Quality Control & Safety Requirements
CEFR: B2
Read/Listen first
Yesterday our team inspected a flight simulator that had just received a new battery pack. We had already run several quality control tests, but during a long safety test one unit suddenly overheated. The temperature alarm went off, so we stopped the procedure immediately and recorded every detail in the test report. If this happened during real training, it would be dangerous for the crew and could damage the simulator. Now we must follow the safety requirements from the military customer and repeat the full test protocol with the supplier. Next week we are going to simulate different failure scenarios to check how the battery behaves when it is stressed. We hope we will confirm that the system is safe before we send the simulator back. We also need to wear protective equipment, respect the lockout rules and keep the emergency exit completely clear during every test.⚡ Learning goals
- Can explain key steps in quality control and safety testing for technical equipment.
- Can describe non-conformities and risks using past and conditional forms.
- Can outline safety requirements and future test actions agreed with a customer.
✨ Key language
- follow the safety requirements “We must follow the safety requirements on every test.”
- run a safety test “They ran a long safety test on the new battery.”
- it would be dangerous “If this happened again, it would be dangerous.”
⚙️ Rules & Grammar — 4 Structures
1️⃣ Past simple for test events
Rule: Use the past simple to describe completed test actions and incidents at a specific time in the past.Examples: We inspected the simulator yesterday.; The alarm went off during the test.; We stopped the procedure immediately.
Common pitfall + fix: Learners sometimes use present simple for past events — Add the correct past form of the verb and time expression (yesterday, last week).
Choose the correct past simple form to complete the sentence.
Tip: Only one option uses regular past simple with -ed.
Fill with the best answer: Yesterday we __________ before the safety test.
Tip: Use the past simple phrase from the mini text about checking the simulator.
2️⃣ Past perfect for earlier actions
Rule: Use the past perfect to show that one action happened before another past event in the test sequence.Examples: The simulator had just received a new battery pack.; We had already run several quality control tests.; The team had prepared the protocol before they started the procedure.
Common pitfall + fix: Learners forget “had” and only use past simple — Add “had” plus past participle to make the order of events clear.
Which option correctly shows an earlier action using past perfect?
Tip: Look for “had” plus the past participle to show the first action.
Fill with the best answer: Before the alarm, we __________.
Tip: Use the past perfect sentence about tests from the mini text.
3️⃣ First conditional with would/could for risks
Rule: Use if + past simple with would/could to talk about the possible consequences of an unsafe situation.Examples: If this happened during real training, it would be dangerous for the crew.; It could damage the simulator if the battery overheated again.; If we ignored the alarm, we would break the safety rules.
Common pitfall + fix: Learners mix present and past forms — Keep “if” clause in past simple and result with would/could plus base verb.
Complete the idea: If the battery overheated again, __________.
Tip: Use would or could in the result to talk about risk.
Fill with the best answer: If the unit overheated again, __________.
Tip: Use the conditional result about damage from the mini text.
4️⃣ Modals must / need to for safety rules
Rule: Use must and need to to express strong safety obligations that protect people and equipment.Examples: We must follow the safety requirements from the customer.; We need to wear protective equipment in the test area.; You must keep the emergency exit completely clear during every test.
Common pitfall + fix: Learners sometimes use “can” or no modal — Replace it with must or need to when the rule is not optional.
Which sentence correctly shows a safety obligation?
Tip: Safety requirements are not optional, so use a strong modal.
Fill with the best answer: All engineers __________ in the test area.
Tip: Use the obligation from the mini text about protective equipment.
✍️ Vocabulary
quality control
Meaning: process that checks if a product or system meets required standards.Synonyms: quality assurance, inspection program, compliance checking.
Chunk/Idiom: quality control procedure.
Example: Our team follows a strict quality control procedure for every simulator test.
Morphology: noun phrase, control as noun from verb control.
Self-practice: Describe the quality control procedure in your company.
safety requirements
Meaning: official rules that protect people, equipment and the environment.Synonyms: safety rules, safety standards, protective regulations.
Chunk/Idiom: meet all safety requirements.
Example: The simulator must meet all safety requirements before real training starts.
Morphology: noun phrase, plural noun requirements from verb require.
Self-practice: List three safety requirements that apply in your workplace.
overheating
Meaning: condition when something becomes too hot and may fail or cause damage.Synonyms: excessive heating, too much heat, thermal stress.
Chunk/Idiom: risk of overheating.
Example: One unit showed a serious risk of overheating during the long test.
Morphology: noun from verb overheat, -ing form used as gerund.
Self-practice: Explain how your team reduces the risk of overheating.
test protocol
Meaning: detailed plan that explains how tests must be prepared, run and recorded.Synonyms: test procedure, test plan, testing guideline.
Chunk/Idiom: follow the test protocol.
Example: We followed the test protocol exactly when the alarm went off.
Morphology: noun phrase, protocol as noun from Greek roots proto and kolla.
Self-practice: Summarize one important step in your standard test protocol.
risk assessment
Meaning: systematic review of possible dangers and their impact on people or systems.Synonyms: hazard analysis, risk analysis, safety review.
Chunk/Idiom: complete a risk assessment.
Example: After the incident, we completed a new risk assessment for the battery pack.
Morphology: noun phrase, assessment as noun from verb assess.
Self-practice: Describe one control you added after a recent risk assessment.
protective equipment
Meaning: clothing and tools that keep workers safe in dangerous environments.Synonyms: safety gear, personal protective equipment, protective clothing.
Chunk/Idiom: wear protective equipment.
Example: All technicians must wear protective equipment when they enter the test area.
Morphology: noun phrase, equipment as uncountable noun for tools and devices.
Self-practice: List the protective equipment you use in your normal working day.
☁️ Examples (+ audio)
We must follow the safety requirements before we power up the simulator.
If a battery overheats, it could damage the whole training system.
The engineer has already recorded the incident in the quality control report.
Next week they are going to repeat the complete test protocol.
✏️ Exercises
Grammar
Which verb correctly completes the sentence: The temperature alarm _____ during the test.
Tip: Use past simple to match the incident described in the mini text.
Which option matches the idea: the tests were finished before the alarm?
Tip: Choose the form with “had” plus past participle to show earlier action.
Fill with the best answer:
If this happened during real training, it __________.Tip: Use the conditional result from the mini text.
Fill with the best answer:
During every test, we __________.Tip: Complete the sentence with the obligation from the mini text.
Vocabulary & Comprehension
Which phrase means a systematic review of possible dangers?
Tip: Think about which phrase focuses on analysing hazards and impact.
What problem did the team see with one battery unit?
Tip: Choose the word that describes the serious temperature issue.
Fill with the best answer:
They recorded every detail in the __________.Tip: Use the two-word noun from the mini text about documentation.
Fill with the best answer:
All technicians need to wear __________ in the test area.Tip: Use the noun phrase for safety clothing and tools from the text.
✅ Guided practice
Mini-dialogue:
A: Did you read the new safety requirements for the battery tests?B: Yes, I did. We must keep the emergency exit clear and wear full protective equipment.
A: If the alarm went off again, what would you do first?
B: I would stop the test immediately and start a new incident report.
Why this matters:
Careful quality control and clear safety rules protect people, equipment and reputation. When you describe tests accurately, customers trust your reports. Conditional sentences help you explain realistic risks and justify extra safety measures.Verb & Adjective Pack:
monitor the temperature — We monitor the temperature during every long safety test.comply with requirements — Our team always complies with the strict safety requirements.
critical — The report marked the overheating incident as critical.
Try & compare:
Fill with the best answer: We hope we will __________ before real training starts.
Tip: Use the future idea about checking the system from the mini text.
Self-correction: Fix the sentence: We already run several quality control tests.
Tip: Use past perfect to show tests were finished before the incident.
Practice aloud: Listen, repeat, then type the sentence.
We must follow the safety requirements on every test.
Tip: Pay attention to the rhythm of must follow the safety requirements.