Issue 2 Nov 03
FIRE SERVICE MANUAL (VOLUME 1)
INSPECTION AND TESTING OF
EQUIPMENT
FIREFIGHTER INITIAL
This training note contains extracts from the Fire Service Manual Volume 1 – Inspection and Testing
of Equipment. The tests included in this note are those considered to be relevant to the Firefighter
Initial course. The contents of this note are intended to assist you with your studies and will form a
part of the assessment process.
© Crown copyright is reproduced and adapted with the permission of the Controller of Her Majesty’s
Stationery Office.
ALL AREAS OF THIS TRAINING NOTE ARE
CONSIDERED TO BE OF PRIME IMPORTANCE
HM Fire Service Inspectorate Publication Section London: TSO
(Reproduced By IFTC)
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CONTENTS
1.
Inspection, Testing and Maintenance
2.
Hose and Hose Assemblies
3.
Hydrants
4.
Ladders – Portable
5.
Pumps – Vehicle Mounted and Portable
6.
Lines
7.
Personal Protective Equipment
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1.
Inspection, testing and maintenance
Inspection, testing and maintenance, including cleaning is required in order to keep work equipment in
good working order and to ensure that it remains safe. If inspection, testing and maintenance is not
carried out properly, two types of risk can be created:
•
The performance of the equipment, including any safety features, may deteriorate to the point
where the users are put at risk;
•
The persons carrying out the inspection, testing and maintenance may be put at risk
It is essential that an appropriate ‘competent person’, conducts the inspection, maintenance and/or
testing of equipment.
Equipment failing to meet the requirements of a specific inspection and/or test shall be dealt with
immediately either by rectifying the fault or reporting it as appropriate. Consideration shall be given as
to whether the equipment may remain in service.
It is essential that all inspections and/or tests together with any maintenance activities or repairs of
equipment be recorded. Whilst the manner for doing so will need to be determined by the Brigade, it
is essential that any system chosen is able to accurately identify the specific item together with details
of the inspection and test history of the equipment. As a minimum, such records shall include the
following:
•
information on the type and model of equipment;
•
any identification mark or number that it has;
•
its normal location;
•
the date that the inspection was carried out;
•
who carried out the inspection;
•
any faults found as a result of the inspection;
•
any action taken regarding such faults;
•
to whom, and by whom, these faults have been reported;
•
the date when repairs or other necessary action were carried out.
Notwithstanding the fact that inspection, testing and maintenance need to be conducted by a
‘competent person’, there remains a responsibility on all personnel to identify defective or potentially
defective equipment, whenever this may come to their attention and to take appropriate action.
The inspection and/or test frequency identified for each particular item of equipment shall be regarded
as a minimum requirement and should be increased for equipment that is used extensively or
following an occasion where an item of equipment may have been used outside its recommended
working limits or for a purpose for which it was not intended. When determining the frequency of
inspection and/or test, consideration should also be given to the following:
•
Intensity of use – frequency and maximum working limits;
•
Operating environment, for example, marine, outdoors;
•
Legislative requirements;
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•
Manufacturers guidance;
•
Variety of operations – is the equipment performing the same task all the time or does this
change?
•
Risk to health and safety from malfunction or failure.
In the context of this Manual the term “after use2, means after each individual occasion that an item of
equipment has been used. The term “after each period of use” means after the item of equipment has
been or may have been used on a number of occasions within a definite period of time, for example,
during a drill period or at an operational incident.
Where the testing of equipment requires the application of a specific mass or force this shall always
be achieved by the application of a calibrated mass or tensile force. Under no circumstances should
the mass required for testing an item of equipment be substituted by the use of one or more
firefighters or any other ad hoc arrangement.
In all cases where it is necessary to apply mass or force to an item of equipment in order to conduct a
test, it is essential that the designated loading is applied carefully and without subjecting the
equipment to any shock or dynamic loading, thereby avoiding the possibility of damage to the
equipment.
For the test procedures detailed within this document, where it is necessary to apply a force as a part
of the test requirement, the forces quoted are derived from the mass of an operationally equipped
firefighter which has been taken to be 90kg.
It is not usually practicable to carry out thorough pre-use inspections immediately prior to emergency
service use. Therefore, after use inspections are critical to establish that the integrity of the
equipment has not been compromised and it is ready for immediate re-use.
An appropriate competent person shall determine the nature of inspections and maintenance to be
carried out and the skills required to do so. The levels and areas of competence required will vary
according to the type of equipment in use.
A competent person (as defined in the PUWER & LOLER Regs.) is one who, by virtue of their
knowledge and qualification or relevant experience, has an adequate knowledge of the equipment to:
•
enable them to know what to look at (know the key components);
•
know what to look for (fault finding);
•
know what to do (reporting faults, making a record, who to report to).
The maintenance of equipment may involve risks to health and safety and consideration should be
given to assessing the risks and introducing appropriate control measures. The control measures can
be classified into the following categories:
•
ensuring the competence of personnel;
•
making the equipment safer (isolation);
•
introducing safe systems of work for maintenance personnel to follow;
•
providing and implementing inspection, testing and maintenance schedules.
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Once a programme of inspection, testing and maintenance has been developed, responsibilities shall
be allocated to appropriate employees (usually supervisors or managers) requiring them to monitor
the programme in order to ensure its effectiveness. Such persons shall check, on an ongoing basis,
that:
•
inspection, testing and maintenance is being carried out at the intervals specified in the
schedules;
•
inspection, testing and maintenance records are being kept up to date;
•
any recommendations for action (for example rectification of faults, replacement of worn out
parts) made by the maintenance operative are carried out and a record is provided to indicate
the completion of the work required.
Brigades shall ensure that all persons who work equipment and those who manage or supervise
those persons are provided with adequate training, supported by the provision of the relevant
information relating to its safe use.
It is necessary for Brigades to determine what constitutes ‘adequate training’, as requirements will
vary according to the job or activity and work equipment etc. In general, there is a need to:
•
evaluate the existing competence of employees to operate the full range of work equipment
that they use;
•
evaluate the competence needed to manage or supervise the use of work equipment;
•
train the employee to make up any shortfall between their competence and that required to
carry out the work with due regard to health and safety;
•
take account of the circumstances in which the employee works;
•
provide refresher training as necessary. Particular attention should be given to people who
deputise for others on occasions, as they may need more frequent refresher training.
Information and instructions shall be made available to all persons who will be required to use,
supervise, maintain and manage work equipment.
This information shall include that provided by manufacturers or suppliers or work equipment such as
instruction sheets or manuals, instruction placards, warning labels and training manuals. It may also
include Brigade instructions from training courses etc.
Any information and written instructions provided shall cover:
•
health and safety aspects including risks arising from the use of the work equipment;
•
any limitations on the use of the work equipment;
•
any foreseeable difficulties that could arise and precautions to be taken;
•
inspection, testing and maintenance criteria;
•
the methods to deal with them.
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2
HOSE AND HOSE ASSEMBLIES
Layflat delivery hose and semi-rigid hose reel hoe assemblies shall be subjected to an annual test.
Annual Pressure Test
•
Lay-flat Delivery Hose
Prior to conducting the test, hose and hose assemblies shall be visually inspected for signs of
damage or distortion and plungers on instantaneous couplings examined to ensure correct seating.
Lay-flat delivery hose and hose assemblies shall subsequently be tested to a pressure of 10 bar, or
1.5 times the nominal working pressure of the hose, where this exceeds 7 bar, whichever is the
greater, and maintained at that pressure for 1 minutes.
It is essential that the pressure shall be applied gradually to allow the hose to take the strain imposed
on it.
•
Semi-rigid Hose Reel Hose
Semi-rigid hose reel hose assemblies shall be visually inspected over the whole of their length for
signs of damage or distortion. If satisfactory, they shall subsequently be tested to a test pressure of
40 bar or to that of the maximum operating pressure of the pump with which they operate and
maintained at that pressure for 1 minute.
Suction Hose
Suction hose shall be inspected and tested in conjunction with the tests for vehicle mounted and
portable pumps
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3
HYDRANTS
Hydrants shall be subject to a periodic test and/or inspection at intervals to be determined by the
brigade following a risk assessment as recommended in the guidance given in DCOL 1/2001 Item D
in line with the National Guidance Document on the Provision of Water for Firefighting 2nd Edition
2002. This guidance document encourages brigades and water companies to move away from flow
testing of hydrants and use other methodologies instead.
Inspection and Testing Methodology
DCOL 1/2001 Item D recommends that inspection and testing of hydrants should be considered of
one of three examinations:
•
Above ground;
•
Below ground;
•
Wet and pressure test.
The period between inspections should be risk assessed and should take into account such factors as
area location and risk, hydrant position, age, material, previous history, etc.
Above Ground Examination
This will involve a visual inspection of the hydrant frame, cover, surface surrounding the hydrant and
the hydrant indicator plate.
Below Ground Examination
This will involve the visual inspection of the hydrant pit and the hydrant itself. Defects that would
affect the ability to deliver water for firefighting purposes or create a hazard should be reported
immediately.
Wet and Pressure Test
The hydrant test is conducted by fitting s standpipe to the outlet and then partially opening the valve to
allow a small amount of water to flow (equivalent to a domestic tap). A blank cap is to be fitted in the
standpipe head or the valve in the head closed and the hydrant fully opened. Whilst under pressure,
all joints are to be visually inspected for signs of leakage and only those leakages that would impair
the hydrant for firefighting purposes, or cause, hazard, should be reported to the Water Company.
The hydrant is to be turned off without excessive force and the standpipe removed. This test should
only be carried out where there is reason to doubt the hydrants integrity or at an interval
recommended by the hydrant manufacturer.
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LADDERS – PORTABLE
Portable ladders, i.e. those not permanently mounted on vehicles, shall be subject to a visual
inspection in accordance with BS EN 1147 Annex N quarterly, after use and also an annual test.
Damaged ladders, or ladders having defects, should be removed from service, repaired and tested
prior to further use.
Visual Inspection
Portable ladders shall undergo a visual inspection quarterly and after use. This inspection should be
in accordance with the manufacturers instructions and shall include an examination to ensure the
tightness of bolts, rivets or screws and the security of the rounds/rungs. It shall also include an
examination to ensure that the joints in the ladder are tight and that there are no cracks or apparent
defects in any welded parts. The feet should also be inspected for excessive wear or other defects.
In the case of extending ladders particular attention shall be paid to the extending lines and wire ropes
and the various pulleys and other fittings, including any safety devices. The ladder pawls and any
locking assemblies shall also be inspected for correct operations together with the mounting and
securing fixtures on the respective vehicle.
Any ladder markings should be clearly legible and replaced when necessary.
Annual Test
This test shall be conducted by trained and competent personnel or, if so required, by returning the
ladder to the manufacturers or suppliers.
All portable ladders shall undergo a thorough visual inspection as above, including “sighting” down the
ladder to assess the overall shape, followed by a load test programme, appropriate to the particular
ladder to assess the overall shape, followed by a load test programme, appropriate to the particular
ladder type, which will have been developed in conjunction with the ladder manufacturer, an
appropriate “competent person” shall be commissioned to develop or verify any proposed testing
arrangements.
The annual test shall additionally be carried out under the following circumstances:
•
When it is known or suspected that the ladder has been subject to overloading, exposure to heat,
impact loading, or any other situation where the ladder may have been subject to unusual use or
suspected of being unsafe;
•
In addition the ladder shall be tested after any defects have been repaired, unless the repair only
involved the replacing of rope or cable.
N.B UNDER NO CIRCUMSTANCES shall any test programme utilise the weight of personnel to
effect the load that is required to undertake the test as dynamic loading may result which can cause
damage to the ladder.
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5
PUMPS – VEHICLE MOUNTED AND PORTABLE
Vehicle mounted and portable pumps shall be subject to a quarterly test.
Quarterly Dry Vacuum Test
It is anticipated that station personnel will normally conduct this test.
An initial visual inspection of all the lengths of suction hose to undergo testing shall be conducted.
All the lengths of suction hose that have been visually inspected shall then be coupled to the suction
inlet of the pump with a blank cap in place on the end of the final length and with the blank caps
removed from all deliveries.
The pump shall then be operated at the specified priming speed in order to obtain 0.8 bar vacuum
which shall be achieved within 45 seconds.
Having achieved this, the compound gauge shall then not fall to 0.3 bar within 1 minute.
Failure to achieve the above performance indicates an excessive air leak within the system, which
may be due to leakage at pressure gauge connections, delivery valves, couplings etc.
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6
LINES
Lines, with the exception of those associated with Breathing Apparatus (BA) and Rope Rescue
Equipment shall be examined at least annually by a competent person. Lines should also be
inspected after operational use and before drills.
Visual Inspection
The whole length of the lines shall undergo a visual inspection with particular attention being paid to
hawser-laid ropes, which shall be slightly untwisted during inspection, and to whippings, splices and
fittings such as snap hooks to ensure they are free from defects.
BS 3367:1999 “Ropes and lines for fire service use other than rope rescue purposes” Annex E
contains recommendations on the inspection and care of lines, which should be used for reference.
N.B. Lines shall not be subjected to a load test.
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7
PERSONAL PROTECTIVE EQUIPMENT
The Personal Protective Equipment at Work Regulations 1992 requires that every employer shall
ensure that any personal protective equipment provided to his employees is maintained (including
replaced or cleaned as appropriate) in an efficient state, in efficient working order and in good repair.1
An effective system of maintenance of PPE is essential to make sure the equipment continues to
provide the degree of protection for which it was designed. Maintenance includes, where appropriate,
cleaning, disinfection, examination, replacement, repair and testing. The responsibility for carrying out
maintenance should be laid down, together with the details of the procedures to be followed and their
frequency. Where appropriate, records of tests and examinations shall also be kept. The
maintenance programme will vary with the type of equipment and the use to which it is put.2
PPE should be examined to ensure that it is in good working order before it is issued to the wearer.
PPE should also be examined before it is put on and should not be worn if is found to be defective or
has not been cleaned. Such examinations should be carried out by properly trained staff in
accordance with the manufacturers instructions. While most PPE will be provided on a personal
basis, some may be used be a number of people. There therefore should be arrangements for
cleaning and disinfecting id necessary before PPE is reissued.2
Manufacturers maintenance schedules and instructions (including recommended replacement periods
and shelf lives) should normally be followed. Any significant departure from these should be
discussed beforehand with the manufacturers or their authorised agent. Some British or European
Standards on PPE also contain useful information on maintenance.2
Simple maintenance can be carried out by the trained wearer, but more intricate repairs should only
be done by specialist personnel. With complex equipment a high standard of training will be
required.2
Additional guidance is available in the following BSI published document PD CEN/TR 14560:2003 –
“Guidance fore selection, use, care and maintenance of protective clothing against heat and flame”.
1
Personal Protective Equipment at Work Regulations 1992 Regulation 7 (1) Maintenance and replacement of personal protective equipment
2
Personal Protective Equipment at Work – Guidance on Regulations
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