LICQual Level 3 Certificate in Quality Control and Quality Assurance (QA/QC) in
Electrical

Purpose

This Knowledge Providing Task is designed to:

• Provide learners with a realistic workplace scenario in electrical QA/QC.
• Help learners identify, analyse, and prevent quality failures and incidents.
• Enable learners to apply vocational knowledge of QA and QC principles to electrical systems.
• Develop analytical, reflective, and decision-making skills by interpreting why incidents occur and how proper procedures prevent them.
• Reinforce the application of UK-specific laws and standards, including BS 7671, Electricity at Work Regulations 1989, Health and Safety at Work Act 1974, and ISO 9001 quality standards.

The task follows a Mini Case Study approach, with detailed context and guided reflective questions, ensuring learners can relate competency to real-life electrical work.

Vocational Workplace Scenario (Mini Case Study)

Scenario Title: Overheating in a Newly Installed Electrical Distribution Board

Background:

You are a QA/QC Electrical Inspector working for a UK-based commercial building contractor. Your role involves ensuring electrical installations comply with BS 7671, company procedures, and UK electrical legislation.

The project involves the installation of multiple low-voltage distribution boards across a commercial building. During commissioning, one board shows overheating and minor insulation melting on some incoming cables.

Detailed Observations

• The distribution board was assembled according to approved electrical drawings.
• Terminal screws were found loose, despite torque values being previously recorded as compliant.
• The installer skipped part of the standard verification checklist due to time pressures.
• QA procedures included verification of staff competence and calibration of tools, but the procedural verification for this board was not completed.
• No additional QC inspections were performed before the board was energised.
• The overheating was detected during commissioning tests, and the board was immediately de-energised.
• Corrective actions were applied, and a full internal investigation was launched to prevent recurrence.

Vocational Relevance

This scenario highlights several practical challenges in electrical QA/QC:

• Process adherence: QA processes were not fully followed, increasing the risk of defects.
• Inspection effectiveness: QC inspections were incomplete, failing to detect defects prior to energising.
• Human factors: Pressure to meet deadlines caused procedural shortcuts, demonstrating the importance of staff training and awareness.
• Safety and compliance: Failure to comply with standards could result in fire hazards, equipment damage, or electric shock

Applicable UK Standards and Legislatio

• Electricity at Work Regulations 1989: Ensures electrical systems are safe to use and maintained by competent persons.
• Health and Safety at Work etc. Act 1974: Protects employees, contractors, and the public.
• BS 7671 (IET Wiring Regulations): Provides technical standards for electrical installation safety and inspection.
• ISO 9001 Quality Management Systems: Provides framework for consistent quality and process control in electrical projects.

Analysis of QA and QC in the Scenario

1. Quality Assurance (QA) Considerations

QA aims to prevent errors before they occur. In this scenario, QA failures included:

• Skipped procedural verification checklist for the panel.
• Lack of double-checking that staff followed torque procedures correctly.
• Incomplete documentation of verification processes.

2. Preventive QA actions that could have helped:

• Strict adherence to installation checklists and QA procedures.
• Competency verification of the installer for terminal assembly.
• Use of calibrated torque tools and verification logs to ensure proper tightening.

3. Quality Control (QC) Considerations

QC focuses on detecting defects during or after work. QC failures in this scenario included:

• No visual inspection of terminal tightness before energising.
• No functional testing or verification of load performance before commissioning.
• Failure to perform final QC inspection after assembly

4. QC inspections that would detect the issue:

• Visual inspection for loose terminals.
• Torque verification against manufacturer and BS 7671 specifications.
• Continuity and insulation resistance testing to detect overheating risks.

5. Linking QA and QC to Safety and Compliance

The scenario demonstrates that QA and QC complement each other:

• QA ensures the right processes are in place, and staff are competent.
• QC ensures errors that slip through QA are detected before energising.
• Together, they prevent incidents, maintain compliance with BS 7671, and reduce risk to workers and equipment.

Guided Reflective and Analytical Questions

Learners are required to analyse the scenario and answer the following:

• Identify which aspects of the incident represent Quality Assurance failures and which represent Quality Control failures. Explain why.
• Analyse the root causes of the overheating incident, considering procedural gaps, staff competence, and inspection lapses.
• List two QA measures that should have been applied to prevent the defect, referencing UK standards and legislation.
• Identify two QC inspections or tests that could detect loose terminals before energising, and explain how they prevent incidents.
• Explain why compliance with BS 7671 and the Electricity at Work Regulations 1989 is critical in this scenario.
• Propose one corrective action to prevent recurrence and explain how QA and QC roles would interact to ensure full compliance

Competency-Based Learning Focus

This KPT develops learner competencies in:

• Applying QA/QC principles to real electrical work environments
• Analysing root causes of electrical quality failures and safety incidents
• Making informed preventive and corrective decisions
• Understanding the relationship between QA, QC, safety, and compliance
• Applying UK laws and standards to practical situations
• Improving critical thinking, reflective learning, and decision-making in electrical QA/QC

Learner Task

Read the mini case study and answer the guided questions:

• Identify the QA failures and QC failures in the scenario.
• Explain the root causes of the overheating incident.
• Describe two QA measures that could have prevented the defect.
• Describe two QC inspections that would detect the problem before energising.
• Explain why compliance with BS 7671 and the Electricity at Work Regulations 1989 is critical.
• Suggest one corrective action to prevent recurrence, showing how QA and QCwork together.