PAT Testing Checklist: Planning, Inspection and Records

A PAT testing checklist helps organise preparation, inspection, appropriate testing and records. It cannot replace training, manufacturer instructions or a procedure selected for the actual equipment.

Use this as a planning checklist, not a universal electrical test sequence.

The high-level structure

Every PAT test follows the same broad sequence:

1. Pre-test preparation
2. Formal visual inspection
3. Electrical tests (sequence depends on class)
4. Functional check

Labelling and documentation

Select the checks appropriate to the equipment and procedure. This planning checklist is not a universal test sequence: some items need different methods or specialist assessment.

Section 1: Pre-test preparation

Before touching any appliance, confirm:

• Check that instrument calibration, verification and condition meet the manufacturer's instructions and any applicable requirements.
• Tester batteries are good: low battery causes inaccurate readings
• Test leads are intact: damaged leads = invalid tests
• Workspace is clear: enough space to set down appliances safely
• Power supply is reliable: avoid testing on extension leads where possible
• Select any PPE from the task-specific risk assessment; PPE is not a substitute for safe isolation or an appropriate procedure.
• You have your record sheet ready: don't try to capture results from memory

Section 2: Formal visual inspection

Visual inspection is essential: an instrument test cannot detect every defect. Examine the equipment, plug, cable and suitability for its environment.

The plug

• Plug body intact, no cracks or damage
• Pins straight, no bending or signs of overheating
• Pin sleeves on live and neutral (modern requirement)
• No exposed copper at the plug entry
• Correct fuse rating for the appliance
• On rewireable plugs: cord grip secure, no wires exposed beyond the strain relief
• On rewireable plugs: terminal screws tight, wires correctly terminated
• On rewireable plugs: no excess copper outside terminals
• Plug face clean, no scorch marks
• Pins not loose in body when wiggled

The cable

• No cuts, splits or abrasions along the full length
• No signs of crushing or compression damage
• No exposed conductors anywhere
• No taped joints (a major fail — repair, don't tape)
• No signs of overheating (browning, hardening, smell)
• Cable enters plug cleanly with intact strain relief
• Cable enters appliance cleanly with intact strain relief
• Sufficient length for intended use (no undue tension)
• Correct rating for the appliance load
• No twisted or kinked sections

The appliance casing

• No cracks in the body
• No missing screws or visible internal access
• No signs of impact damage
• Class 1 appliances: metal parts properly bonded
• Class 2 marking visible where applicable
• CE/UKCA marking and rating plate present and legible
• No signs of overheating (discolouration, damage)
• Air vents clear (where applicable — overheating risk)
• Switches and controls intact
• Indicator lamps where present working

The environment and use

• Appliance suitable for the location it's used in
• Not exposed to inappropriate moisture, heat or dust
• Not used outdoors if not rated for it
• Cable routing safe (not under chair wheels, doors, etc.)

If anything fails visual inspection, don't proceed to electrical testing. Mark as failed, remove from service, and document.

Section 3: Electrical tests

The competent tester must select a procedure suitable for that specific appliance and test instrument. Test current, voltage, connection points and acceptance limits depend on the equipment and manufacturer instructions. A single 25 A earth test, 500 V insulation test or blanket resistance limit is not suitable for every item. Do not energise equipment with a known defect, or repeatedly test it until a passing result appears.

• Confirm the protection class and the manufacturer’s required checks.
• Check that the instrument, leads and adapters are suitable and functioning correctly.
• Use the appropriate protective-conductor, insulation or leakage tests where applicable; these are not interchangeable by default.
• Account for sensitive electronics, surge protection, filters, cable length and any specialist equipment requirements.
• Keep defective or uncertain equipment out of use and refer it for competent assessment.

See HSE HSG107 for the maintenance framework. Permanently connected, three-phase and specialist equipment may need a separately competent person.

Section 4: Functional check

Only carry out a functional check where it is appropriate and safe following the inspection and relevant tests. Plan for moving parts, heating elements and unexpected operation. Do not power up a known faulty appliance just to see whether it still works.

Section 5: Labelling and documentation

Appliance labelling

For each tested appliance:

• Apply pass/fail label (date, tester ID, next test date)
• Position label visibly but where it won't be damaged
• Remove old labels (avoid label buildup that could become illegible)

Documentation

For each tested appliance, record:

• Asset ID
• Description
• Test date
• All test readings (not just pass/fail)
• Tester name and qualification
• Tester equipment used (with calibration date)
• Result (pass/fail)
• Next test date
• Any visual issues noted
• Action if failed

For full documentation guidance, see our record sheet template post.

Section 6: Failure handling

When an appliance fails:

• Remove from service immediately (don't leave it plugged in)
• Apply red "FAIL" label
• Document failure reason in detail
• Notify the appliance owner / responsible person
• Decision: repair, replace, or scrap
• If repaired: full retest before returning to service
• If replaced: register new appliance with new asset ID
• Update record sheet with disposal/replacement details

Common mistakes to avoid

• Skipping visual inspection: most failures are visual, not electrical
• Testing damaged equipment: visual fail = stop, don't proceed to electrical tests
• Recording only pass/fail: actual readings matter for trend analysis
• Leaving old labels in place: causes confusion about which test is current
• Using an instrument without the calibration, verification or condition checks required for the work can undermine confidence in the results. Investigate suspect readings and follow the applicable procedure.
• Insufficient documentation: a test without proper records is operationally useless
• Battery low on tester: inaccurate readings, false passes possible
• Testing through extension leads: introduces resistance that affects readings

Frequently asked questions

What is the correct order?

Prepare the work and inspect the equipment before selecting electrical tests. Stop on an unsafe condition. The subsequent sequence must suit the actual appliance and instrument.

Is there one pass threshold?

No. Apply the correct acceptance criteria for the test, equipment and relevant guidance. Account for lead resistance and the instrument’s limitations.

What if the reading is marginal?

Investigate the reason rather than accepting a result because it is just above or below a number. The acceptable direction depends on the measurement. A low earth-path resistance and a high insulation resistance have different meanings.

Should I record readings?

Recording the relevant readings and method can help identify deterioration. Include the inspection result and action taken, not only the instrument’s pass/fail display.

The takeaway

A useful checklist supports competent judgement. Use equipment-specific instructions, deal with defects promptly and keep records that explain what was inspected, what was measured and what action followed.

The earlier PDF repeated a one-size-fits-all electrical procedure and is no longer linked here. Use HSE’s maintenance guidance alongside the equipment instructions and your approved working procedure.