Test and Tagging — Safe Work Method Statement
Safe Work Method Statement for in-service inspection and testing of portable electrical equipment, leads and RCDs on construction sites and workplaces, including visual inspection, electrical testing, tagging and removal of faulty equipment.
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Test and tagging of portable equipment is not itself high risk construction work, so a SWMS is not legally required for it under the model WHS Regulations. Many principal contractors still ask for one before a tester comes on site, and writing the method down is good practice because the tester handles equipment that is unknown, possibly damaged and sometimes still plugged in.
The WHS Regulations require electrical equipment used in higher risk environments, including construction work, to be regularly inspected and tested by a competent person, and RCDs to be tested regularly. AS/NZS 3760 sets out the in-service inspection and testing method, and AS/NZS 3012 covers construction and demolition sites, where the usual test interval for portable equipment and leads is every three months. What counts as a competent person to test and tag varies between states and territories. Some accept a tester with a recognised test and tag unit of competency, others have extra conditions, so check your state or territory regulator.
The hazards in this job are specific. A damaged appliance or lead can be live on its case or on exposed conductors before you test it. The insulation resistance test applies 500 V DC to the equipment, which can give the tester or a bystander a shock if they touch the item during the test. Leakage current and RCD trip tests are done with the equipment energised. Faulty equipment that is tagged as failed but left in a toolbox can end up back in use the same day. Many test locations are also busy site areas with forklifts, plant and trip hazards.
Your SWMS should set out the inspection-before-test rule, how the test area is set up, how energised tests are controlled, and how failed items are removed from service so they cannot be used again.
Customise this template with the site and areas covered, the test interval set for the site, the tester's competency details, the make and calibration date of the portable appliance tester, the tag colour or format used, and who receives the register and the list of failed items.
Personal Protective Equipment
Risk Assessment
1.Set up a test area and collect equipment
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Struck by forklift or plant while collecting equipment around site | High | Sign in with the site supervisor and agree a test location away from plant movement zones, ideally a site shed or a coned-off area. Wear high-visibility clothing and use marked pedestrian routes when collecting equipment. Ask trades to bring items to the test area where practicable. | Low | Tester / Site Supervisor |
| Trips over leads laid out for testing | Moderate | Test leads on a bench or table where possible. Coil leads as soon as they are tested. Keep the test area tidy and do not run the tester's supply lead across walkways. | Low | Tester |
| Manual handling of heavy tools and lead reels | Moderate | Use a trolley for heavy tools, transformers and full lead reels. Unwind long leads before lifting rather than carrying full drums. | Low | Tester |
2.Visual inspection before electrical testing
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Electric shock from damaged equipment that is still energised | High | Unplug every item before handling it for inspection. Inspect the plug, cord, cord grip, enclosure and switches for damage, exposed conductors, burns, crushed or taped cords and missing pins. Any item that fails the visual inspection is failed without electrical testing and does not get plugged in. | Low | Tester |
| Cuts from damaged tools, sharp blades and broken enclosures | Moderate | Wear cut-resistant gloves when handling damaged items. Ensure blades and bits are removed or guarded before inspection. Do not open equipment enclosures; repairs go to a licensed electrician or repairer. | Low | Tester |
3.Electrical testing of appliances and leads
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Shock to tester or bystander during insulation resistance test | Moderate | Keep hands off the item while the insulation resistance test runs and keep bystanders out of the test area. Use a portable appliance tester that is in calibration, check its self-test before starting, and follow its test sequence. Discharge capacitive items as the tester instructs before handling. | Low | Tester |
| Energised tests (leakage current, run tests) exposing the tester to live parts | High | Run energised tests only through the tester's supply output or an RCD-protected outlet. Secure the item so moving parts cannot start unexpectedly, keep guards fitted, and stand clear of blades and chucks. Stop the test immediately if the item sparks, smokes or trips protection. | Low | Tester |
4.RCD testing
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Loss of power to work in progress when RCDs are tested on site | Moderate | Before testing fixed RCDs on the site switchboard, coordinate with the site supervisor so trades can stop work safely; a sudden loss of power can leave a person in a dark area or stop a pump. Test portable RCDs at the test area. Record trip times and fail any RCD that does not trip within the required time. | Low | Tester / Site Supervisor |
| Working inside switchboards to access fixed RCDs without the right licence | High | Test fixed RCDs only through outlets or test points. Any work that requires removing switchboard covers or escutcheons is electrical work for a licensed electrician. | Low | Tester / Licensed Electrician |
5.Tagging, removing failed items and recording results
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Failed equipment returned to use | High | Fit a clearly marked 'Do not use' or out-of-service tag to every failed item immediately. Cut the plug off or lock out items that will be disposed of, with the owner's agreement. Hand failed items to the site supervisor or owner and list them in writing; do not leave them in toolboxes or on benches. | Low | Tester / Site Supervisor |
| Incomplete records leaving untested equipment in use | Moderate | Record each item's ID, description, test results, date and next test due date in the register. Tags must show the tester's name, test date and retest date. Give the register to the site supervisor before leaving and flag any items that were not available for testing. | Low | Tester |
Relevant Codes of Practice
Worker Acknowledgement
By signing below, I confirm that I have read, understood and agree to comply with this Safe Work Method Statement.