LEV Testing

What Is LEV Testing?

In the HSE's HSG258: Controlling Airborne Contaminants at Work: A Guide to Local Exhaust Ventilation (LEV) guidance, an LEV test is defined as: "A detailed and systematic examination sufficient to make sure that the system can continue to perform as intended by design and will contribute to the adequate control of exposure. The thorough examination would normally include such functional testing to provide sufficient evidence to indicate adequate control is being achieved."

Tests help businesses ensure LEV equipment is maintained. They ensure that adequate control measures are in place to protect workers who regularly work with hazardous substances. LEV COSHH testing also ensures that the extraction equipment is maintained in efficient working order.

LEV extraction testing can be used as a preventative maintenance method. It can help companies identify and resolve mechanical issues that may arise over time and affect operations. Our engineers are specialists in this area and have in-depth knowledge of system design and operation, enabling them to identify potential faults or weaknesses before a breakdown.

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Why Do You Need to Test?

LEV systems are necessary in the workplace to remove harmful substances from the air, preventing workers from inhaling contaminants that can cause dangerous consequences. Like any workplace equipment, systems are heavily regulated to ensure they are in good working condition and are operated correctly. The Health and Safety at Work Act requires companies to conduct regular LEV testing. You should undergo testing to comply with the law, avoid severe penalties, and prevent staff from suffering injury. HSE inspectors may visit your workplace unannounced and find that procedures aren't being followed. The last thing you want is for your business to be hit with a heavy fine or, even worse, for employees to end up with serious injuries.

How Long Does a Test Take?

The length of an LEV test can vary depending on several factors, such as the number of systems to be tested, the complexity of your setup, the specific requirements of the testing protocol, and more. Testing can take anywhere from a few hours to a full day.

If you're unsure how long a test will take and want to know how it will affect your operations, please don't hesitate to get in touch; one of our experts can provide more information.

What Does the Law State About LEV Testing?

Testing of dust extraction systems and fume extraction systems is a legal requirement for compliance with health and safety standards, and test reports often form part of a company's insurance. Inadequate testing can result in employers being prosecuted, insurance being invalidated, and employees falling ill.

The Management of Health and Safety at Work Regulations 1999 have been in force since December 1999 and supplement the Health and Safety at Work Act 1974. Regulation 7 of the guidance states: "Employers must ensure that whoever carries out maintenance, examinations and tests is competent to do so."

This is also repeated in Regulation 7 of the Control of Substances Hazardous to Health (COSHH) Regulations (2002), which also states that: "Engineering control measures provided to control exposure must be thoroughly examined and tested at suitable or specified intervals. This is to ensure that they are continuing to perform as intended."

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What's Involved in Testing?

An extraction system test measures an extraction unit's airflow against its initial benchmarked performance levels. An annual LEV test covers these three core areas...

Checking and Maintenance

Checking and maintenance include the visual examination of the local exhaust ventilation system's condition, including:

• Flexible ducts
• Mechanical integrity (including corrosion, damage, seals, dampers, and sash suspensions)
• Cleanliness of hoods (including canopies and duct interiors)
• The operation of LEV monitors
• Airflow indicators
• Pressure relief or inerting systems
• Leakages
• Illumination in booths and hoods
• Noise levels
• Alarm systems operate correctly
• Water quality check (if appropriate, for example, on a Wet Collector)
• Make-up air (without draughts or blockages) and list spare parts, if required

A Thorough Examination and Test

An annual LEV test report details:

• LEV identity and its location
• The time and date the test was performed
• The control and test methods employed
• The comparison with commissioning or subsequent test reports, where available

Technical Performance

Technical performance includes:

• Measuring the static pressure target values in the duct
• The points and other identified points
• The target velocities for each point and other velocities
• The operators' exposure compared to exposure benchmark performance levels

A Thorough LEV Testing Report

Our testing procedure is one of the most detailed and comprehensive reports on the market today and primarily focuses on capturing and reporting qualitative data. Our report includes mandatory details required by the HSE, such as velocity readings, pressure readings and schematic drawings. We also detail our findings to help make the working environment safer and cleaner. Our qualified engineers detail problems and faults identified during the thorough examination and test. We'll certify extraction systems that are suitable for use are maintained in an efficient state, in efficient working order, in good repair and a clean condition.

The most detailed report in the industry...

Our testing report is one of the most thorough and detailed reports in the industry and one of our most critical LEV testing services. We rigorously test systems to ensure they perform to the initial benchmarked performance levels and comply with HSE's HSG258 guidance.

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What Does The Law State About Keeping Records?

Employers must look after the welfare of their employees. COSHH regulations (Control of Substances Hazardous to Health) of 2002 and HSE guidance HSG258 state that: "LEV equipment should be thoroughly examined and tested at least once every 14 months." Systems should be in good working order and good repair. It's essential to find the best UK LEV testing companies to ensure you continue to follow the law.

In addition, the HSE requires employers to keep test report records, and manuals should be kept in a logbook for at least five years and kept readily accessible at any reasonable time for an examination.

Regular LEV risk assessments will help you control exposure to hazardous substances. We always recommend nominating a competent person to complete regular risk assessments. We've put together a post on the '7 Essential Elements of COSHH', which you can use FREE to help your business control exposure to dust and fumes. We also recommend regular staff health surveillance. These steps can help identify whether personal protective equipment is needed.

LEV Testing Frequency

The maximum period between LEV tests for most systems is once in a 14-month period. However, we typically recommend regular testing. Read our article, Annual LEV Testing - Everything You Need to Know.

HSE's HSG258 guidance states: "If wear and tear on the LEV system are liable to mean that the system effectiveness will degrade between tests, then LEV tests should be carried out more frequently."

There are exceptions for some systems where different processes and materials are undertaken which require more frequent testing; these processes include:

1 Month	6 Months
Processes in which blasting is carried out in or incidents additional to the cleaning of metal castings in connection with their manufacture Jute cloth manufacture	Processes, other than wet processes, in which metal articles (other than gold, platinum or iridium) are ground, abraded or polished using mechanical power in any room for more than 12 hours a week Processes giving off dust or fume in which non-ferrous metal castings are produced

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LEV Test Record Keeping

Businesses should keep records of all LEV tests and maintenance to document and demonstrate that the system is working as it should. By logging all of a system's paperwork, you can keep track of problems and sort repairs before they become more severe.

In the HSE's INDG408: Clearing the Air - A Simple Guide to Buying and Using Local Exhaust Ventilation (LEV), it advises: "You already need to keep thorough examination and test reports for at least five years; it may also be helpful to you to keep your logbook for at least five years."

A Business-by-Business Approach

We understand that all businesses are different, so we take an individual approach and tailor our solutions. As a professional LEV testing company, we have the knowledge and experience to address all aspects of engineering risk as they apply to your business, and we'll work with you in the way that suits you best.

Additional Benefits of LEV Inspections

Inspections on Time	Minimise Overheads	Maximise Profitability
We work with companies to ensure a plant is examined when required and to flag when an LEV inspection is likely to become overdue. We have systems and processes to alert you so you can reschedule quickly. We do this so your business is less likely to suffer plant failures, protecting your turnover as a result.	We maintain a secure LEV Test Report Portal. Our portal is a digital file-sharing platform that sends automatic reminders to help keep you HSE-compliant. It also archives documentation after five years (as per HSE recommendations) to save you time and money on administration.	Scheduling regular maintenance as part of a PPM (planned preventative maintenance) schedule helps to prevent unplanned breakdowns. A comprehensive PPM can reduce the risk of breakdown, confirm safety, and ensure the LEV system operates efficiently.

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Spray Booth Testing

We offer a comprehensive Smoke Clearance Testing service in line with the HSE's guidance to ensure your equipment adequately controls and removes smoke from the working environment in a controlled and reasonable time. Smoke clearance time tests and LEV tests are essential parts of a spray booth's maintenance regime. This is a practical way to measure how long it takes to clear the booth or room of smoke.

We can help your business with high-quality, thorough spray booth smoke clearance testing to protect employees. Our range of LEV testing services will ensure you comply with COSHH Regulations 2002.

Find out more about Spray Booth LEV Testing - Everything You Need to Know

What if a System Fails Its Test?

An LEV test helps identify whether the plant or equipment has any defects or pending defects. For an LEV system to meet the required benchmark performance levels, we recommend completing the necessary maintenance work. A Remedial Works quotation will be assembled to reinstate the system to the required benchmarked performance levels.

We conducted over 7,200 tests during 2019. 16% of the LEV inspections revealed defects that could pose an imminent risk of ill health to employees.

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What Are the Consequences of Not Testing?

Systems require regular testing by a qualified, competent person to ensure the equipment works as intended. Under the law, testing is required at least every 14 months, although we advise annual testing. Testing ensures the systems work effectively and are safe to use. Without regular LEV inspections, you risk ignoring issues, experiencing malfunctions, and having accidents. For this reason, missing a test can seriously affect you and your business. Companies have been fined significant amounts for failing LEV systems or not performing regular testing.

Will an LEV Test Affect Business Operations?

We understand that one of your concerns during an LEV test is how it could affect your business operations. However, you can rest assured that we will work around your requirements and ensure you face no interruption. If you have any concerns beforehand, we can advise you on how the examination will impact your operations, if at all. No matter what, we strive to ensure minimal to no downtime for our customers. If more suitable, we can schedule a test outside your normal operating hours, depending on availability.

What Is Meant by a Competent Person?

Competency is usually judged based on several factors, including experience, knowledge, ability, skills and training. The HSE specifically defines a competent person as someone who holds a "combination of knowledge, skills and application experience" that enables them to do an "effective and reliable job." Given the serious nature of LEV systems and the consequences of failure, it's essential that people who use, maintain, and test them are competent.

The combined factors mentioned previously are all vital, and simply completing a training course, for example, would not be enough to deem a person competent. In-depth experience with LEV systems is valuable for an examiner as they may identify the smallest problematic areas that an inexperienced person might overlook. Auto Extract's specialists are highly experienced and have the skills, knowledge and qualifications needed to perform thorough LEV examinations, preventing avoidable issues should an HSE inspector visit your site.

How Can You Prove Your Staff Are Competent?

We are highly experienced in LEV systems and recognise the importance of maintaining health and safety regulations within the industrial workplace. Auto Extract Systems hires the best people based on their qualifications, skills, and knowledge, using the HSE framework to guide us. We use references and supporting evidence to ensure our staff are suitable for the role they are offered. Where possible, we can provide evidence demonstrating our team's capability and competence.

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What Our Customers Are Saying

We believe we offer a complete testing solution to help businesses in all industries comply with health and safety regulations and maintain a safe workplace for employees and the public. Our engineers are fully qualified, offer excellent customer service and provide all necessary reports. With a service level agreement tailored to you, we ensure your business never misses a maintenance schedule. We can also serve commercial customers across the United Kingdom. But don't just take our word for it! Here's a snippet of what our customers think of our LEV testing services...

"Our Fleet workshop based in Hull, Yorkshire have used Auto Extract Systems for all our LEV testing, certification and repairs over the last 4 years.

"We have been extremely pleased with the full service from contact to inspection from all members of there staff.

"All the staff are helpful, professional and committed to giving the best value and service as well as the aftercare which is second to none with a fantastic portal service which is very useful to the client.

"I would have no hesitation recommending Auto Extract Systems to any potential company requiring there services." - Tony Kirk

Insurance Company LEV Testing

It’s a common misconception that LEV equipment must be tested and maintained by the installer or the insurance company; however, test reports often form part of a company’s insurance policy. Inadequate testing can result in employers being prosecuted, insurance policies being invalidated, and even employees becoming ill. We strongly advise that, if your insurance company provides testing, it be comprehensive and thorough to meet the HSE standards expected of an LEV system inspection.

In our experience, insurance companies typically offer testing as a 'free' service when a policy is taken out. As with anything, nothing's ever free. That is why we advise businesses who opt for their insurance companies to complete their testing to ensure it is comprehensive and that, should any remedial work be advised, they seek advice from a specialist provider to remedy the problems identified.

At Auto Extract Systems, we're happy to work with businesses that choose to have their LEV testing undertaken by an insurance company (or another business, such as an occupational hygienist). Our dedicated engineering teams are experts in installing, maintaining, and testing all kinds of systems. Get in touch today for a free, no-obligation remedial quotation.

Should LEV Systems Be Serviced?

To preserve your system's longevity and effectiveness, we recommend completing LEV testing alongside LEV Servicing.

As part of a thorough PPM (planned preventative maintenance) schedule, we also recommend servicing LEV equipment at least every 12 months, and more frequently if usage is high. This helps it operate within required performance benchmarks and reduces exposure to hazardous substances.

What Industries Require Testing?

There are no limits to the types of industries that must follow LEV guidance. Every business, regardless of its sector, should follow health and safety laws when working with hazardous substances. That said, some industries are more likely to work with hazardous substances. If a workplace uses an LEV system to extract harmful materials, such as dust and fumes, then the system must undergo regular LEV testing.

Here is a brief list of just some of the industries where testing is a likely requirement:

• Metalworking
• Education
• Workshops
• Woodworking
• Welding
• Manufacturing
• Engineering
• Oil & Gas

Visit our industry page to learn more about the different types of companies that we have worked with.

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The Essential Elements of COSHH 

Employers must complete regular COSHH risk assessments. Regulation 7 first requires employers to make all reasonable efforts to follow the COSHH hierarchical approach. The hierarchical approach recommends substituting substances to eliminate or reduce the risk of exposure. However, if elimination or substitution can't be avoided, employers should implement control measures, such as engineering controls, to control the risk.

COSHH Regulations place the duty of care on companies to ensure employees (and other people in a workplace) who may be exposed to specific substances are protected. To learn more about the steps you need to take to ensure your workplace complies with the COSHH Regulations, read our article, The 7 Essential Elements of COSHH [Infographic]. 

Who Doesn't Want to Save Money?

Obviously, every business owner wants to save money where possible, as long as you're still adding value to the service provided. That's why we've developed our Service Level Agreement (SLA) plan. By taking out a Service Level Agreement, you'll still benefit from the same outstanding service you've come to expect from Auto Extract Systems; however, we'll also save you money on future LEV tests and servicing plans. We'll tailor a bespoke SLA to your business or site's exact requirements.

Safeguard Your Business Today

If HSE inspects your workplace and finds your business to be in breach of health and safety law, you will be liable to pay them for their time. They will use that time to identify what is wrong and help you put it right. This scheme, known as Fee for Intervention (FFI), is in place to recover costs incurred from LEV system inspections, investigations, and enforcement actions. The current rate is £160 plus VAT, per hour, per HSE inspector. We've put together a blog article, titled 'Fee For Intervention - Explained', which details the severity of not complying with the legislation and regulations. 

Reduce the risk of ‘No-Win, No Fee’ negligence claims. Poor air quality can damage a worker's long- and short-term health, while also affecting productivity and the ability to work. Common health effects from exposure to contaminants (such as fumes, dust, vapours, and mists) can include occupational asthma, COPD (chronic obstructive pulmonary disease), and even cancer.

Safeguard your business against uncontrollable FFI costs and potential liability claims with a comprehensive LEV system.

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Checklist to Help You to Choose the Right LEV Supplier

If you’re in the market for a new Local Exhaust Ventilation system, it can be tough to decide which solutions provider is best. We want to help, so we’ve assembled a checklist (and article) to guide you in selecting the right LEV supplier for your business and requirements. Read our article, How to Choose a Local Exhaust Ventilation (LEV) Supplier, and download the checklist.

Learn How We Helped Businesses Like Yours

We are one of the most experienced LEV testing companies around. To find out more about the latest installations we've been working on, check out our Case Studies section.

We Do Exceptional Customer Service

Customer service is the foundation of our business, and we take great pride in delivering the highest standard of service. We know we offer the most thorough and complete service available in our field.

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