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Fault Finding Diagnostics and System Testing Risk Assessment

Fault Finding Diagnostics and System Testing Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
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Fault Finding Diagnostics and System Testing Risk Assessment

Product Overview

Identify and control organisational risks associated with Fault Finding Diagnostics and System Testing through a structured, management-level WHS Risk Management approach that underpins planning, policy, training and equipment selection. This Risk Assessment supports compliance with the Work Health and Safety legislation, strengthens Due Diligence, and helps protect your business from operational and legal liability.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • Governance, WHS Duties and Regulatory Compliance: Assessment of executive and officer due diligence obligations, safety leadership, and integration of diagnostics and testing into the organisation’s WHS management system.
  • Competency, Licensing and Training for Diagnostics: Management of competency frameworks, authorisation, refresher training, and verification of competency for personnel performing fault finding and system testing.
  • Technical Documentation and Information Management: Controls for maintaining up‑to‑date schematics, manuals, and test procedures, including version control, accessibility, and document approval processes.
  • Diagnostic Equipment, Tools and Calibration Systems: Governance of selection, inspection, calibration, maintenance and safe use of diagnostic instruments, test rigs, laptops and software tools.
  • Work Planning, Permit to Work and Isolation Interfaces: Integration of diagnostics into work planning processes, permits, isolation/lockout systems, and coordination with other work on plant and equipment.
  • Management of Live Testing and Commissioning‑Type Activities: Protocols for risk assessing energised work, simulation and functional testing, including barriers, supervision, and escalation criteria.
  • Change Management and Configuration Control During Fault Rectification: Systems to manage temporary overrides, software changes, parameter adjustments and hardware modifications arising from fault finding.
  • Data Quality, Diagnostic Interpretation and Human Error: Assessment of risks associated with misdiagnosis, incomplete data, confirmation bias, and reliance on automated fault codes or analytics.
  • Interfaces with Contractors, OEMs and Remote Support: Management of third‑party access, remote connections, information sharing, and delineation of responsibilities during diagnostic activities.
  • Asset Integrity, Deterioration Monitoring and Reliability Programs: Integration of diagnostics and testing outcomes into asset management, condition monitoring, reliability‑centred maintenance and defect elimination programs.
  • Fatigue, Workload and Time Pressure in Fault Response: Controls for after‑hours call‑outs, extended fault‑finding sessions, service level expectations and their impact on safe decision‑making.
  • Workplace Environment, Access and Layout for Diagnostic Activities: Assessment of access, lighting, ergonomics, confined spaces and other environmental factors affecting safe system testing.
  • Emergency Preparedness During Diagnostics and System Testing: Planning for abnormal events, unplanned energisation, system instability and emergency response arrangements during testing.
  • Information, Consultation and Reporting for Diagnostic Activities: Structures for toolbox talks, shift handover, incident and near‑miss reporting, and consultation with workers on diagnostic risks.
  • Continuous Improvement, Auditing and Assurance of Diagnostic Systems: Ongoing review of diagnostic practices, audits, performance indicators and corrective actions to strengthen organisational controls.

Who is this for?

This Risk Assessment is designed for Business Owners, Engineering Managers, Maintenance Leaders and Safety Professionals responsible for planning, governing and assuring safe Fault Finding Diagnostics and System Testing activities across their operations.

Hazards & Risks Covered

Hazard Risk Description
1. Governance, WHS Duties and Regulatory Compliance
  • • Lack of clear allocation of WHS duties for diagnostics activities under WHS Act 2011 and WHS Regulations
  • • Senior management not exercising due diligence in relation to diagnostic and testing risks
  • • Inadequate awareness of legal requirements for electrical, plant and pressure systems fault finding
  • • Absence of documented WHS policy covering diagnostic, testing and fault‑finding activities
  • • Inadequate consultation with workers and HSRs on risks associated with fault finding and system testing
  • • Poor integration of WHS obligations into contracts with clients, OEMs and service providers
2. Competency, Licensing and Training for Diagnostics
  • • Inadequate technical competency for complex fault finding on engineered systems and existing installations
  • • Workers performing electrical or pressure diagnostics without required licences or qualifications
  • • Lack of specific training on diagnostic software, vibration analysis tools and specialised test equipment
  • • Insufficient understanding of system failure modes and limitations of diagnostic methods
  • • No structured assessment of competency prior to independent fault finding
  • • Poor refresher training on emerging technologies, firmware changes and updated diagnostic techniques
3. Technical Documentation and Information Management
  • • Outdated or incorrect schematics, P&IDs, wiring diagrams and configuration files used during fault finding
  • • Missing OEM manuals, diagnostic procedures or software instructions
  • • Uncontrolled paper copies of drawings leading to use of superseded information
  • • Poor version control of firmware, configuration baselines and calibration records
  • • Inadequate access to historical maintenance, breakdown and vibration trend data
  • • Lack of clear documentation for non‑standard modifications or temporary repairs
4. Diagnostic Equipment, Tools and Calibration Systems
  • • Use of faulty, uncalibrated or unsuitable test instruments for electrical and mechanical diagnostics
  • • Incorrect vibration sensors, mounting methods or ranges leading to misinterpretation of machine condition
  • • Incompatible interfaces between diagnostic equipment and plant control systems causing damage or unsafe states
  • • Lack of inspection and maintenance regime for test leads, probes, clamps, pressure hoses and adaptors
  • • Shared or uncontrolled passwords and access tokens for diagnostic software and remote access tools
  • • Inadequate electromagnetic compatibility of diagnostic tools impacting safety‑critical control systems
5. Work Planning, Permit to Work and Isolation Interfaces
  • • Unplanned or ad‑hoc fault finding without formal risk assessment or work planning
  • • Diagnostics commenced without verifying plant status, isolations or energy states
  • • Overlap and conflicts between diagnostic activities and live operations or production demands
  • • Bypassing of interlocks or safety systems during testing without formal authorisation
  • • Inadequate interface between permit to work, lock‑out/tag‑out and diagnostic requirements
  • • Incomplete communication of isolation boundaries to diagnostic personnel
6. Management of Live Testing and Commissioning‑Type Activities
  • • Uncontrolled exposure to live electrical, hydraulic, pneumatic or rotating equipment during operational tests
  • • Unexpected energisation or automatic start of machinery during fault replication or system proving
  • • Inadequate exclusion zones during vibration analysis and performance verification on operating machinery
  • • Incorrect re‑instatement of interlocks, guards or protective devices after testing
  • • Inadequate supervision of high‑risk dynamic testing and commissioning activities
  • • Live testing that adversely affects system stability or process safety (e.g. trips, pressure surges)
7. Change Management and Configuration Control During Fault Rectification
  • • Uncontrolled changes to control logic, protection settings or equipment parameters during troubleshooting
  • • Temporary workarounds or patches becoming permanent without risk review
  • • Loss of baseline configuration due to undocumented firmware or settings changes
  • • Conflicting changes made by multiple technicians or external vendors
  • • System performance drift after minor parameter changes not being monitored
  • • Inadequate back‑out plans if configuration changes introduce new faults or hazards
8. Data Quality, Diagnostic Interpretation and Human Error
  • • Incorrect diagnosis due to misinterpreted vibration data, sensor noise or transient conditions
  • • Over‑reliance on software diagnostics without critical evaluation of underlying data
  • • Cognitive overload or distraction leading to misreading of system parameters or trends
  • • Confirmation bias resulting in premature conclusions and inappropriate repairs
  • • Inadequate peer review of complex diagnostic conclusions on safety‑critical systems
  • • Use of inappropriate acceptance criteria or thresholds for performance verification
9. Interfaces with Contractors, OEMs and Remote Support
  • • Contractors or OEM technicians performing diagnostics without understanding site‑specific hazards and procedures
  • • Remote access sessions altering system configurations without adequate oversight
  • • Poor communication between internal staff and external specialists leading to conflicting instructions
  • • Inadequate vetting of contractor competency for specialised diagnostics (e.g. main engine vibration analysis)
  • • Lack of clarity on who controls the plant during external diagnostic interventions
  • • Unrecorded changes or advice from remote support not integrated into site documentation
10. Asset Integrity, Deterioration Monitoring and Reliability Programs
  • • Undetected deterioration of critical equipment due to inadequate monitoring regimes
  • • Reactive‑only maintenance approach causing rushed, high‑risk diagnostics after failures
  • • Incomplete integration of vibration analysis, condition monitoring and fault histories into maintenance planning
  • • Failure to recognise early warning signs of systemic issues across multiple assets
  • • Inadequate prioritisation of defects and recommendations arising from diagnostic activities
  • • Loss of reliability data when systems are upgraded or replaced
11. Fatigue, Workload and Time Pressure in Fault Response
  • • Technicians attending after‑hours call‑outs for urgent breakdown diagnostics while fatigued
  • • Compressed timeframes for fault finding and repair due to production pressures
  • • Extended troubleshooting sessions on complex systems without adequate breaks
  • • Inadequate staffing levels resulting in single‑person diagnostics for high‑risk tasks
  • • Management expectations that discourage escalation or job rescheduling when risks increase
  • • Increased likelihood of human error in data interpretation and configuration changes under fatigue
12. Workplace Environment, Access and Layout for Diagnostic Activities
  • • Poor access to diagnostic points on engines, auxiliary equipment and control panels leading to unsafe body positioning
  • • Inadequate lighting, noise and environmental conditions during troubleshooting
  • • Congested work areas around machinery under test, increasing slip, trip and impact risks
  • • Inadequate fixed provisions (test points, isolation valves, monitoring ports) requiring improvised connections
  • • Diagnostic stations or laptops set up in unsafe zones near rotating machinery or hot surfaces
  • • Environmental contamination (dust, moisture, chemicals) affecting diagnostic equipment and readings
13. Emergency Preparedness During Diagnostics and System Testing
  • • Delayed response to equipment instability or abnormal behaviour observed during testing
  • • Unclear emergency stop responsibilities when multiple parties are involved in diagnostics
  • • Inadequate planning for worst‑case outcomes of performance tests (e.g. engine overspeed, pressure excursions)
  • • Limited awareness of isolation points and emergency shut‑down procedures by diagnostic personnel
  • • Emergency equipment not suited to hazards associated with diagnostic work (e.g. arc flash, fluid release)
  • • Insufficient drills or simulations for emergency scenarios arising specifically from testing activities
14. Information, Consultation and Reporting for Diagnostic Activities
  • • Workers not informed about planned diagnostic activities that may affect system performance or availability
  • • Under‑reporting of near misses, misdiagnoses or test‑related incidents
  • • Limited consultation with frontline technicians when developing diagnostic procedures or selecting tools
  • • Inadequate communication of known system anomalies, temporary bypasses or degraded modes of operation
  • • Lack of feedback loop from diagnostic findings to broader WHS and maintenance planning
  • • Inconsistent handover of diagnostic status between shifts or work groups
15. Continuous Improvement, Auditing and Assurance of Diagnostic Systems
  • • Stagnant diagnostic practices that do not keep pace with technology or emerging risks
  • • Undetected non‑compliance with diagnostic procedures, permits or isolation requirements
  • • No systematic review of the effectiveness of diagnostic‑related controls after incidents or major faults
  • • Fragmented lessons learned, with improvements not shared across sites or teams
  • • Over‑reliance on individual experts without institutionalising knowledge in systems and procedures
  • • Audit findings not leading to timely corrective and preventive actions

Need to add specific hazards for your workplace?

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Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
  • AS/NZS ISO 45001:2018: Occupational health and safety management systems — Requirements with guidance for use
  • AS IEC 61508 / AS IEC 61511 (where applicable): Functional safety of electrical/electronic/programmable electronic safety‑related systems and safety instrumented systems
  • AS/NZS 3017: Electrical installations — Verification guidelines (for electrical testing and verification interfaces)
  • AS/NZS 4836: Safe working on or near low‑voltage electrical installations and equipment (for live testing considerations)
  • Safe Work Australia Codes of Practice: Including Managing Risks of Plant in the Workplace and Managing Electrical Risks in the Workplace
  • ISO 55001: Asset management — Management systems (for integration with asset integrity and reliability programs)
Standard Risk Assessment Features (Click to Expand)
  • Comprehensive hazard identification for all activities
  • Risk rating matrix with likelihood and consequence analysis
  • Existing control measures evaluation
  • Residual risk assessment after controls
  • Hierarchy of controls recommendations
  • Action priority rankings
  • Review and monitoring requirements
  • Consultation and communication records
  • Legal compliance references
  • Sign-off and approval sections

$79.5

Safe Work Australia Aligned