressure for the actual receiver and system, rather than assuming that the compressor’s current gauge reading is the correct figure. If the data plate, safe operating pressure or system arrangement is unclear, ask a competent person to assess it.

What Does a Written Scheme of Examination Cover?

A WSE identifies the parts of a pressure system that require periodic examination and sets out the nature and frequency of those examinations.

For a compressed air installation, its scope may include:

• Air receivers and other pressure vessels where a defect could create danger.
• Protective devices, including relevant pressure relief equipment.
• Parts of associated pipework where a defect could create danger.
• Any particular preparation needed to examine the system safely.
• An examination before first use, where appropriate.

The content must reflect the actual installation. A generic form that has not been assessed and certified as suitable by a competent person is not a substitute.

An appropriately competent person may be external or, where the necessary expertise and independence exist, within the organisation. The user or owner remains responsible for ensuring the scheme has the right scope.

Does Manufacturer Paperwork Replace the WSE?

No. A manual, conformity marking or supplier inspection record provides useful information about the equipment, but it does not automatically establish a suitable WSE for the pressure system as installed and used.

Keep the manufacturer’s documentation. The competent person may need it to identify vessel details, safe operating limits, protective devices and previous examinations. Also check whether a supplier has already provided a suitable WSE and current examination report, especially for hired or leased equipment.

For a fixed installation, the business using the system normally has PSSR duties. For a mobile system that can readily move between sites, the owner has the corresponding duties. Hired equipment should come with clear confirmation of who is responsible and whether the required documents and examinations are current.

What If You Replace a Compressor or Add a Receiver?

A new compressor can change an existing pressure system. Replacing a receiver, adding a second vessel, changing protective devices or altering pipework may change the scope or suitability of the current WSE.

Before using the changed installation, provide the competent person with the new equipment details and ask them to review the scheme and examination requirements. Do not assume that an existing WSE automatically covers the replacement.

The same principle applies to second-hand equipment: its age does not determine whether PSSR requires a scheme. Check the system and its documentation before it is put into use at the new location.

Is Compressor Servicing the Same as a PSSR Examination?

No. Both matter, but they answer different questions.

A maintenance contract should not be treated as proof that the written-scheme and examination duties have been met.

New Compressor Checklist: What Should You Send for Review?

If you are buying or have just received a compressor, gather:

• Photos of the compressor and each receiver, including legible data plates.
• The internal volume of each receiver in litres.
• Pressure ratings and the manufacturer’s operating information.
• Details of safety valves and other protective devices.
• A description or photos showing how the compressor connects to existing vessels and pipework.
• Any WSE, examination report or service history already supplied.
• Whether the system is fixed, mobile, purchased or hired.

This gives a competent person the information needed to establish the system boundaries and advise on the written scheme and first-use examination.

Final Takeaway

A new compressor is not automatically exempt from PSSR. Check the complete compressed air system before it is operated, including the pressure-volume product of each receiver and any equipment already connected to it.

Where a WSE is required, arrange for a competent person to draw it up or certify it, and complete the examination called for before first use. Keep the scheme and report alongside the equipment records.

Frequently Asked Questions

Do new air compressors need a Written Scheme of Examination?

They can. If the compressed air system is subject to PSSR’s written-scheme requirements, the WSE must be in place before the system is operated. New equipment is not automatically exempt.

Does a 50-litre compressor need a WSE?

It depends on the relevant pressure and the complete system. At an illustrative pressure of 8 bar, a 50-litre receiver gives 400 bar litres, above the 250 bar litre threshold.

What happens at exactly 250 bar litres?

The small-system exception applies where the pressure-volume product of each vessel is less than 250 bar litres. A vessel at exactly 250 does not satisfy that condition.

Do you add the volumes of several receivers together?

The small-system exception refers to the pressure-volume product of each pressure vessel. The competent person should still assess the complete system, its connections and the appropriate scope of the WSE.

Is an examination always needed before first use?

The WSE must be in place before a qualifying system is operated. It must provide for an examination before first use where appropriate. The competent person establishes what examination is required for the particular system.

Can the supplier’s WSE be used?

Possibly, if it is suitable for the actual system and has been drawn up or certified as suitable by a competent person. Check that it covers the equipment and installation being used and that the relevant examination documentation is current.

Can someone within the business prepare the WSE?

Yes, where the organisation has a person with the necessary competence and independence to draw up or certify a suitable scheme. An external competent person can also provide this service.

Does annual compressor servicing cover PSSR?

No. Servicing maintains the equipment. A WSE specifies the statutory examination requirements, and a competent person examines the relevant parts in accordance with it.

Does a replacement receiver need a new WSE?

A replacement should prompt a review of the existing scheme. Changes to the receiver, pressure rating, protective devices or system layout may require the WSE and examination arrangements to be updated before use.

Resources

• HSE – Pressure Systems Safety Regulations 2000
• HSE – Written Schemes of Examination, INDG178
• HSE – Safety of Pressure Systems, Approved Code of Practice L122

A davit arm can look fine on the surface and still fail inspection if the paperwork behind it is missing.

If your davit arm, socket or anchor system has failed inspection, the issue may not be obvious damage. In many cases, the problem is missing evidence.

Under BS 7883:2019, inspectors need more than a certificate or a quick visual check. They need to understand how the system was designed, what it is fixed to, which components were used, and whether the installation remains suitable for safe use.

That evidence should sit inside the system technical file.

If that file is missing, incomplete or was never handed over, your davit system may not be straightforward to recertify.

Here’s what this guide covers:

What Is a Davit Arm Technical File?

A technical file is the evidence pack behind a davit arm, anchor system or fall protection installation.

It should help prove how the system was designed, installed, fixed and checked.

For davit systems, this can include:

• System design and layout
• Design calculations
• Structural fixing details
• Product traceability
• Serial numbers and batch numbers
• As-built drawings
• Installation photographs
• Details of hidden fixings or concealed elements
• Previous inspection and test records

This matters because a davit arm does not work in isolation. The arm, socket, fixings, structure and intended use all need to make sense together.

A certificate may show that something was tested at one point in time. The technical file helps explain whether the system was designed and installed correctly in the first place.

This should include evidence that the fixing method was suitable for the substrate and specified as part of the original system design. A later pull test should not be used as a substitute for proper design information, installation records or fixing specifications.

Why Davit Arms Fail Inspection

A davit arm can fail inspection for several reasons. Some are visible straight away. Others only become clear once the inspector checks the documentation, fixing method or load path.

Common issues include:

• Missing or incomplete technical files
• No evidence of design calculations
• Unknown fixing details
• Hidden anchor elements with no installation photographs
• Corrosion around sockets or fixings
• Damaged, loose or worn components
• Incorrectly matched parts or incompatible components
• No clear record of previous inspections or pull testing

The frustrating part for duty holders is that the system may have been in place for years without anyone questioning it. Then a more detailed inspection highlights that the evidence simply is not there.

Why BS 7883:2019 Changed the Conversation

BS 7883:2019 gives guidance for inspecting fall protection anchor devices and systems.

The important shift is the focus on evidence. Inspectors need enough information to assess whether the system is safe, suitable and correctly installed.

For older systems, that can create problems. The original installer may no longer be available. Drawings may have been lost. Fixings may be hidden behind roof coverings, cladding or other finishes. Previous certificates may not explain how the system is actually anchored to the structure.

That does not automatically mean every system is unsafe, but it does mean further investigation may be needed before a clear pass can be given.

Why Pull Testing Alone Does Not Prove a Davit Is Safe

One of the biggest misconceptions around davit inspections is that a successful pull test proves the installation is safe.

It does not.

A pull test, load test or similar proof test demonstrates that the installation withstood the applied test load at that moment in time. It does not prove the original design was suitable, that the correct fixing was specified, or that the substrate was appropriate for the system.

For example, a pull test does not automatically confirm:

• The fixing was correctly specified for the substrate.
• The system designer or manufacturer approved the fixing method.
• The installation followed the original design.
• Hidden fixings are free from fatigue, damage or deterioration.
• The system will remain safe the next time it is loaded.

A safe davit installation starts long before any pull test takes place. It starts with suitable design, correct fixing selection, competent installation, commissioning records and complete technical documentation.

Pull testing can be a useful part of the evidence, but it should not be treated as a replacement for the technical file.

Does Missing Documentation Always Mean a Fail?

Not always. Missing information does not automatically mean the davit system is unsafe, but it can stop an inspector from giving a clear pass.

Depending on what is missing and whether there is an immediate safety concern, the outcome may be a pass, conditional pass, conditional fail or fail.

For example, a system may be visually sound but still need further evidence before it can be fully recertified. That might include design calculations, fixing details, installation photographs or supplementary testing.

The key point is that missing evidence should be treated seriously. If the inspector cannot verify how the davit arm or socket is fixed into the structure, the duty holder may need further investigation before the system can be returned to normal use.

What Should You Do If Your Davit Arm Fails Inspection?

First, do not keep using a failed davit system unless a competent person has confirmed it is safe to do so.

Next, gather any information you have:

• Previous inspection reports
• Installation certificates
• Drawings or plans
• Manufacturer details
• Photos of the installation
• Records of repairs, refurbishment or load testing

Then speak to a competent provider who can review the davit arm, socket, fixings, documentation and intended use.

Velocity Safety can support with davit arm installation, inspection, maintenance and pull testing, including system review, defect reporting, supplementary inspection and advice on what is needed to move the system towards recertification.

FAQs

Here are some common questions about davit arm inspection failures, technical files, BS 7883:2019 and what to do if your system cannot be recertified.

Can a davit arm fail inspection because the technical file is missing?

Yes. Missing documentation can create an inspection issue because the inspector may not be able to verify how the system was designed, fixed or installed. Depending on the risk and missing evidence, further investigation may be needed.

What should be included in a davit arm technical file?

A technical file may include design calculations, fixing details, system layout, as-built drawings, product traceability, installation photographs and previous inspection or test records.

Does a previous certificate prove my davit arm is compliant?

Not always. A certificate is useful, but it may not prove how the system was designed, what it is fixed to, or whether hidden elements were installed correctly. The supporting technical file gives much stronger evidence.

What happens if hidden fixings cannot be verified?

If hidden fixings or structural details cannot be verified, supplementary investigation may be required. This may involve further inspection, access to concealed areas, review of installation records or additional testing.

Does passing a pull test prove a davit installation is compliant?

No. A successful pull test only shows that the installation withstood the applied test load at that moment in time. It does not prove the fixing was correctly designed, that the substrate was suitable, or that hidden defects do not exist. These details should be supported by the technical file and installation documentation.

Can Velocity Safety help after a failed davit inspection?

Yes. Velocity Safety can inspect davit arms, sockets, fixings and supporting documentation, then advise on remedial action, pull testing, refurbishment or recertification requirements.

Do you provide davit arm pull testing nationwide?

Yes. Velocity Safety provides davit arm inspection, maintenance, pull testing and certification across the UK, including support for construction, facilities, industrial and confined space environments.

Resources

• BS 7883:2019: Personal fall protection equipment anchor systems — system design, installation and inspection code of practice
• LOLER 1998: Lifting Operations and Lifting Equipment Regulations
• PUWER 1998: Provision and Use of Work Equipment Regulations
• HSE: Working at height guidance

How Multi-Discipline On-Site Safety Inspections Work: Gas Monitors, Tripods, Winches & Fall Arrest Blocks

Some jobs aren’t one-discipline visits.

For many clients – especially those working in confined spaces, utilities, civils or construction – staying compliant means keeping dozens of different bits of safety kit inspected, calibrated, serviced and traceable.

That’s why multi-discipline on-site inspections exist.

Instead of booking separate contractors for gas monitors, fall arrest blocks, tripods, winches, harnesses and fire equipment, a competent provider can complete everything in a single visit – reducing downtime, disruption and cost.

Velocity Safety carries out these multi-discipline inspections nationwide, often organising, labelling and certifying equipment across entire fleets of vans or site teams. It’s quicker, cleaner and far easier to manage.

Here’s how it actually works in the real world, and what gets tested on each piece of equipment.

Here’s how a proper multi-discipline visit actually works – what gets tested, how it’s organised, and why the one-visit approach makes life easier for busy site teams.

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Why Businesses Choose Multi-Discipline Safety Inspections

When you spread inspections across several contractors, three problems appear quickly:

• Downtime multiplies – teams wait around for different specialists.
• Record-keeping becomes messy – different certificates, formats and expiry dates.
• Consistency drops – different contractors interpret “competence” differently.

By contrast, a multi-discipline inspection from one competent provider gives you:

• One agreed schedule
• One set of reports
• One point of accountability
• Consistent labelling across all equipment
• Far less site disruption

Velocity Safety often carries out these visits on Fridays (the quiet day in many industries) to minimise business interruption – exactly as Ross described in his post.

1. Gas Monitor Calibration & Functional Testing

Gas monitors are life-critical. They aren’t simply switched on to see if they beep – they require proper calibration and bump testing.

A full on-site gas monitor calibration includes:

• Zeroing the sensors
• Exposing each sensor to test gas
• Verifying the reading matches the reference value
• Checking high/low alarms trigger correctly
• Verifying TWA/STEL where applicable
• Inspecting the sensor ports and filters
• Recording calibration drift and pass/fail outcome

Calibration intervals vary by manufacturer, but most require:

• 6-monthly calibration
• Monthly bump tests

Businesses often underestimate the failure rate of sensors left untested.

A gas monitor that doesn’t alarm when it should is one of the most dangerous failures in safety management – which is why Velocity Safety calibrates with fully traceable equipment.

2. Tripod Inspections (Confined Space Entry)

Tripods are used for confined-space access and rescue, meaning every component must work exactly as expected under load.

A correct inspection includes:

• Checking leg integrity, bends and distortion
• Verifying locking pins
• Checking spreader chains, brackets and attachment points
• Inspecting the top cap and anchor points
• Confirming compatibility with the winch or fall arrest block
• Checking for corrosion, hairline cracks or material fatigue

Tripods fall under PUWER, meaning they must be:

• Suitable for use
• Maintained correctly
• Inspected at appropriate intervals

Velocity Safety also labels each tripod with asset IDs and next inspection due dates, reducing confusion on multi-team or multi-van sites.

3. Winch Inspection & Servicing

Winches are often paired with tripods for confined-space entry or rescue. They must lift smoothly, lower safely, and lock reliably.

A proper on-site inspection includes:

• Strip-down of outer casing
• Inspection of pawls, gears and cogs
• Checking the ratchet mechanism
• Inspecting steel wire rope for kinks, heat damage or broken strands
• Verifying ascent/descent function
• Ensuring the brake holds under load
• Lubricating moving components with manufacturer-approved products

Some winches fall under LOLER depending on use (lifting persons), while others fall under PUWER.

Either way, frequency and scope must match the application.

4. Fall Arrest Block / SRL Inspection

Fall arrest blocks are complex systems containing energy absorbers, brakes, springs and friction components.

A competent on-site fall arrest block inspection includes:

• Verifying locking speed and engagement
• Inspecting webbing or cable for cuts, glazing, abrasion or crushed sections
• Checking retraction force and recoil
• Ensuring connectors and swivels move freely
• Listening for internal noise that signals wear
• Verifying activation distance

Blocks that require full internal servicing (e.g., annual strip-downs) will be removed, serviced at an approved centre, and returned with full certification.

Velocity Safety’s Ridgegear approval strengthens this even further.

5. Harness & Lanyard PFPE Checks

PFPE is often overlooked – yet it’s the item most workers rely on in a fall event.

A correct PFPE inspection includes:

• Checking webbing condition
• Stitch pattern integrity
• Shock pack condition
• D-ring strength and distortion
• Corrosion, cracks or excessive wear
• Batch numbers, serials and label legibility
• Compatibility with other kit in the system

If the label is unreadable – it’s legally unserviceable.

No exceptions.

Why Businesses Choose Velocity Safety

Clients choose our team because:

• We test multiple disciplines in one visit
• Our equipment is fully calibrated and traceable
• We’re manufacturer-approved for fall arrest block servicing
• We understand confined-space, work-at-height and gas detection requirements inside out
• Labels, asset registers and documentation are clean and audit-ready
• We explain findings clearly and honestly

It’s end-to-end competence – not quick “tick-box” testing.

When a large vessel docks for a tight turnaround, every hour matters.

When that vessel is staring down £300,000 per day in delay costs, every hour really matters.

Velocity Safety was contacted by a client whose ship had just arrived into Hull – only for the team to discover that 200 onboard extinguishers had been supplied incorrectly and failed compliance checks. The vessel couldn’t sail until the issue was fixed.

• Time window: less than 48 hours
• Risk: ship stuck in port
• Requirement: replace and commission 200 MED-approved extinguishers
• Outcome: ship sailed on schedule

This is how it happened.

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The Problem: A Full Set of Non-Compliant Extinguishers

When the ship arrived, routine checks flagged immediate issues:

• Extinguishers supplied by a previous provider did not meet MED (Marine Equipment Directive) requirements
• Several units failed basic conformity checks
• Certification was incomplete or missing
• Delays would trigger six-figure costs for the client

The client’s request was simple and brutal:

“We need 200 compliant extinguishers on board, commissioned and ready, before the vessel sails.”

Most companies would have walked away.

Velocity Safety didn’t.

The Response: A Same-Day National Procurement Operation

By 8:30am the next morning, Velocity Safety had:

• Identified the correct MED-approved extinguishers
• Ordered stock from three separate suppliers across the UK
• Secured same-day couriers to get all units to Hull before evening
• Mobilised a team to travel to the port and prepare for onboard commissioning

This wasn’t a “collect 200 extinguishers from a warehouse” job.

This was a nationwide emergency supply chain compressed into a few hours.

The Complications (Because There Are Always Complications)

No serious operation runs perfectly – and this one tried its best not to.

• One technician called in sick
• Another arrived without photo ID (no ID = no access to port)
• The ship delayed equipment lift-on
• Onboard mobilisation windows kept shifting

What should have been a four-person commissioning team dropped to two, just hours before the lift-on window.

Most providers would have cancelled the job.

Velocity Safety stayed until it was finished.

The Work: Commissioning 200 Extinguishers Onboard

Once the units were lifted onto the vessel’s deck, the team worked until midnight to:

• Unbox and prepare all extinguishers
• Apply correct labels and MED identification
• Allocate serial numbers for traceability
• Commission each extinguisher to BS 5306
• Integrate them into the vessel’s fire plan
• Ensure replacement units matched the vessel’s risk profile
• Remove non-compliant extinguishers for disposal

By the time the pilot boarded, the final extinguisher had been commissioned.

The ship sailed on time.

Why This Case Matters

This wasn’t “just” an extinguisher job.

It was a compliance-critical, time-sensitive project where:

• The wrong equipment risked delaying a vessel
• Contractor failures created immediate operational cost
• MED compliance was non-negotiable
• The client needed a provider who could act, not talk

Velocity Safety succeeded because:

• We understand marine compliance and MED requirements
• Our supply chain partners know we can mobilise at speed
• We always use certified, approved extinguishers
• We don’t sign off work unless it’s genuinely compliant
• When problems hit, we don’t walk away

Most importantly:

Our team keeps its word – if we say a ship will sail, it sails.

Key Takeaways

• The vessel avoided £300k+ per day delay costs
• 200 extinguishers were sourced, delivered and commissioned within 24 hours
• All units were MED-approved and fully traceable
• The work was completed despite multiple setbacks
• The ship sailed with a fully compliant fire safety system

Velocity Safety isn’t a “box-shifting” fire equipment supplier.

We solve real operational problems – fast.

When it comes to fall arrest blocks, inertia reels, harnesses and lanyards, it’s easy to assume that “any competent tester” can service or inspect them.

But personal fall protection equipment (PFPE) isn’t like most workplace kit – it’s life-critical.

That’s why manufacturers such as RIDGEGEAR operate approved service networks, and why choosing a centre that’s properly trained, assessed and authorised makes a measurable difference to safety and compliance.

Velocity Safety is an approved service and repair centre, trained directly by the manufacturer on the latest SRLs – including the new 30m unit (RGA30). That approval isn’t just a badge. It changes what gets inspected, how it’s repaired, and what your certificate is actually worth if things ever go wrong.

Below is a breakdown of what “approved” really means, what gets tested inside fall arrest equipment, and why it matters for your workers, your insurers and your legal defence.

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What “Approved Service Centre” Actually Means

Manufacturers don’t hand out approvals lightly. Becoming an approved PFPE or fall arrest service centre involves:

• Formal training on specific product ranges
• Assessment of competence on strip-downs, rebuilds and reassembly
• Use of genuine replacement parts
• Use of calibrated load-testing equipment
• Authorised access to service manuals and repair procedures
• Regular audits to ensure standards are maintained

An approved centre isn’t guessing, improvising, or relying on general height safety knowledge.

They’re following the manufacturer’s own engineering requirements, which dictate exactly what must be checked, replaced or tested.

It’s the difference between kit that looks fine and kit that’s actually safe to use.

What Gets Tested on Fall Arrest Blocks & Inertia Reels (SRLs)

A proper SRL / fall arrest block service goes far beyond pulling the cable out and checking the brake engages.

Here’s what an approved service includes:

1. Full Internal Strip-Down

Inside a fall arrest block is:

• Braking pawls
• Springs
• Drums
• Gears
• Shock pack components
• Energy absorbers
• Friction surfaces

These wear over time – and cannot be inspected visually from the outside.

Approved centres dismantle the unit completely to inspect and measure internal wear.

2. Inspection of Critical Components

Servicing includes checking:

• Brake activation speeds
• Drum alignment
• Pawl engagement
• Corrosion inside the casing
• Shock absorption capacity
• Condition of internal bearings and cogs
• Cable or webbing integrity

Most failures occur internally.

An unapproved provider simply cannot test these elements.

3. Replacement of Wear Parts With Genuine Components

Manufacturers specify:

• The exact shock packs
• Specific springs
• Correct fasteners
• Correct lubricants
• Torque settings

Using non-genuine components (or lubricants) can invalidate the certification – and compromise performance.

4. Calibrated Dynamic & Static Load Tests

Approved centres load-test SRLs to confirm:

• Braking force
• Arrest distance
• Locking performance
• Cable payout
• Recoil strength

These tests require calibrated equipment and manufacturer training.

You cannot legally do this “on a bench”.

5. Verification Against Manufacturer Tolerances

Each unit has tolerances that dictate whether the equipment is:

• Serviceable,
• Repairable, or
• Must be removed from use.

Approved centres have these tolerances.

General PFPE inspectors do not.

What Gets Tested on Harnesses & Lanyards

Harness and lanyard testing isn’t just about checking for frayed webbing.

An approved inspection includes:

• Stitch pattern checks
• Stitch integrity and tension
• Webbing wear patterns
• Label legibility (essential for compliance)
• D-ring distortion
• Corrosion and pitting
• Shock pack swelling, tears or activation
• Correct marking, serial numbers and batch codes
• Hardware compatibility

If the label is unreadable, or a component fails inspection, the harness legally has to be removed from service.

Approved inspectors enforce this correctly.

Why Using a Non-Approved Provider Is a Risk

Here’s what often goes wrong when companies use non-approved PFPE testers:

1. They can’t open or service the unit internally

Fall arrest blocks aren’t designed to be opened by untrained technicians.

If they do, it’s a breach of manufacturer instructions.

2. They can only perform surface-level checks

No matter how “competent” they are, they cannot:

• Inspect internal braking
• Measure internal wear
• Replace internal components
• Verify tolerances

3. Warranty and product certification may be void

Manufacturers typically state:

“Only authorised service centres may undertake repairs or internal inspections.”

If an SRL later fails and the certificate wasn’t issued by an approved centre, you’re exposed.

4. Reports may not stand up in an investigation

If someone falls and the kit was serviced by an unapproved provider:

• The insurer may challenge the validity
• The HSE may question competence
• The LE procedure may be scrutinised

You want the certificate to be defensible – not debatable.

5. Critical failures get missed

The majority of SRL failures occur inside the unit.

Most non-approved testers never open it.

It’s that simple.

Why Manufacturer Training Matters

Being manufacturer-trained means:

• You know how each unit behaves when worn
• You know the failure patterns
• You know which parts degrade faster
• You know the engineering logic behind each safety system

That’s very different from general PFPE knowledge.

It’s like the difference between:

• An MOT tester, and
• The mechanic who built the engine.

Both have a role – but only one can safely take it apart.

How Often Should PFPE Be Inspected or Serviced?

As a general rule:

• Harnesses & lanyards: every 6–12 months
• SRLs / fall arrest blocks: every 12 months (or sooner depending on use)
• High-use or harsh environments: more frequent inspections
• After a fall event: equipment must be removed from service immediately

But the key is simple:

Follow the manufacturer’s instructions.

Not every brand or model is the same.

Approved centres know the exact requirements for each product line.

Why Businesses Choose Velocity Safety

Velocity Safety is an approved PFPE and fall arrest service centre because we:

• Follow the manufacturer’s servicing procedures to the letter
• Use calibrated equipment for dynamic testing
• Replace components with genuine approved parts
• Provide traceable service records
• Identify defects that surface-level checks simply won’t catch
• Understand PFPE engineering, not just inspection checklists

It’s a level of assurance that general testers cannot match.

When a worker is relying on a fall arrest system, the difference matters.

A lot of businesses believe LEV systems need a Thorough Examination & Test (TExT) every 14 months.

It’s one of the most commonly repeated “facts” in health & safety.

And in some cases, it’s true.

But in many others, relying on the 14-month rule can leave you non-compliant, exposed, and with a false sense of security – especially when your LEV system falls under Schedule 4 of COSHH 2002, where more frequent testing is required.

If you provide extraction for welding fume, wood dust, isocyanates, metalworking fluids or other higher-risk processes, then “every 14 months” is almost certainly wrong.

Below is a simple guide to when LEV needs testing, why the 14-month rule is often misused, and what the law actually requires.

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Why People Think LEV Needs Testing Every 14 Months

COSHH Regulation 9 states that LEV must be examined and tested:

“…at least once every 14 months unless more frequent intervals are specified in Schedule 4.”

This line gets repeated endlessly in workplaces, often becoming:

“LEV is every 14 months. End of story.”

But that’s not what COSHH says.

COSHH actually says:

• 14 months is the maximum interval, not the default.
• Some systems legally require shorter intervals.
• Risk-based increases in frequency may be necessary where exposure potential is high.

So if your system doesn’t fall under the 14-month category, you’re already non-compliant even if you think you’re doing the right thing.

What Schedule 4 of COSHH Actually Says (In Plain English)

Schedule 4 lists specific LEV processes and substances that must be tested more often than 14 months.

Here are the most common examples:

Every 6 Months – Mandatory

These LEV systems must legally be tested at least once every 6 months:

✔ Wood dust extraction

Wood dust is a known carcinogen and respiratory sensitiser, hence the stricter interval.

✔ Welding fume extraction

Including MIG, TIG, MMA, fume arms, on-torch extraction and plasma cutting.

✔ Metalworking fluids (MWF) LEV

High risk of respiratory illness, mist exposure and bacterial contamination.

✔ Spray booths and isocyanate processes

Includes automotive refinishing, 2K paints and any process producing isocyanate mist.

✔ Abrasive blasting

Both free-standing and cabinet blasting systems.

✔ Certain dusts and fumes listed under Schedule 4 hazardous substances

If your LEV falls under any of these, a 14-month test isn’t legally acceptable.

Every Month – In Some High-Risk Scenarios

This is the part most businesses overlook.

Schedule 4 includes processes requiring monthly examination, usually where:

• LEV performance can degrade very quickly
• The consequences of failure are severe
• Exposure potential is high or continuous

Examples include:

• Electrolytic chromium processes
• Certain high-toxicity dusts and vapours
• Processes generating highly corrosive or rapidly clogging contaminants

These are less common but still present in UK manufacturing.

When 14 Months Is Acceptable

The 14-month interval generally applies to:

• Basic benchtop LEV systems
• Low-risk dust extraction
• Simple point-of-use extraction in non-hazardous processes
• Systems not specified in Schedule 4
• Situations where risk assessments show low degradation and low exposure potential

However – and this is key:

14 months is the absolute longest allowable interval.

Not the default, not the recommendation.

If the system’s performance can degrade sooner, testing must be more frequent.

Common Myths That Lead to LEV Failures

Myth 1: “It’s the same LEV system, so the interval is always the same.”

Wrong.

The process determines the frequency – not the equipment type.

Myth 2: “Our last provider said it’s always 14 months.”

Also wrong.

Plenty of providers don’t follow Schedule 4 correctly.

Myth 3: “We’ve never had an issue, so 14 months is fine.”

HSE doesn’t accept “we’ve always done it this way” as a defence.

Myth 4: “We can switch between substances without changing the interval.”

The interval must follow the highest-risk material being extracted.

Myth 5: “Our in-house checks mean we can extend the interval.”

LEV thorough examinations are a legal requirement, not a risk-based optional control.

What Can Happen If You Test LEV Too Infrequently

Inaccurate or outdated LEV testing exposes a business to:

• Workers inhaling hazardous dusts, fumes or mist
• Uncontrolled exposure to carcinogens and sensitisers
• Invalidated COSHH assessments
• Enforcement notices
• Compensation claims
• Invalid insurance in the event of occupational disease
• Failed audit outcomes

Most exposure-related enforcement cases start with one finding:

“LEV was not examined at the required intervals.”

How to Set the Correct LEV Test Frequency

A competent LEV engineer should:

• Identify the process
• Identify the contaminants
• Reference Schedule 4
• Review deterioration potential
• Review hours of use
• Assess risk of blockage, corrosion or filter wear
• Recommend the correct interval (not just the convenient one)

Velocity Safety does this automatically as part of every LEV Thorough Examination & Test.

A Quick Reference Guide

These are the test intervals that actually appear in COSHH Schedule 4 (translated into plain English):

Process / Contaminant	Legal Test Frequency
Wood dust	Every 6 months
Welding fume	Every 6 months
Isocyanates / Spray booths	Every 6 months
Metalworking fluids	Every 6 months
Abrasive blasting	Every 6 months
Electrolytic chromium	Every month
Other Schedule 4 processes	1–6 months depending on risk
Low-risk processes not in Schedule 4	Up to 14 months

If your LEV system handles any of the substances above, the interval is already set for you.

If it isn’t listed, then you fall into risk-based territory – and that’s where many businesses accidentally drift into non-compliance by defaulting to 14 months.

The safest approach?

Match the interval to the process risk, not the convenience of the calendar.

Why Velocity Safety Gets LEV Testing Right

Instead of simply recording airflow numbers and handing over a certificate, Velocity Safety looks at how the system actually performs in the real world. That means:

• Confirming the correct test interval under COSHH and Schedule 4
• Using calibrated, traceable instruments
• Checking whether controls are still adequate for the task
• Reporting defects clearly, with no sugar-coating
• Advising if the interval needs tightening due to process risk

Compliance isn’t a box-tick – it’s making sure the LEV is genuinely protecting people.

When a business books a LEV test, noise assessment, HAVS measurement, air purity test, or PSSR inspection, one assumption is quietly made:

“The readings will be accurate.”

Those readings are only dependable when the technician’s instruments are suitable, properly maintained and checked at appropriate intervals. Accurate measurements support reliable reports, informed control decisions and clear compliance records.

This is why Velocity Safety maintains a documented servicing and calibration schedule for its measurement equipment. Annual calibration is used where appropriate, alongside more frequent functional or field checks when required by the manufacturer, applicable guidance or the way the instrument is used.

Below is a practical breakdown of what calibration actually involves, what kit needs it, and why it ultimately protects your business – not ours.

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What “Annual Calibration” Actually Means

Calibration is the process of checking an instrument against a known, verified standard.

It answers one simple question:

“Is this tool giving the correct reading, and if not, how far out is it?”

A documented calibration process will normally include:

• Comparison – checking the instrument against an appropriate reference
• Recorded results – documenting the readings, deviations and calibration date
• Adjustment where required – correcting the instrument where necessary, permitted and technically possible
• Traceability – maintaining a documented chain between the reference used and recognised measurement standards

Calibration does not always involve adjustment. It may instead confirm and record how closely an instrument agrees with the reference under specified conditions.

Without appropriate checks and records, it becomes harder to demonstrate that measurements used in reports, risk assessments or compliance decisions were reliable at the time they were taken.

Why HSE Expects Accurate, Calibrated Equipment

Many compliance tasks rely on measured values:

• Airflow in LEV systems
• Pressure in an air receiver
• Noise exposure levels
• Hand-arm vibration levels
• Torque on lifting gear fixings
• Electrical safety readings

If the equipment is out of calibration, your paperwork might say the workplace is safe when it isn’t – or unsafe when it is.

That’s why calibration ties directly into:

• COSHH (Reg 9)
• HSG258 (LEV testing)
• HSG53 (RPE suitability & testing)
• Noise Regulations 2005
• PUWER 1998
• PSSR 2000

In short: compliance decisions based on measurements need reliable instruments, competent interpretation and properly maintained records.

What Equipment May Need Scheduled Calibration – and Why

Below is the kind of kit used across inspections, testing and assessments – and the compliance impact of inaccurate readings.

Torque Wrenches & Torque Screwdrivers

Used for: LOLER, PFPE, lifting gear fixings, anchors

Why it matters: Incorrect torque can contribute to loose or overstressed fixings and affect the reliability of inspection, installation or maintenance work.

Pressure Gauges (for PSSR, compressors & air receivers)

Used for: air receiver safety checks, pressure relief valve testing

Why it matters: An inaccurate gauge can provide a misleading picture of system pressure and affect decisions about operation, maintenance or further examination.

Rotating Vane Anemometers & Hot Wire Anemometers

Used for: LEV thorough examinations and tests

Why it matters: Airflow measurements are an important part of many LEV examinations. An inaccurate instrument can undermine the reliability of the reported results.

Manometers & Differential Pressure Meters

Used for: filter checks, duct pressure verification

Why it matters: Inaccurate readings lead to the wrong conclusions about filter condition, fan performance or system health.

Portable Appliance Testers (PAT Testers)

Used for: electrical safety testing

Why it matters: Live/earth/insulation readings must be reliable. Faulty PAT testers can give incorrect “passes” to dangerous equipment.

Gas Monitors & Detection Equipment

Used for: confined space entry, air purity, oxygen detection

Why it matters: Gas detectors are safety-critical instruments. Calibration and function-check intervals vary by manufacturer, model, application and site risk. Many units require periodic calibration alongside more frequent bump or function checks.

Across all these instruments, appropriate calibration and functional checks help establish whether the measurements can be relied upon.

Equipment that is damaged, overdue for calibration or performing outside its expected tolerance may produce unreliable readings.

Those readings can lead to poorly informed safety and compliance decisions.

The Risks of Using Uncalibrated Equipment

Businesses rarely think about calibration until something goes wrong.

Here’s what uncalibrated instruments can lead to:

❌ LEV systems passing when they should fail

Workers remain exposed to wood dust, silica, metal fumes or paint mists.

❌ Air receivers operating at unsafe pressures

If a gauge or relief valve test is inaccurate, the tank becomes a pressure vessel with unknown stress levels.

❌ Vibration readings that under-report actual exposure

HAVS risk assessments become invalid.

❌ Noise assessments with incorrect dose calculations

Incorrect data → wrong hearing protection → long-term injury risk.

❌ Torque readings that compromise lifting safety

Anchors fail because the torque tool said a fixing was “tight enough”.

❌ Weaker evidence following an incident or insurance claim

Following an incident, investigation or claim, a business may be asked whether measurements were taken using appropriately maintained and calibrated equipment.

Missing or out-of-date calibration records can make the findings more difficult to support and may raise questions about the reliability of the original assessment.

What Good Calibration Paperwork Should Include

Depending on the instrument and type of calibration, a calibration certificate may include:

• Instrument serial number
• Date of calibration
• Next due date
• Measured values and deviations
• Pass/fail results
• Traceability statement
• Technician or lab details
• Environmental conditions (for sensitive instruments)

The information required varies between instruments and calibration procedures. If important details are missing, ask the calibration provider to explain the results and the traceability of the references used.

When Annual Calibration Isn’t Enough

There is no universal annual calibration interval for every type of measurement equipment. The correct schedule should reflect manufacturer instructions, relevant standards or guidance, frequency of use, operating conditions and previous calibration results.

Additional checks may include:

• Gas monitors: frequent bump or function checks alongside periodic calibration, following manufacturer instructions and site procedures
• Noise meters: field verification before and after measurements, supported by scheduled calibration of the meter and acoustic calibrator
• LEV testing instruments: functional checks and calibration at intervals appropriate to the instrument, its use and the examiner’s quality procedures
• Pressure gauges and torque tools: intervals based on manufacturer recommendations, usage, handling, operating conditions and previous results

Annual calibration may form part of the schedule, but it does not replace intermediate checks or equipment-specific requirements.

Why Velocity Safety Takes Calibration Seriously

Our measurement equipment is maintained and calibrated through a documented schedule because:

• Reliable readings support better workplace decisions
• Workers depend on accurate exposure and performance data
• Calibration records help support audits and internal reviews
• Our reports should clearly explain the measurements and evidence behind their findings

It’s not just about taking a measurement.

It’s about using suitable equipment, interpreting the result competently and keeping the records needed to support it.

Working safely at height on mobile access towers means being prepared for emergencies. A clear, step-by-step rescue plan is essential to protect your team if something goes wrong.

Here’s a practical guide to the decisions and preparations involved in a mobile tower emergency, informed by work-at-height requirements and PASMA good practice.

Step 1: Assess Responsiveness

When an emergency occurs, first check if the person involved is responsive.

• If yes: proceed to assess their ability to communicate the problem or concern.
• If no: immediately summon a first aider on site, request an AED/Defibrillator for standby, and call emergency services (999/112) without delay.

Step 2: Establish Whether Self-Rescue Is Safe

If the casualty is responsive, establish what has happened and whether they can safely remain where they are while assistance is arranged.

• If they are uninjured and able to descend safely: provide calm verbal guidance and keep the access route clear.
• If they are injured, distressed or unable to descend: activate the site-specific rescue plan and prevent untrained personnel from attempting an improvised rescue.
• If their condition deteriorates: contact the emergency services and follow first-aid guidance while the planned rescue response is implemented.

Any person entering or climbing the tower to assist must be competent, authorised and working in accordance with the planned rescue method.

Step 3: Evaluate Hazards or Injuries

Look for any signs of injury or hazard.

• If hazards/injuries are present: call for a first aider immediately and prepare for possible professional rescue.
• If no hazards are apparent: an instructor or competent person can assist or remotely rescue the casualty.

Step 4–6: Check Casualty Coherence and Mobility

Determine if the casualty is coherent and calm.

Assess whether they can climb down unaided, with limited physical assistance, or need remote or professional rescue.

Each stage guides rescuers to provide the appropriate level of aid while minimising risk.

Step 7: Manage Rescue Internally if Possible

If the casualty can climb down with verbal assistance, check if the situation can be handled internally.

• If yes: continue with assisted rescue procedures.
• If not: escalate to professional rescue teams.

What Should a Mobile Tower Rescue Plan Include?

A rescue plan should be prepared before the tower is used, not improvised after an incident has occurred.

The level of detail required will depend on the tower configuration, platform height, access method, location, surrounding hazards and the work being completed. The plan should identify how foreseeable emergencies will be managed without exposing rescuers or other workers to additional danger.

A suitable mobile access tower rescue plan should cover:

• Emergency responsibilities: Who stops the work, raises the alarm, contacts first aiders and coordinates the response.
• Communication arrangements: How workers on the platform and ground will communicate during an incident.
• Casualty assessment: How responsiveness, injuries, mobility and immediate danger will be assessed.
• Rescue method: Whether the plan relies on safe self-rescue, assisted descent or a specialist rescue team.
• Competent rescuers: The trained and authorised people permitted to carry out the planned procedure.
• Rescue equipment: Any equipment required to reach, stabilise or lower a casualty safely.
• Site hazards: Traffic, machinery, electricity, fragile surfaces, restricted access, weather and unstable ground.
• Emergency access: How first aiders and emergency services will reach the casualty and tower location.
• First-aid arrangements: Available first aiders, equipment and procedures for managing the casualty after recovery.
• Practice and review: How the procedure will be communicated, rehearsed and updated when conditions change.

The rescue method must not rely on workers taking actions for which they have not been trained. PASMA also identifies emergency and rescue planning as an important part of work-at-height competence and training.

Mobile Tower Emergency Planning Checklist

Use this checklist during the risk assessment and before the mobile access tower is put into use.

Why Follow This Plan?

A clear, structured rescue plan ensures every team member knows their role during an emergency, minimising confusion and delays that can worsen outcomes.

It also helps organisations meet PASMA training standards and comply with health and safety regulations regarding working at height (HSE).

Mobile Tower Rescue FAQs

Is a rescue plan required when using a mobile access tower?

Yes. Work at height must be properly planned, including arrangements for emergencies and rescue.

The rescue plan should reflect the tower configuration, work activity, site hazards and the people available to respond. It should not rely solely on calling the emergency services. :contentReference[oaicite:3]{index=3}

Who should carry out a mobile tower rescue?

Only people who are trained, competent and authorised to follow the planned rescue method should attempt the rescue.

Other workers should raise the alarm, isolate the area, contact first aiders or emergency services and follow the site procedure rather than improvising.

Can a casualty climb down the tower themselves?

A responsive and uninjured person may be able to descend using the normal internal access route if it remains safe to do so.

They should not be encouraged to move if they are injured, confused, trapped or at risk of falling. The decision should follow the site-specific rescue plan and casualty assessment.

Should a rescuer climb the tower to assist the casualty?

Not automatically.

A rescuer should only enter or climb the tower where this forms part of the planned method and they are competent, equipped and authorised to do so. An improvised climbing rescue can create a second casualty.

What equipment may be needed for a tower rescue?

The equipment required depends on the planned rescue method and may include communication equipment, first-aid supplies, barriers, access equipment or specialist rescue equipment.

Any specialist equipment must be suitable for the task, inspected and used by trained personnel.

Should mobile tower rescue procedures be practised?

Yes, where proportionate to the risks.

Practice helps workers understand their roles, confirms that equipment and access arrangements are suitable and exposes weaknesses before a genuine emergency occurs. HSE recommends that emergency responsibilities and procedures are clearly agreed, recorded and rehearsed. :contentReference[oaicite:4]{index=4}

Can workers use a harness and lanyard on a mobile access tower?

PASMA and HSE generally advise against using a harness and lanyard as routine fall protection on a correctly assembled mobile tower because the guardrails provide collective protection.

Any departure from normal tower use requires specialist assessment and should not be introduced as an improvised rescue measure. :contentReference[oaicite:5]{index=5}

What should happen after a mobile tower emergency?

The tower and surrounding area should remain out of use until the incident has been investigated and the equipment assessed by a competent person.

The risk assessment and rescue plan should then be reviewed, with any defects, training gaps or procedural weaknesses corrected before work resumes.

About Velocity Safety’s Rescue Planning Expertise

This rescue plan is based on guidance developed by our PASMA accredited instructor Ross Ciraolo, who has over 12 years of experience in mobile access tower safety.

We support clients with tailored rescue planning, emergency procedure training, and compliance audits to ensure your teams are prepared for any eventuality.

At Velocity Safety, we’re always investing in the latest technology to provide our clients with the most accurate and efficient safety testing services.

Recently, we took delivery of a new 60kN pull tester, greatly expanding our testing capabilities to include:

• Anchor pull testing up to 60kN
• Eyebolt pull testing up to 60kN
• Shear testing
• REID lifting davit socket testing

What Makes Our New Tester Special?

The new equipment is more than just powerful – it’s smart and versatile.

We attended a detailed training session with Staht, the manufacturer, to get hands-on experience with the tester’s advanced features including:

• A digital LCD screen and an easy-to-use app for real-time data capture
• A transferable load cell that can be used across multiple testing applications
• Customisable reporting options via the app, allowing us to tailor reports for each client’s specific needs
• A unique adapter for testing REID lifting davit sockets, reducing manual handling and improving safety

What This Means for You

With this new tester, Velocity Safety can deliver more reliable, efficient, and safer testing for your anchors, eyebolts, and other critical lifting equipment.

Our custom reports provide clear, actionable information – helping you meet compliance requirements with confidence.

Portable dust extraction plays a vital role in protecting workers from hazardous dust exposure.

However, many sites struggle with a simple but significant issue: connecting dust extractors to tools correctly.

Different brands of dust extractors and power tools often come with a wide variety of plastic attachments and reducers, making secure connections challenging.

Why Proper Attachments Matter

One common problem we see: hoses taped together, only to fall off repeatedly – causing loss of extraction efficiency and unnecessary dust exposure.

The best solution we’ve found? Silicone attachments.

They are:

• Flexible and durable
• Available in a wide range of sizes
• Include straight couplers, reducing couplers, elbows, reducing elbows, and offsets
• Quick, inexpensive, and easy to install

Don’t Forget Your Legal Obligations

Portable dust extractors are considered Local Exhaust Ventilation (LEV) under HSE guidance.

That means they require a Thorough Examination and Test (TExT) regularly to ensure they’re working correctly.

Unfortunately, many insurance inspectors don’t test these units – meaning compliance gaps often go unnoticed.

Need Help With Your Portable Dust Extraction?

If you’re struggling with on-tool extraction setup, hose attachments, or LEV compliance testing, get in touch. Velocity Safety can help you find the right parts, carry out TExTs, and keep your site safe and compliant.