I've not been in work a lot lately, My lads got in touch and said there was a buzzing coming from the CU and sparking as they turned breakers on and off.. I did some searching and concluded that a breaker wanted to trip but wasn't doing so I told them to unplug everything not in use, keep an eye on it and turn it off when they left.
I went in after and it turns out the busbar wasn't clamped into the RCD. It looked like it was and the screw was tight, I didn't think this was possible but it is with the BG RCD that's in there. It certainly isn't possible with a MK one i've got, the opening is occluded as you tighten the screw so it impossible to have the 'prong' on the wrong side of the clamp. It has probably been like that for almost 2 years :(