Which PAT solution is best for you?

Jim Wallace of Seaward Electronic looks at technology advances in portable appliance testing (PAT) and the integration of instruments with test data management software.

Since the early 1990s The Electricity At Work Regulations has provided the impetus for the development of a considerable portable appliance safety testing market for many electrical contractors.

On the face of it little appears to have changed.

The EAWR still insists that all workplace electrical systems must be maintained to prevent danger and that a suitable defence is proof that all reasonable steps have been exercised in avoiding unsafe situations.

The majority of organisations and large employers now recognise their statutory responsibilities for maintaining a safe working environment and the demand for periodic inspection and testing services has enabled many electrical contractors to establish successful portable appliance testing services.

But the times really have changed.

Growth in the PAT market for well over a decade has inevitably generated fierce competition, with PAT test rates continuing to come under pressure.

To remain profitable the onus is therefore on test engineers to carry out as many tests as possible without compromising test quality and the validity of test results.

For the modern day contractor offering portable appliance testing the pressure to complete tests quickly - without cutting corners - is therefore immense.

The answer lies in smarter testing with integrated PAT systems that link testing to data management and enhanced customer services for more efficient working practices.

Testing, testing The essential role of portable appliance testing is to detect potential safety problems with electrical appliances before they occur.

Although obvious equipment defects can be found during visual inspection, to identify all potentially dangerous faults inspection needs to be linked with a programme of periodic testing that is capable of revealing any 'invisible' electrical faults such as earth continuity, insulation integrity and other potential problems.

The essential tests for most electrical products are earth continuity and insulation resistance, although a host of other tests such as IEC cord or lead tests, touch and protective conductor currents may also be required depending on the type of equipment in use and the associated risk factors.

At one end of the instrumentation scale relatively simple to operate pass/fail checkers are available that carry out some of the basic safety checks on equipment and provide an immediate 'go/no go' display.

These basic safety checkers do not possess an internal memory for results storage and are designed for use by those who may be relatively unskilled in electrical work.

For more comprehensive test requirements, sophisticated microprocessor controlled testers are available that combine user-friendly operation with a whole range of other features for particular test demands or routines.

Some of the options available include manual or automatic testing through the selection of pre-set test sequences for certain categories of equipment and the ability to record results in the tester for transfer to test management programs.

Lightweight hand held PAT testers are now available that incorporate all Class I and Class II required electrical safety tests in a compact hand held enclosure.

In some, long life battery power eliminates the reliance on mains outlets for testing, making the instrument totally portable and suitable for universal testing applications.

Other modern PAT testers also include combination test features, linking electrical safety tests with digital multimeter, installation checks and other test functions, such, as temperature measurement, for more versatile testing undertaken by field service engineers.

One of the most recent introductions is the incorporation of Bluetooth technology in advanced testers.

This allows the wireless connection of bar code scanners, label printers and other accessories - allowing time-saving cable-free testing, without the cumbersome and constant plugging in and unplugging of leads and cords.

Advanced PAT testers can also be linked directly safety-labelling printers for the fast and automatic production of appliance test labels on-site and immediately after tests have been conducted.

These labels not only provide confirmation that the equipment is safe to use but often include details of 'next test' due dates.

Managing test data The use of more sophisticated portable appliance testers also enables data to be transferred directly from the instrument to a PC-stored database to allow the automatic updating of test records, the generation of test reports and advance test schedules.

In this way in very basic terms PAT testers might be regarded simply as test data collection tools that measure and check the safety of electrical equipment in the workplace.

In today's competitive market, however, the key to providing a true added value modern PAT service is increasingly about how this test data is acquired, managed and presented.

On a practical level the provision of effective test services is also about enhancing the transfer of data between the tester and the database and how the collected data can be interrogated and used to control safety programmes more effectively.

As a result, entry level software programs are available to enable even those using simple pass/fail PAT testers to benefit from operating efficiencies, for example, by providing storage for basic test records and the ability to print test certificates.

For larger contractors and service companies, and because the testing of electrical appliances is invariably carried out by field test engineers at customer locations, more powerful test data management packages are available that facilitate two-way transfer of data between the tester and the software.

In this way engineers can pre-program or upload some testers directly from a PC with the necessary equipment and test information before the day's work begins and then download results into the records programme at the end of the shift.

The same software programs can also be used to create asset registers for customers, print test certificates and output test reports in different formats.

New PDA based PAT software programs takes this smarter working to a different level by promoting greater flexibility for field service engineers whether or not their testers possess an internal memory for results storage.

For example, new PAT workabout software allows direct input of equipment, tests and inspections from a central results database into a hand held PDA, with the results of test routines being quickly and easily recorded as soon as testing is completed.

Test results files can then be transferred back to head office records either directly from the PDA or remotely from test locations using email and mobile phone technology.

Higher up the technology scale, the use of Bluetooth enabled testers further enhances this flexibility, especially for large PAT service and contracting organisations.

Here the effective use of data management software can greatly improve the margins associated with operating efficiencies of remote off-site working - for example, by cutting down on the time and expense associated with engineers having to regularly return to head office to transfer test data.

For more specific monitoring of PAT productivity in the field special software is also available that interrogates the PAT results database to provide a clear picture of tester usage.

The new time manager software provides clear information on the test activity of individual users and engineers - providing such details as time of test, number of tests undertaken and time between jobs.

Analysis of such information enables team managers to understand how often testers are used, identify improvements in any staff training needed and help field staff to test faster and more efficiently.

Another recent innovation to help contractors manage testing and boost levels of business is the use of PAT management software to identify and plan re-testing schedules.

This feature works through specialist software that constantly monitors the test records stored in a PAT results database, automatically triggering re-test notices for those that are approaching the next test date.

The pre-trigger feature enables re-test schedules to be highlighted prior to appliances becoming overdue for test, with special e mail alerts being sent to customer contact personnel to give advance warning of the likely presence of any potentially unsafe electrical equipment in the workplace.

The system can also be configured to submit formal re-test price quotations with the alerts for a complete test scheduling and costing proposal, boosting repeat business and enhancing the levels of customer support provided.

PAT systems approach With such a variety of PATs to choose from, very rarely is the choice of test instrument simply down to price.

For most contractors and test organisations, user competency, test specifications and supporting data management software are among the factors to be considered in any purchasing decision - and other considerations like availability of accessories, staff training and instrument calibration can also come into the equation.

Modern PAT testing is now as much about managing a client's electrical equipment register on their behalf as it is about organising teams of field engineers to undertake the testing.

Such an approach gives PAT contractors and companies the important ability to inform customers when their workplace electrical equipment is due for re-test rather than waiting to be asked - with this proactive approach boosting client confidence and generating important new business proposals.

To help contractors in this situation, new total PAT solutions have been developed that streamline the selection of integrated test systems in keeping with exactly the sort of portable appliance testing being undertaken.

In this concept, individual PAT testers, accessories, results management software, training and after sales support are all made available in defined packages to provide practical test solutions for all levels of user.

In this way contractors can ensure that they can undertake the safety testing of all electrical items as cost-effectively as possible and as part of an overall test service that enhances value for money considerations.

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