Test & measurement
WHY ACCURATE TESTING AND MEASUREMENT ARE CRITICAL TO SAFETY IN ENGINEERING
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In the evolving landscape of mechanical and electrical engineering, where systems are becoming increasingly complex across industries, the demand for accuracy, reliability and efficiency has never been greater. A minor fault, left undetected, can escalate into major safety issues and risks. Effective measurement is paramount for safety and, more widely, the overall profitability of engineering contracts. In mechanical and electrical engineering, measurement is often the starting point for an important decision. Dave Curry, safety manager at mechanical and electrical engineering specialist Salko UK, discusses how accurate testing and measurement can support safer operations, identify potential equipment failures early and improve compliance, while advances in digital monitoring, sensors and data-driven inspection are making testing more proactive and efficient.
he aim of effective testing and measurement is simple: engineers and manufacturers need accurate and reliable data to understand how their systems are performing.
Measurement forms the foundation of all engineering and scientific disciplines, translating abstract concepts into tangible, quantifiable realities. Consistency allows engineers to use reliable data, establishing a dependable baseline for design, manufacturing and quality control across all industries.
For engineers and on-site safety professionals, this shows an important link between technical assurance, risk management and safety. Accurate measurements provide data on which assessments and decisions can be based, making thorough testing and measurement an essential part of safety planning and management.
INSPECTION IS KEY
Complex industrial and manufacturing environments demand not just skilled design and creation, but ongoing system validation and proactive maintenance to ensure safety. This is where high-quality test equipment is essential, playing a vital role in proving system integrity during and after the process and enabling early detection of faults or degradation through regular diagnostics. By identifying issues before they escalate, these tools help engineers not only avoid safety risks but also reduce costly downtime and maintain
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operational continuity across projects. Through its comprehensive services and integration of high-precision testing equipment, Salko UK ensures that engineering systems meet rigorous standards for performance, safety and efficiency. At the Woodsmith Project in North Yorkshire, Salko UK has undertaken electrical installation at two of the deepest commercial mineshafts in Europe.
Some of the electrical test instruments used by Salko UK included low-resistance ohmmeters, insulation resistance testers, multifunction testers, proving units and approved voltage indicators – all of which are calibrated annually to ensure the test results provided are accurate and valid. Testing at this level not only validates the original installation but also sets a benchmark for ongoing maintenance, ensuring that the system continues to operate at peak health throughout its lifecycle.
THE IMPORTANCE OF TESTING FOR SAFETY AND ONGOING RESULTS In manufacturing and engineering, even minor defects can lead to serious safety concerns. Unchecked electrical faults or system inefficiencies can affect on-site safety, result in unplanned production downtime, waste materials and reduce overall output.
High-quality test equipment is essential not only during ongoing operations but also at the planning and creation stages. It ensures that new machinery and electrical systems are correctly set up, calibrated and performing to specification
from the outset. Testing systems and equipment should always be considered during the planning stages to prepare for this.
Calibration and proving of test equipment are critical to protecting those who work on electrical systems, where strict, methodical steps are used to “test for dead”.
An example from Salko UK’s Risk Assessment and Method Statement specifies that voltage needs to be checked often. In the event that voltage is detected, work needs to be halted and findings reported to the Permit Office for an isolation check. Teams need to be prepared to test with an approved voltage indicator in accordance with HSE Guidance Note GS38.
Before testing, the voltage indicator must be proved on a calibrated proving unit. Cables need to be tested for dead and, if live, work needs to
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advancements shift safety from a reactive practice to one that prevents hazards before they arise.”
October 2026 Instrumentation Monthly
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