Fixed LEV System – LEV Thorough Examinations

Fixed LEV Systems Within Industry

Fixed Local Exhaust Ventilation (LEV) systems are permanently installed engineering controls designed to capture and remove hazardous airborne contaminants directly at source. Unlike portable or temporary extraction units, fixed LEV systems are integrated into the building and process layout, providing consistent and reliable control of dusts, fumes, vapours, mists, and gases generated during routine operations. They are widely used across manufacturing, engineering, laboratories, woodworking, welding, chemical processing, and many other industrial environments.

A fixed LEV system typically consists of capture hoods or enclosures, ductwork, air movers (fans), and filtration or air cleaning equipment, all designed to work together as a single system. The capture hood is positioned as close as practicable to the point of contaminant generation, ensuring pollutants are removed before they can enter the operator’s breathing zone. The design of the hood—its shape, size, and position—is critical to achieving effective capture and preventing contaminant escape.

Because fixed LEV systems operate continuously or frequently, system design and balance are essential. Ductwork must be correctly sized and routed to maintain adequate airflow to all capture points, and fans must provide sufficient pressure to overcome system resistance. Over time, changes such as additional extraction points, process alterations, or blocked filters can unbalance the system, reducing performance at individual hoods without obvious signs of failure.

Under the Control of Substances Hazardous to Health (COSHH) Regulations 2002, fixed LEV systems must be properly maintained and thoroughly examined and tested at least every 14 months by a competent person. This statutory examination confirms that airflow performance, capture effectiveness, mechanical integrity, and filtration remain adequate for the substances being controlled. The resulting report provides legal evidence that the system continues to protect workers from hazardous exposure.

When correctly designed, used, and regularly examined, fixed LEV systems offer a robust and long-term solution for controlling airborne hazards. They help organisations protect employee health, maintain a cleaner working environment, and demonstrate ongoing compliance with COSHH, making them a cornerstone of effective workplace exposure control.

 

What’s covered during your SEIS Thorough Examination.

Here’s a detailed breakdown of what is covered during an inspection and testing of a Fixed LEV System, in accordance with COSHH2002 Regulation 9 . The purpose is to ensure the system is safe, serviceable, and fit for purpose. Below is an in depth description of how your equipment is thoroughly examined;

LEV Inspection Procedure

A COSHH 2002 LEV inspection of a fixed LEV system—formally known as a thorough examination and test—is carried out to verify that the system continues to effectively control exposure to hazardous substances at source. Because fixed systems often serve multiple processes or capture points, the inspection assesses both individual components and overall system performance.

Below is a clear overview of what is covered during a statutory LEV inspection of a fixed LEV system.

Capture Hood Performance and Positioning

Each capture hood or enclosure is assessed to ensure it continues to:

  • Be correctly positioned relative to the contaminant source

  • Provide effective capture without allowing escape into the workplace

  • Remain suitable for the process being carried out

Air velocities are measured at or near hoods to confirm that sufficient capture is being achieved, taking into account thermal effects, cross-draughts, and operator movement.

Airflow Measurements and System Balance

The inspection includes quantitative airflow measurements throughout the system, such as:

  • Air velocities or volume flow rates at individual branches

  • Static pressure measurements at key points

  • Assessment of overall system balance

These checks confirm that adequate airflow is reaching all capture points and that system changes, blockages, or wear have not compromised performance.

Ductwork Condition and Integrity

Ductwork is examined to identify defects that could affect airflow or safety, including:

  • Leakage, corrosion, or mechanical damage

  • Blockages or material build-up

  • Poorly sealed joints or access panels

Any deterioration that could reduce system effectiveness or lead to failure is recorded.

Fans and Air Movers

The extract fan is a critical component and is inspected for:

  • Correct operation and rotation

  • Signs of wear, vibration, or overheating

  • Secure mounting and guarding

  • Performance relative to system demand

Fan performance is considered in relation to measured airflow results.

Filtration and Air Cleaning Equipment

Where filtration is fitted, the inspection covers:

  • Filter type and suitability for the substances captured

  • Filter condition and loading

  • Evidence of bypass or leakage

  • Safe access for filter replacement and waste handling

Poor filtration can reduce airflow and increase exposure risk.

Discharge Arrangements

The discharge point is checked to ensure that extracted air is:

  • Released safely to atmosphere

  • Not re-entering the building

  • Compliant with environmental considerations

This is particularly important for hazardous or toxic substances.

Controls, Indicators, and Safety Features

The competent person will check system controls, including:

  • On/off controls and interlocks

  • Airflow indicators, pressure gauges, or alarms

  • System labelling and identification

These features help ensure users can identify reduced performance or system failure.

Suitability for Current Processes

The inspection considers whether the LEV system remains suitable for:

  • Current substances and quantities used

  • Changes to processes or equipment

  • Additional capture points added since commissioning

Process changes are a common cause of LEV systems becoming ineffective over time.

Statutory Reporting and Documentation

Finally, a written report of thorough examination and test is produced, detailing:

  • Test methods and results

  • Identified defects or limitations

  • Clear conclusions on system effectiveness

  • Required remedial actions and timescales

This report is a legal requirement under COSHH and must be retained for inspection.

 Summary

An LEV Thorough Examination ensures that the system is safe, compliant, and fit for use. It helps prevent accidents and work place illnesses caused by poorly maintained, or poorly operating systems. While it does not replace regular maintenance, PUWER and LEV (COSHH2002) inspections are a crucial legal requirement for keeping your working operations safe and avoiding costly breakdowns or incidents.

Why Fixed LEV System Thorough Examinations Matter For You & Your Business. 

Why COSHH2002 Thorough Examinations Of LEV Systems Matter

COSHH2002 LEV thorough examinations are a legal requirement in the UK for all Local Exhaust Ventilation equipment used at work, and for good reason. These inspections ensure that LEV equipment, such as fume cupboard, receiving hoods, spray booths, and captor hoods are safe to use, and fit for purpose. The environments of LEV equipment is required means that equipment failure can lead to catastrophic consequences, including serious injury, respiratory issues, work place illness and in the long term, fatalities. By carrying out regular, scheduled thorough examinations by a competent person, businesses can identify wear and tear, structural damage of ducting, or faulty mechanisms before they result in an incident.

Pros of Getting an LEV Thorough Examination in line with COSHH2002

Legal Compliance and Risk Reduction: The most obvious advantage is staying compliant with health and safety law. Compliance avoids potential legal action, fines, or even prosecution. More importantly, it drastically reduces the risk of workplace accidents caused by lifting equipment failure.

Improved Safety Culture: Regular inspections foster a proactive safety culture within the organisation. Employees are more likely to trust equipment and feel safe in their work environment when they know thorough checks are in place.

 Extended Equipment Lifespan: Regularly maintained and inspected equipment typically lasts longer. Examinations can identify early signs of damage or fatigue, allowing for preventative maintenance that avoids costly replacements or repairs.

 Insurance and Liability Protection: Insurers may require evidence of LOLER compliance in the event of an incident. Without valid inspection records, insurance claims could be denied or reduced, leaving the business liable for damages.

 Operational Efficiency: Detecting potential issues before they lead to equipment failure helps prevent unscheduled downtime. This keeps operations running smoothly and avoids the knock-on effects of delayed projects or interrupted workflows.

Cons of Failing to Carry Out COSHH2002 LEV Thorough Examinations

 Legal and Financial Consequences: Failing to comply with COSHH2002 can result in enforcement action from the Health and Safety Executive (HSE), including improvement notices, prohibition notices, fines, or even prosecution. Legal battles and associated costs can be financially crippling.

 Increased Risk of Accidents: Equipment that hasn’t been thoroughly examined is far more likely to fail. Such failures can lead to injuries or fatalities, particularly in high-risk environments like construction or manufacturing. Beyond the human cost, the reputational damage to a business can be severe and long-lasting.

 Higher Repair and Replacement Costs: Neglecting inspections can allow minor issues to develop into major faults. These may require costly emergency repairs or complete equipment replacement, expenses that could have been avoided through routine examinations.

 Loss of Business and Clients: Clients often expect their contractors or suppliers to uphold strict safety standards. A failure to meet legal obligations like COSHH2002 can result in lost contracts or blacklisting from future work, especially in regulated industries.

 Increased Insurance Premiums or Invalidated Coverage: As mentioned, insurers may increase premiums or deny coverage entirely if a business can't provide evidence of up-to-date COSHH2002 compliance, placing a heavier financial burden on operations.

LEV thorough examinations aren’t just a box-ticking exercise - they are an essential component of a responsible, safety-first approach to using lifting equipment. The benefits of compliance are wide-ranging, from protecting human life to reducing costs and maintaining operational integrity. Conversely, the risks of neglecting these inspections can be devastating on multiple levels.

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