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1. 1. 1 NEBOSH UNIT-IC Questions Matrix S# - UNIT - S. # Questions Dates
Element IC1 General workplace issues 1-IC1 - 09 A sewage drain has
collapsed and it is necessary to inspect the damage prior to its repair. The
inspection requires entry into a confined space 10 metres deep. OUTLINE
the possible risks to those entering the sewer. Marks-10 - Restricted
space for entry causing RISK of head injury, slip and trip, - Risk associated
with the presence of gases and vapours either toxic and / or flammable -
Risk of oxygen deficiency which could lead asphyxiation and /or
suffocation - Working on slippery surface and the presence pipe, cables or
tools which could result in falls - The possibility of the sudden ingress of
water with the danger of drowning - The presence of chemical or
biological contaminants either on the surface water or in the sludge
deposited in the sewer with the risk of contracting illness such as weil’s
disease. - Working in a restricted space with low headroom which might
lead to musculoskeletal injuries. - Thermal issues such as heat exhaustion
that might occur when working in high temperatures. - Contact with
sharps with the resultant needle stick injuries - The ever present risk of
entrapment which could be caused by the collapse of the sewer Jul 2012
Jan 2011 2-IC1-05 (a) OUTLINE the possible health and safety effects of
inadequate workplace lighting. Marks-4 (b) OUTLINE the factors that
should be considered to ensure that lighting in a workplace is adequate.
Marks-16 a). Health effects includes: headache, visual fatigue , eye strain,
blurred vision; -inadequate posture creating neck and backache to get
adequate VIEW for the tasks to be performed. - Safety implications : likely
to increase the incidents such as slip, trip and fall, striking with objects
because of insufficient lighting arrangements causing unidentified objects
– wrong type of lightings which are creating stroboscopic effects - Human
error which may put others at risk - Factors that should be considered: -
The type of work to be taken - The amount of precision required and
whether tasks require general, local and/or localised lighting - The level of
natural light available - The workplace layout giving attention to the
effects of screens, furniture or racking - the considerations of those
objects casting shadows - The different types and level of lightings
required for stairs, corridors and outside security lights. - The level of
lighting in adjacent areas in order to avoid the effects of moving from a
strongly lit area to one which is dimly lit and vice versa; - The individual
needs of the employee whether on account of age or disability - The
possibility of glare on display screen - The colour and type of lighting fitted
o prevent stroboscopic effects - The need for emergency lighting
particularly for fire escape routes - The need for portable lighting when
work has to be carried out in confined space - The ease of maintenance
whether replacing spent bulbs or cleaning the light fittings for probable -
All glazed windows and skylights used for the lighting of workrooms shall,
so far as is practicable, be kept clean on both the inner and outer surfaces
and free from obstruction, OUTLINE the health and safety issues which
 should be identified during a lighting audit of a factory which includes
production, maintenance workshops and offices Jan, 2012 Jan, 2009
2. 2. 2 3-IC1 - 01 A contractor is to repair the felt roofs of an office. OUTLINE
the measures that should be taken to reduce the risks to workers and
members of the public. -10 1-Selection of contractor 2– Risk Assessments,
SSW, method statements 3– Access and egress 4– Correct use of ladders
5– Edge Protection / Fall protections 6 – Means for transporting tools,
materials 7– Garbage chute – 8 Competent employees 9 – Precautions
while handling gas cylinders 10– Precautions for possible contacts with
hazardous substances such as tar, asbestos 11– PPE (knee pad etc) 12 –
Additional measures / protection of public: Barriers, Signs at ground,
Arrangement for vehicle movement – Restricted access / security, Traffic
control / flagman. Jan -09 4-IC1 -02 A rectangular warehouse building (40m
x 100m ground area and 18m high) was constructed on a structural steel
framework, with a flat roof and coated steel walls. During a storm, the
warehouse suffered a catastrophic failure of one of its long walls which in
turn caused the collapse of the roof and buckling of the other walls. (a)
OUTLINE the possible causes of this structural failure. -10 (b) OUTLINE the
health and safety issues to be considered when planning the subsequent
Demolition of the damaged warehouse. -10 - Cause of failure – 1.Exceeded
the designed wind loading due to adverse weather, - 2.Overloading of
structure by excess weight on roof due to accumulation of snow or rain
water. – 3.Alteration to the structural members which had invalidated the
original design calculations. – 4.Collapsing or nearby excavations and
tunneling operations creating instability – 5. Vibrations caused by the
volume of passing traffic 6. Wind variations which would result in fatigue. –
7. Poor workmanship - Even superior quality materials, if used imperfectly,
may not successfully serve the planned function, or be as durable as
designed. -8. Faulty Construction- occurs when inappropriate material is
used for construction. Faults that result in structural failures include bad
welds, improper torque used on nuts and bolts, sand that is too salty for
concrete, bad riveting and inferior steel. -9.Bad Foundation - cause
displacement which alters the stress distribution of the building so the
construction and design are changed and no longer meet the necessary
specifications. - Safety issues for demolition: 1-Selection of Demolition
contractor (competency) 2– Risk Assessments, SSW, method statements
3– Access and egress 4– Correct use of ladders 5– Edge protection / fall
protections 6.Identifications / insulations of buried services (EWG), 7.
Inspection, examination and maintenance of plants / equipment 8 – Means
for transporting tools, materials 9– Garbage chute – 10 Competent
employees 9 – Precautions while handling gas cylinders 10– Identification,
Precautions for possible contacts with hazardous substances such as lead
paint, asbestos, 11. Protections of adjoining property 12– PPE 13 –
Additional measures / protection of public: Barriers, Signs at ground,
Arrangement for vehicle movement – Restricted access / security, Traffic
control / flagman. Jan, 2009, Jan 2007 SSW – safe system of work EWG –
 electricit y, water, gas 5-IC1 -03 A company has been contracted to
undertake maintenance work on the roof of a building, which is partly
constructed of fragile material. a. IDENTIFY the characteristics of the
fragile materials that may contribute the risk of falls through the roof. 5 b.
OUTLINE the measures to be taken to reduce the risks to those involved in
the roof work and those who may be affected by it. 15 a / Characteristics:
The age and condition of material; The type of material such as fiber
board, asbestos or polycarbonate and thickness; The sheet profile; The
span between roof supports; The design of supporting structure such as
the purlins; The July 2008
3. 3. 3 condition of the fixings; The slippery nature of the surface and The
fact that the fragile materials might well be hidden by deposit of dirt,
grass etc. b/ 1-Selection of Demolition contractor (competency) 2– Risk
Assessments,3. Consequent production of a method statement detailing
the SSW, - 4. The SSW should be followed, which will include - Access and
egress, access scaffolds, crawling board 5– Edge protection / fall
protections - harness with suitable anchorage 6. Identification and
demarcation of areas of the roof containing fragile 7. Demarcation can be
done using barriers and signages 8- Suitable Cover can also be used to
prevent fall through the fragile areas 9- Provision of Safety nets or and air
bags under the areas of the roof which contain fragile materials can
provide additional safeguards 10- Means / hoists for transporting tools,
materials, equipment 11– Garbage chute – 10 Competent employees 11–
PPE 12 – Additional measures / protection of public: Barriers, Signs at
ground, Arrangement for vehicle movement – Restricted access / security,
Traffic control / flagman 06-IC1 - 06 It is proposed to inspect, clean and
repair the inside of a tank that is 6 metres in diameter and 10 metres high
and which has previously been used for storing leaded petrol. OUTLINE the
arrangements that should be considered in order to comply with the
Confined Spaces legislation. Or, OUTLINE the steps that should be
considered in order to enter this confined space and to carry out the work
safety. The relevant specified risks in this case relate to fire and
explosion, and loss of consciousness due to asphyxiation or high
temperatures, works at height. A SSW is required for entering confined
space, to comply with confined space legislation and to carry out work
safely – To develop a safe system of work a full RISK ASSESSMENT needs
to be carried out considering the likelihood of - Toxic effects of lead, -
Flammable atmospheres from the previous contents of the tank - Air
contamination from the cleaning or repair methods used - The build-up of
heat within the tank – hazard associated with Working at height -
Completion of the risk assessment would point to appropriate
arrangements / preventive measures / precautions such as - Initial
Arrangements - The need to purge the tank with an inert gas, - The use of
forced ventilation, - Atmospheric testing before and during entry, and - The
provision of PPE including air-fed breathing apparatus - The requirements
for electrical equipment (e.g. intrinsically safe, flameproof) and earthing
 arrangements – If heat were to be a foreseeable problem, then
consideration should be given to issues such as job rotation and fluid
intake. - The physical arrangements for working at height would need to
be considered in terms of both prevention of falls from height and, means
of access and egress in the event of escape or rescue. - Procedural
arrangements would centre on the - Implementation of an entry permit -
Limiting the number of people working in the tank, - Communication with
standby personnel and - Drawing up the emergency arrangements - The
emergency arrangements to be considered would include issues such as
The provision and maintenance of cutting equipment, - Tripod / Hoists, -
Fire-fighting equipment, - PPE (e.g. breathing apparatus) - First-aid
facilities including CPR apparatus and Liaison with emergency services
Additionally, Arrangements should also be in place to ensure that all
personnel involved in the operation have received sufficient training in the
work methods, the precautions needed and emergency procedures. JUL
2008, JUL 2005 SSW – safe system of work 07-IC1 - 08 (a) GIVE the
meaning of the term ‘confined space. Marks-2 (b) OUTLINE the factors that
should be considered to ensure that emergency rescue arrangements for
confined space work Jul 2007, Jul 2009
4. 4. 4 are suitable and sufficient. Marks-8 Confined spaces are defined as
‘any place . . . in which, by virtue of its enclosed nature, there arises a
reasonably foreseeable specified risk’ (i.e. of serious injury, drowning or
asphyxiation). Or any enclosed o partially enclosed place such as a
chamber, tank etc or other similar space in which, by virtue of its enclosed
nature, there arises a reasonably foreseeable specified risk such as lack
of oxygen or the possibility of drowning in free flowing solids. - Confined
spaces include: Chambers, Tanks (sealed and open-top), Vessels,
Furnaces, Ducts, Sewers, Manholes, Pits, Flues, Excavations, Boilers,
Reactors and Ovens. - The risks identified and how an emergency rescue
might take place and could include - o The means provided for emergency
access / egress, o The equipment required e.g. Life lines, lifting equipment
(Tripod / Hoist), air fed breathing apparatus, o Methods for raising the
alarm with others outside the confined space e.g. Radio, personal alarms
etc, to initiate rescue procedures o The availability of first aid assistance
until the arrival of professional medical help. o Ensuring that there are
persons present who are competent to undertake (CPR) resuscitation
procedures, o The number and competence of those who would be
involved in the rescue operation. o Precautions taken to protect rescuers
from the risks to health and safety identified in the risk assessment o
Precautions taken in the event of fire such as the provision of fire
extinguishers; o Identification of plant which may need to be shut down
during an emergency rescue and o Means provided for contacting public
emergency services and supplying them with relevant information. o
Training or refresher trainings for emergency personnel. 08-IC1 - 05 A
vegetable packing plant employing 200 men and 60 women is about to
open. OUTLINE the specific welfare arrangements that need to be
 provided before the plant opens. Marks-10 / 20 Sanitary Conveniences:
Sufficient numbers of well-lit and ventilated sanitary conveniences -
Maintained in a clean and tidy condition. - Provision of Toilet paper, a coat
hook - Separate rooms or blocks for men and women (or capable of being
locked from inside if the sanitary conveniences in the same room).
Washing Facilities: Sufficient numbers of well-lit and ventilated washing
facilities - Changing rooms and Showers to be provided and maintained in
a clean, tidy condition - Supply of hot and cold or warm running water, -
Soap and a means of drying Drinking Water: An adequate supply of
drinking water with cups - Readily accessible, located away from sources
of contamination - Marked conspicuously Accommodation for Clothing /
Facilities for Changing Clothing: Clothing accommodation with a hook/peg
located in a clean, warm, dry, ventilated place should be provided for each
worker to hang their own clothes if not worn during the working day. -
Changing facilities separate for men and women and contain means of
drying wet clothing and separate storage of contaminated clothing -
Decontamination facilities with shower and a clear division between clean
and dirty areas JUL 2010 JUL 2008
5. 5. 5 Facilities for Rest and to Eat Meals: Rest and eating facilities -
Readily accessible, contain adequate seating and tables - Be maintained
in a clean condition - Arrangement for preparing and heating food and for
boiling water - Means or procedure for preventing contamination of the
area where food and drinks are taken - Rest rooms and areas should be
arranged to ensure that non-smokers do not have to be exposed to
smokers - separate rooms/areas, prohibition. - Adequate Facilities for
nursing mothers and pregnant women to rest. First aid facilities including
trained personnel taking into account the number of persons employed
and the proximity of emergency services 09-IC1-12 OUTLINE the main
design features of a workplace designed to reduce the risk of injury
associated with INTERNAL TRANSPORT. OR. OUTLINE the main design
features of a ware housing operation design to reduce the risk of injuries
associated with INTERNAL TRANSPORT. Features that could have been
included are: - 1. SEGREGATION of vehicles and pedestrians. - Separate
pedestrian access and egress; Inclusion of passing places and refuges;
barriers, guard rails, raised walkways and curbs to protect pedestrians,
and clearly marked crossing places. 2. TRAFFIC ROUTE should be
sufficient width, on stable leveled ground, Suitable road surfaces; Design
of layout to avoid sharp bends and blind corners and to avoid the need to
reverse, through use of one ways systems. Provision Convex mirrors on
blind corners to improve visibility; Route should have speed limit, speed
retarder and suitable road marking. Provisions of hazard signs – to warn
blind corners, crossings, low-head rooms or width restrictions. All the
routes should be well lit – including color balance, avoidance of glare in
the transitions area between inside and outside the buildings, - 3. VEHICLE
Movements should be carried out in safe area with sufficient space and
operatives provided with high visibility clothings. Vehicle should be fitted
 with reverse alarm and flashing beacon lights. Designated parking spaces
to avoid congestion. 4. PROCEDURAL ARRANGEMENTS – control of visitors
in the premises, training and certification for the drivers, prevention of
unauthorized use of vehicles; training and information to pedestrians on
the risks, selection for suitability and maintenance of vehicles , monitoring
and reporting the defects, maintenance of traffic routes, enforcement of
speed limits and the use of banksman will further reduce the risks.
Protection of racking or other vulnerable items, to reduce the likelihood of
items falling and to avoid from collision with moving vehicles. Provision of
suitable and sufficient Jan 2008, Jan 2010 Q of Me.IC07. 01 END OF UNIT
1
6. 6. 6 Element IC2 Principles of fire and explosion 10-IC2-04
Compartmentation in buildings consists of fire resisting doors, walls,
floors, ceilings and windows. Window frames are potentially a weak point
in this fire resistance. (a) OUTLINE how window frames made with the
following materials might behave in a fire: (i) wood; Marks-3 ; (ii)metal;
Marks-3; (iii)plastic. Marks-3 (b) IDENTIFY which of these window frame
materials gives the best overall fire resistance. Mark-1 Jan 2012 July 2009
11-IC2-07 You have been asked to investigate a boiler explosion at one of
your company’s sites. The maintenance manager has drawn you a sketch
showing the position of the water column isolating valves at the time of
the explosion (see below diagram will be given). (a) Describe the chain of
events that could have led to an explosion due to the water column valve
being closed. 6 (b) Other than the safety feature on the water column,
identify FOUR other safety features that you would expect to find on the
boiler. Marks-4 Jan 2012 July 2010 12-IC2-02 In relation to dust
explosions: (a) Outline the conditions that must be present for a primary
dust explosion to occur; Marks-4 (b) Outline the additional conditions
necessary for secondary explosions to occur; Marks-4 (c) IDENTIFY FOUR
factors that may affect the reliability of a nitrogen inerting system used in
a powdered aluminium process; Marks-4 (d) IDENTIFY the design features
that would minimise the likelihood and effect of a dust explosion. Marks-8
a. Conditions that must be present for a primary dust explosion: - The dust
must be combustible – the concentration of dust must fall within the
explosive limits – The ignition source must come in the contact with the
dust – Sufficient Oxygen should be present in the atmosphere to sustain
the combustion. (the dust must be capable of becoming air born and
mixing with air, the particle size must be capable of propagating flame) b.
Conditions necessary for Secondary Explosions: Dislodgement / Force
removal of accumulated dust from horizontal surface within the affected
building by the pressure wave and consequent air turbulence. Ignition:
When lying dust is distributed by the primary explosion and form a second
dust cloud , the dust cloud then can be ignited – By the combustion of
products from primary explosion - By the heat released through the
primary explosion - Any other source of ignition within the area with
sufficient heat energy c. Factors that may affect the reliability of a
 nitrogen inerting system: The number and location of sampling points - The
type and calibration of the sensors - The presence of containments in the
system which could interfere with readings Inadequate provision of a safe
means of shut down if oxygen levels are too high - The adequacy of supply
of inerting gas - The number of locations where air can enter the plant or
process and the reliability of the electronic control system d. The design
features that would minimise the likelihood and effect of a dust explosion
Jul 2012 Jul 2011 Jan 2009
7. 7. 7 - The initial design of ducting and equipment to withstand the effects
of an explosion, - Ensuring that the ducting was dust tight, - Providing
local exhaust ventilation at point of transfer, - Installing explosion relief or
suppression systems together with systems for suppressing fire, - Using
screw conveyors instead of pneumatic systems for moving materials
Providing a magnetic extraction system for removing metal from product
fed to the plant, - Interlocking equipment to prevent overfilling of vessels
and over pressurization, - Using instrument systems with integral
emergency shutdown - Using intrinsically safe electrical equipment and
bonding all metal work to earth, - Preventing dust build up in the plant by
the use of sloping surfaces and introducing a mechanised system for
humidification of the air. 13-IC2-01 A diesel engine is being used to power
a machine in a potentially flammable atmosphere. (a) IDENTIFY the
sources of ignition from the diesel engine. Marks-4 (b) OUTLINE the
protection that should be applied to the engine to minimize the risk of an
explosion. Marks-6 OR, (a) Identify the sources of ignition from a typical
diesel-engined fork-lift truck. (b) Outline the protection that should be
provided on such a truck in order to minimise the risk of explosion when it
is required to work in a potentially flammable atmosphere. a. Source of
ignition: Flame and sparks from the exhaust and inlet system – sparks
arising of Trucks electrical system – sparks arises to static electricity –
through over speeding / over loading – from frictions / surface temperature
– Fuel get hotter than Flash point b. Precautionary measures: 1. Fitting of
spark. Flame arrestors to prevent flash back to the atmosphere, - 2.
Inspect, test and maintenance of electrical joints on diesel engine
systems – 3. Electrical equipment on the truck should be suitable for zones
1 and 2 4. Electrical starters wired to plug and socket in a safe area. 6.
Inspect, test and maintain cooling systems on diesel engine systems – 7.
The use of a water jacket on the exhaust system together with thermal
sensors and air cooling for ‘hot spots’ would provide additional protection.
8. Mechanical alternatives (e.g. fuel gauge) should be fitted where
possible. 9. The use of electrically conducting materials for parts such as
tyres and drive belts would reduce static build up 10 The engine and
exhaust system should be designed in such manner that their surface
temperature are always below the flash point of flammable substances –
diesel etc. Jan 2011 Jan 2007N A process plant stores and use large
quantities of a substance that has the potential for giving rise to an
explosive atmosphere. OUTLINE a range of control measure which will
 minimize the possibilities of explosion. 10 marks - Avoid / minimize release
by using enclosed systems and maintenance of plant to prevent loss of
containment. - Control release at source by using early detection and auto
shut off systems - Prevent formation of an explosive environment by using
ventilation or inert atmosphere - In case of release – ensure that it is
suitably contained, safely collected and removed to a safe place, or
otherwise contained safe by use of bunding. - Emergency arrangement –
for tackling major spillage. - Avoid ignition source by ensuring that areas
are zoned, and flame proof electrical equipment are selected and used. a.
Build of static charge is obvious – therefore all the storage tanks, pump
needs to be properly grounded, suitable clothing, Safety shoes (anti-static)
to be worn by the operatives. b. No Smoking policy must be adhered and
PERMIT to Work system to be followed.
8. 8. 8 - Avoid adverse conditions by protection of storage vessels against
weather and vehicle - Finally ensure segregation of incompatible
dangerous substances. 14-IC2-03 OUTLINE the principles of a vapour cloud
explosion AND give an example of a major incident associated with a
vapour cloud explosion. -8 OUTLINE the effects of a vapour cloud
explosion. Marks-2 Or With examples of actual incidents, describe the
principles and effects of a vapour cloud explosion. Principle: A vapour
cloud explosion may be confined (in a tank, vessels or building etc) or un
confined when released in large quantity in the air. - For Explosion to
occur – The presence of flammable vapour concentration above the lover
explosive limits, the source of ignition such as a spark, is required with
energy greater than the minimum ignition energy. - The (unconfined)
vapour cloud can travel large distances before igniting / explosion and
Cloud dispersal may bring the mixture below the lower exposure limit
depending on the condition - The vapour cloud may be produced by a rapid
release of liquefied gas following vessel rupture due to overpressure and
subsequent vaporisation. It may also be produced by an uncontrolled build-
up of vapour above the lower explosion limit inside a vessel. The effects of
Vapor cloud explosion: Overpressure, Fire, explosion, and thermal effects
and debris over a wide area from confined vapour cloud explosion. In
confined Explosion – vessel or containment rapture may occur resulting in
a rapid release of liquefied gas. Example - The explosion in process
vessels at the Hickson and Welch chemical plant In unconfined explosion –
damage to people and property may be caused by pressure wave and
thermal radiation – Example - the explosion in flixborough July 2010 Jan,
2008 With examples of actual incidents, describe the principles and
effects of a BLEVE – boiling liquid expanding vapour explosions. Principle
of BLEVE: A BELEVE (boiling liquid expanding vapor explosion) is initiated
by an external heat source applied to a container of liquid. A drum of
petrol on a bonefire is a simple example. The vessels loses containment,
by rapture or pressure release valve opening, which vents the vapour with
subsequent ignition. There is rapid spread of boiling liquid and vapour and
a fire ball ensues. Effects: The explosion generates debris and missiles
 from the vessels and also a thermal radiation shockwave. The explosion of
tanker carrying a flammable substance at the san carlos de la rapita
Spanish campsite is a notable example. LPG cylinders in fire situation are
a typical example. July 2012
9. 9. 9 15-IC2-R The investigation of an accident at a food processor
handling corn starch products concluded that the explosion had taken
place in two stages, a preliminary explosion followed by a more severe
secondary explosion. a) IDENTIFY the principles underlying the control
measures that may be needed to prevent or minimize the effects of such
an accident. b) For each of principles identified, suggest control measures
which are based upon the principle. a. Principles needed to prevent or
minimize the effects of such an accident. - Elimination of sources of
ignition; Limitation of dust cloud generation and Minimizing harm by
controlling explosion. b. Control measures to eliminate ignition sources
are: - To ensure electrically conducting safety footwear is worn; - The use
of non sparking tools and correctly rated ex electrical equipment; - No
smoking; - Prevention of equipment hot spots; - Magnetic extraction of
rogue ferrous metals; - Electrical bonding and earthing; - Carrying out an
assessment to meet the requirements of relevant legislation (e.g. DSEAR
The Dangerous Substances and Explosive Atmospheres Regulations 2002
of the UK) and; - Correct zoning of areas. Dust cloud suppression could be
achieved by: - Damping down combined with the use of a pressure
monitoring device; - Having LEV at point of transfer; - Use of an interlock
to prevent overfilling of silo; - Good housekeeping to prevent dust build up
and - Ensuring all ducting is dust tight. Controlling explosion could be by
use of: Equipment that is able to withstand explosion; - Explosion relief
venting and explosion panels; - Ensuring building integrity. ETA, RRC 16-
IC2-05 In 1974 a plant in Flixborough, United Kingdom, producing highly
flammable pressurized gas developed a leak on the fifth of six reactors. In
order to continue production the fifth reactor was removed from service
and a bypass assembly then installed between the fourth and sixth
reactor. The bypass assembly subsequently ruptured and an UNCONFINED
VAPOUR CLOUD EXPLOSION followed. (a) DESCRIBE the mechanism for an
unconfined vapour cloud explosion. Marks-3 (b) OUTLINE the technical
failings that contributed to this major accident. Marks-7 a. There were 6
numbers of reactors (R1 to R6), R5 got some repair works. Therefore to get
the production continues it was decided to make some bypass pipe
between R4 and R6. This decision initiated the trouble- and given chance
to uncontrolled release of gas, cyclohexane, from that temporary pipeline
which was used to bypass a reactor R5 taken out for service for repair. -
On release the gas formed a flammable mixture in air within the explosive
limits. - The large vapour cloud either immediately came across a source
of energy or - Travel some distance to find an ignition source where it was
quickly detonated causing rapid flame propagation. b. Probable technical
failure: -The absence of professionally qualified mechanical engineer /
work manager who could oversee the modification between R4 and R5. - A
 plant modification had been done without assessment of the potential
consequences of its installation. - The constructed assembly was of
unknown strength: Pneumatic test were carried out for leak testing and
not in order to assess the strength of the assembly - Only limited
calculation were undertaken on the integrity of the bypass line: The flow
and pressure calculation were taken on straight pipe line not the fitted by
pass dog leg pipe, No calculation had been taken for the dog leg shaped
Jul 2009
10. 10. 10 assembly to withstand the likely strains - No reference were made
to any recognized standards - No drawing was proposed for the assembly -
No reference were taken from the designers’ guidelines so that the
bellows were used out of line without adequate support. - and insufficient
support were provided for the newly installed pipework 17-IC2-05 In
November 1984 the San Juanico gas storage facility near Mexico City
exploded with catastrophic consequences. (a) OUTLINE the
circumstances of the disaster. Marks-8 (b) OUTLINE how a Boiling Liquid
Expanding Vapour Cloud Explosion (BLEVE) occurs with a gas storage
vessel constructed of metal. Marks-8 (c) OUTLINE the immediate rescue
and restoration measures that took place. Marks-4 a. Circumstances of the
Disaster: At approximately 5:35 hours, 19 NOV 1984 a major fire and a
series of catastrophic explosions occurred at PEMEX LPG terminal at San
Juanico Near Maxico city. As a result some 5000 people died and 6000-
7000 people suffered from severe burn and the LPG terminal was
completely destroyed. - The terminal was supplied with LPG from 3
refineries on daily basis, The terminal was being filled from a refinery 400
km away. As on the previous day it had become almost empty. Two large
sphere and 48 cylindrical vessels were filled upto 90% and 4 smaller
sphere to 50% capacity. - A drop in pressure was observed in control room
but the operator was unable to know the cause of such pressure drop,
actually an 8 inch pipe between a sphere and a series of cylinders had
raptured causing the release of LPG. This uncontrolled release was
continued for 5-10 minutes. And the gas was accumulated around the
surrounding tanks measuring 150m to 200m and 2m high, which was
drifted to flare stack and exploded. - This resulted in numbers of ground
fire. Also a series of BLEVE occurred four of SIX spheres and numbers of
cylindrical vessels. Injuries were caused by radiated heat and burning
droplets of LPG. b. BLEVE with a gas storage vessel made of metal: The
gas such as butane and propane are stored under pressure in the liquid
form in the metal storage vessels. When the valve to the vessels is open,
the resulting drop in pressure restores the LPG in gaseous state. -
BOILING LIQUID: If the vessels involve the fire, the liquid gas boils and the
content of vessels will revert to gaseous state with a resulting increase in
pressure inside the vessels. - EXPANDING: The pressure relief valve opens
and vaporized liquid escapes causing liquid level in vessel dropped. The
less liquid cannot absorb the heat and then the metal start to deform and
weaken, ultimately rapture as result of ductile failure. - Vapour Cloud
 Explosion: The remaining contents burn out and vaporize under
atmospheric pressure sending debris from the vessels to the surroundings
area. The vapor cloud which includes the LPG droplets find the ignition
source and EXPLODES. C. Following the explosion, some 4000 emergency
workers were drafted into the terminal. The primary measures were
concerned with the temporary evacuation and transport of the injured.
Further measures were aimed at the prevention of an epidemic, the
removal of debris and identification of those who had been killed. Fires
were extinguished, temporary shelters provided and arrangements made
for the mass internment of those who died. Jan 2010 July 2009 18-IC2-08
In 2004 at ICL Plastics Glasgow nine people were killed and 45 seriously
injured by an explosion in the unventilated basement of a building. Liquid
Petroleum Gas (LPG) had leaked from a crack in a corroded unprotected
underground pipeline that had been laid 35 years earlier. The LPG leak had
migrated into the building Describe how corrosion occurs in buried LPG
metal pipework. Marks-6 Outline how buried LPG metal pipework can be
protected against corrosion. Marks-4 Jul 2010
11. 11. 11 (a) Excluding corrosion protection, outline additional factors to
consider in preventing a recurrence of an explosion in similar LPG
pipework installations. Marks-10 a. The corrosion in the buried LPG
pipework is an electro-chemical process which is caused due to -
Presence of moisture together with the possibility of containments in the
soil, - The presence of corrosion cells such as pitting of the metal
pipework, - The roles played by anode, cathode and electrolytes, - The
liberation and transfer of electrons b. Protection against corrosion by -
Wrapping with protective tape, Coating it with bitumen, Galvanizing,
Sleeving with a dry envelop, Providing cathodic protection or a sacrificial
anode c. Identification and prioritizing at risk installations such as o Those
where hazardous features arise from the design and layout of the building;
o where there are inherent hazards in the layout or the condition of
installation and pipework such as the presence of unventilated voids o
those which are least well maintained or located in the most corrosive
soils o The older installations and the extent of their existing protection. o
For inspection and maintenance of the systems, plan and drawings will be
required, though it must be acknowledged that disturbing the pipe work
may increase the risk of leaks. o There will also be a need for the
introduction of a systematic programme of replacement of metallic pipes
with polypropylene pipe and the condition of at risk systems will need to
be monito The canisters should be fitted with pressure relief valves. July
2011 The use of automatic extinguishing systems and venting and
explosion reliefs.  The installation of automatic fire detection and alarm
systems;  The provision of containment cages to prevent projectiles; 
Using compartmentalization within the warehouse with fire resistant
partitions;  The separation of high flammability canisters by physical
barriers;  The segregation of the canisters from other flammable
products; red pending the replacement 19-IC2.10 new Many household
 aerosol canisters contain propellants that are a mixture of highly
flammable materials such as iso-propane and iso-butane. These canisters
are used for multiple purposes including cleaning products, furniture
polishes, cosmetics, deodorants, (a) DESCRIBE how a fire and explosion
may occur when large quantities of these canisters are stored in a
commercial warehouse. Marks-5 (b) OUTLINE the fire precautions that
could be taken to limit the spread of any resulting fire and explosion in
such a warehouse. Marks-5 a. The canisters may have suffered damage for
example to the valve or body of the canister, leading to loss of
containment and the formation of flammable vapours which if between the
upper and lower flammable limits can be ignited by a heat source, perhaps
a nearby fire or hot work and even by direct sunlight. The canisters may
then be propelled from their original position as projectiles as the radiant
heat from the initial fire causes boiling of the contents of adjacent
canisters. This causes the release and ignition of additional vapour
sources resulting in multiple BLEVEs. a) b. Fire precautions that can be
taken to limit the spread of any resulting fire and explosion in a similar
type of warehouse include
12. 12. 12 END OF UNIT 2 Element IC3 Workplace fire risk assessment 20-IC3-
02 OUTLINE the issues that should be included in a fire safety training
session for workers. Marks-10 Presentation on training - The
consequences of fire such as the effects of smoke inhalation on those
involved : - The potential costs to the business - The principles of the fire
triangle; Fire Types / Classification - The basic elements of fire prevention
such as the storage of flammable materials, good housekeeping and the
need to prevent the accumulation of rubbish; - The action to be taken on
discovering fire such as RACE – raising alarm, alerting concerned/
procedure for calling fire services, and the action to be taken by personnel
on hearing fire alarm (confined fire, evacuate) - The procedure for calling
the fire service; - The action to be taken by personnel on hearing the
alarm; - The location and use of firefighting equipment with practical
training for selected employees - The escape routes and exits from the
premises together with the assembly points - The head counts / roll call
that would have to be carried out - The arrangements for the evacuation of
people with disabilities, assisting visitors and members of the public; - The
identity and role of fire wardens and marshals; - The importance of fire
evacuation practices and drills and - Issues directly concerned with
personal behavior such as refraining from re-entering the building after
evacuation until instructed to do so July 2012 Jan, 2010 Jan, 2008 21-IC3-
05 A factory manufactures upholstery using fabrics and plastic pellets.
These raw materials are delivered to a warehouse. The fabrics and plastic
pellets are machined to form furniture coverings and cushions. The
finished product is then stored in a dispatch warehouse prior to
distribution. The movement of goods around the premises is carried out by
Liquid Petroleum Gas (LPG) fuelled forklift trucks. The company is located
on the outskirts of a small town and employs 230 people. OUTLINE the
 range of factors that must be addressed to ensure an on-site Fire Risk
Assessment is made for the premises. 20 Fuel (LPG, flammable cover,
untreated fillings, material of construction )– Ignition source(electricity,
smoking, hot work, arson) – People issues (no of person to be evacuated,
visitors, disabled employees) – Preventive actions (Compartmentalization,
separate store for LPG-with fixed sprinkler, use of fire resistance cover
materials, minimizing amount of combustibles ) – Mitigation actions
(Detection – Suppression – Alarm system,)– Means of access (clear, fire
doors, travel distance, sign and emergency light) – Assembly points. Jan
2012 July 2009 22-IC3-01 A four-storey general Hospital is to be
refurbished and upgraded on a floor by floor basis, with three floors of the
hospital remaining operational at all times. OUTLINE the factors to be
considered when writing fire evacuation procedures for the parts of the
hospital that remain operational during the project. Marks-10 - The various
sections and activities of hospital – such as ward, operation theater, ICU,
offices, outpatient, visitors etc. - The number of patient and staff to be
evacuated - The mobility of patient including their health condition and
age - Identifying the temporary procedure and means of route to evacuate
the be ridden patient - Review ing the current evacuation procedure and
considering the escape routes, assembly points and fire brigade access -
Ensuring that the escape routes and assembly points are clear from
construction materials - The provision of emergency lighting and
appropriate sign ages - Considering of two stage evacuation procedure
Jan, 2009
13. 13. 13 - Considering the possibility of emergency zoning and classification
for example – full or partial evacuation, area wise nearest assembly point
as per zone (burz khalifa) - Assessing the effect of construction work on
the existing fire detection system, Alarm and firefighting equipment and
the possibilities that might increase the risk of fire. - Assessing the need
for first aid provision and firefighting and fire protection provisions. -
Adequate training for the existing hospital employees as well as the
construction employees. 23-IC3-08 OUTLINE the issues that need to be
addressed when planning a fire evacuation procedure for an office building
occupied by a number of different companies. Your answer should include
examples where appropriate. ERP for Al thurath 1. Identification of
emergency scenario – such as Fire, Earthquake, Riot etc. 2. Selection for
employees to form an emergency control team – Described
responsibilities, - Adequate training to Fire warden , Security and other
members 3. Means of Raising Alarm and Alerting Building occupants 4.
Liaison with emergency services – such as their access requirements and
appropriate locations of assembly areas. 5. Considering the health
situation of occupants and member of visitors in the building , their
sensory disabilities and physical disabilities etc. to be considered 6.
Physical Measures – Such as travel distance, number of access,
Emergency lights, Exit signs, Evacuation routes etc. 7. Firefighting
Equipment – Alarm, Smoke detector, heat detector, Suitable Fire
 extinguishing media (DCP, CO2, sprinkler system, Hose reel etc.) 8. First
Aid measures – First aid providers, first aid medicines, first aid equipment,
CPR arrangements etc. 9. Emergency Rescue Equipment – Stretcher,
Wheel chair etc. 10. Providing door marshals to prevent entry or re-entry to
the store. 11. Security considerations such as minimizing the opportunity
for theft would also be an issue. 12. Assembly points - Well defined,
Displayed and communicated 13. The procedure, once drawn up, would
need to be summarized on prominently displayed fire notices and tested
with regular fire drills. ETA 27 24-IC3-02 A large shopping complex is
arranged on four levels, with retail outlets on basement, ground floor and
first floor levels and with restaurant facilities on the top level. Movement
between floors is achieved by the use of escalators, lift and stair. LULU
center i. Review, with valid reasoning, the systems that might be installed
in the building to detect, suppress and warn of fire ii. Describe the design
features of the building to assist in the safe evacuation of persons in the
event of fire. i. Fire Detection System: might include Heat sensors in the
restaurant areas, Smoke Detectors in general areas, Flame Sensors in
furnishing areas and CCTV – closed circuit television to monitor
throughout. Fire Suppression System: Sprinkler system, Provision fire hose
reel, Portable Fire Extinguishers, Fire blankets in kitchen Fire Alarm
System: could be automatically triggered on detection of FIRE, but
controlled manual activation might be preferable to avoid panic situation.
The alarm itself could be bells, sirens or verbal instructions over public
addressing system. Consideration might be taken for zoning and a staged
alarm system. ii. Design features of the building to assist in the safe
evacuation of persons in the event of fire RRC – IC 3 –LA-Q 1
14. 14. 14 - Escape routes – distance / requirements: The building design
should primarily take the consideration of escape route distances and
travel distances - Fire resistance of materials / Fire doors: Design features
for evacuation should include escape route requirements such as fire
resistance of materials used, and protection against fire and smoke using
fire doors in staircases and corridors - Maximum numbers / location of
persons on the premises: Account must be taken to the expected
maximum number of the persons and their locations , such as higher
concentration of persons in the dining areas – food court - Number and
width of stair case: other design feature should include the numbers and
width of staircases - Protected areas / Control of use of lifts : The need of
protected areas and control of use of lifts, particularly for mobility
impaired persons and fire fighters - Compartmentalization: would need to
be considered, although difficult in common areas in an open plan store,
and - Protection of dust and voids: Also protection of ducts and voids to
minimize and content the spread of smoke - Smoke extraction: through
automatic roof vents and sprinklers and auto shut off of the ventilation
system in the event of fire - Signage / Emergency lighting: Finally signages
would need to be provided and emergency lighting where appropriate. 25-
IC3-03 (a) In relation to automatic fire detection and alarm systems,
 outline the basic principle AND operation of: (i) Heat detectors; Marks-4 (ii)
Smoke detectors. Marks-4 (b) IDENTIFY the circumstances in which EACH
type of detector would be inappropriate. Marks-2 i) Heat Detector: detects
a rise in temperature two types of heat detectors – a. Self Resetting –
(Fixed rate heat detector and rate of rise type) b. Fusible - Fixed rate heat
detectors operate when a fixed, set, temperature is reached, / Has a
sensing element fixed at particular temp. By means of a thermocouple or
similar arrangement, it detects when the predetermined temperatures is
reached - A rate of rise heat detectors operate when either the
temperature rises at more than a certain rate, or when its fixed
temperature is reached / detects abnormally fast temperature rises by
means of electronic resistors or thermistors ii) Smoke detector: - Smoke
detectors are of two main types: ionisation and optical (or photoelectric). -
The ionisation type uses a small radioactive source, smoke passing into
the detector is ionised, which is then detected by an electronic sensor.
The detector reacts and sound alarm when the pre-set flow of electric
current is reduced as smoke enters the detector. - The optical type of
detectors are designed to operate by either - The absorption (obscuration)
of light ray by smoke particles passing through them - The scattering
(Refraction) of light from an optical ray. July 2011 July 2008
15. 15. 15 26-IC3-04 A conference center is planning to extend its existing
building to incorporate childcare facilities on the ground floor and
additional conference rooms to hire out to local businesses on the upper
floors. OUTLINE the range of factors that would need to be reviewed
following completion of the planned work to enable the company’s fire risk
assessment to be updated. Marks-20 DOHA Mall Fire case …relate to The
Planning and Construction phase: The design of the extension need to be
addressed, - The material used for the constructions, - Competent advise
need to be obtained from the Fire Authority / civil defence, - And the means
of access should be remain clear from any obstructions and maintained at
all the time. On completion of the planned extension the additional risk
factors would arises from the additional users such as: - The small
children, - Worried parents in case of fire, - The extra persons on premises
attending the events in conference areas, - The possibility that the
delegates can be under influence of alcohol, - The allowance of smoking
by the delegate in such areas. The above added risk factors would call for
additional precautions such as - Escape routes - Procedures and
conducting fire drills for children and delegates - Extension to the existing
alarm system - Additional firefighting equipment, Emergency lightings,
notices and signage - Requirements of additional fire marshal experience
in handling children in event of fire for evacuation - Train employees in
revised procedures July 2007 27-IC3-06 During a Fire Drill Exercise at a
large multi-storey office premises, the majority of the occupants
evacuated the building in less than three minutes. However, all of the
people based in one area of the building failed to leave the building until a
further four minutes had elapsed. Fortune tower Fire incident (a) OUTLINE
 factors that may have contributed to the delay in evacuation. Marks-15 (b)
OUTLINE reasons for conducting regular fire drills in workplaces. Marks-5
a. Fire Alarm: Fire Alarm too quit due to low volume; - number of fire alarm
are insufficient; - Alarm may sound similar to other alarming system
creating confusion among people; - Alarm may be inactive due to
maintenance work; - signal of alarm may be weaken due to wall and doors
or other obstruction. Design of buildings: inadequate escape routes which
are greater than recommended travel distance; - too complex to traverse ;
- too narrow slowing down the evacuation; less numbers of access
comparing to strength of occupants; even blocked and locked; inadequate
lighting or no emergency lighting in the escape routes; incorrect signs
showing emergency exits; Deficiency in existing Evacuation procedure:
FEP too difficult and complex to understand; - - the procedure may not be
communicated adequately; -no or insufficient instructions for staff
mentioned in the procedure; - actions / responsibilities are not well
communicated; - fire marshal duties may not be well defined; - inadequate
number of fire marshal deputed; - insufficient training / drills conducted for
the occupants of the building. Execution / Compliance of Procedure:
possible noncompliance of procedure during actual exercise ; - Delay in
response to the alarm by finishing work, finishing telephone call, by
shutting of PC, gathering their belonging or may be investigating why
alarm sounded; No response at all Assuming the Alarm as FALSE alarm or
a Drill. Human factors: hearing disabilities; physical disabilities; general
apathy; lack of will to participate; lack of familiarity with the July 2010
16. 16.  Fire resistance of materials: Design features to control the spread of
fire should include escape route requirements such as o fire resistance of
materials used in the construction of walls, floors and o Provision for Fire
protection (insulation) for structural steel works – ERCO edible oil factory
o The treatment of timbers such as fire rated / retardant ETA 24 The
procedure, once drawn up, would need to be summarized on prominently
displayed fire notices and tested with regular fire drills. Jan, 2011 29-IC3-
09 OUTLINE the design features of a building intended to control the
spread of fire and smoke.  Security considerations such as minimizing
the opportunity for theft / vandalism/sabotage.  Providing door marshals
to prevent entry or re-entry to the store.  The Appointment of trained Fire
Marshals who can ensure clear escape routes and trained in evacuating
people in safe manner.  Liaison with emergency services – such as their
access requirements; without obstructing assembly areas and access to
the buildings  Assembly points - Well defined, Displayed and
communicated and always free from any obstructions  The provision of
emergency lighting and appropriate sign ages for demarking the exit
routes from super market and restaurants, being sufficiently separated to
avoid confusion  Ensuring that the escape routes and assembly points
are clear from any obstructions.  The distance of fire evacuation routes;
and the numbers of such routes  Means of Alerting and evacuating people
through Public address system  The type of person such as their sensory
 disabilities and physical disabilities and age (old age, child) etc. to be
considered  The possible number of employees and visitors to be
evacuated 16 layout of the building. b. REASONS FOR REGULAR FIRE
DRILLS: Quick evacuation; - Familiarity with procedure; - familiarity with
evacuation routes, Alarm, assembly points and DO’s and Don’ts in case of
such situations; - legal compliances; - Insurance requirements; -
identification of troubles / defects to find out the scope for improvements;
- Amendments in procedure to suit the requirements maintaining its
efficiency and suitability. 28-IC3-07 21a-IC3-02 19-IC3-01 For a large
supermarket with restaurant facilities: a) OUTLINE the automatic fire
protection systems that should be in place; Marks-6 b) OUTLINE the
factors to be considered when developing a safe means of escape for the
supermarket. Marks-14 a) Fire Detection System: might include Heat
sensors in the restaurant areas, Smoke Detectors in general areas, Flame
Sensors in furnishing areas and CCTV – closed circuit television to monitor
throughout. Fire Suppression System: Sprinkler system, Provision fire hose
reel, Portable Fire Extinguishers, Fire blankets in kitchen Fire Alarm
System: could be automatically triggered on detection of FIRE, but
controlled manual activation might be preferable to avoid panic situation.
The alarm itself could be bells, sirens or verbal instructions over public
addressing system. Consideration might be taken for zoning and a staged
alarm system. Automatic Fire service calls out through auto dialer or
similar techniques. b) Factors to be considered when developing a safe
means of escape for the supermarket.
17. 17.  The height of the storage racks and their distance from the sprinkler
heads; ETA 26, Jan 2007N 31-IC3-11 As Health, Safety and Environment
Manager at a hazardous installation you are responsible for emergency
planning. The site is regulated under the International Labour Organisation
(ILO) Code of Practice ‘Prevention of Major Industrial Accidents’ 1991. (a)
In the event of an uncontrolled release OUTLINE the need for emergency
response measures. Marks-4 (b) OUTLINE the general emergency planning
measures that should be taken by the ‘competent authorities’ in
association with the works management of the installation. Marks-6 The
event of an uncontrolled release, there would be - a need for emergency
planning to localise the release and if possible, contain it; and to minimise
the harmful effects of the release on people, property and the environment
both inside and outside the installation by the use of safety systems,
alarm systems and the emergency services. - Clear and well defined plans
should be made available for quick and effective use and - Where
emergency equipment and manpower are limited, provision should be
made for m The spray pattern required; Will the system be dry or wet 
Fire stopping for sprinklers and pipeworks passing through
compartmentalization  The fire loading of the area to be protected  The
area to be covered and the presence of other combustibles apart from the
stationery;  The design of the pumping system would also be important
with a diesel back up if the decision was taken to install electrically
 operated pumps.  The availability of an alternative if this was to fail for
any reason.  The provision of fire water runoff  The capacity of water
required, ; - The existence of an adequate and assured water supply and 
Protection of electrical system in the warehouse  The need for a voting
system to reduce the likelihood of false activation  Linking of the
sprinkler to the fire alarms  The means of activating the system
(frangible bulbs or detector activated);  Arrangement for testing the
system  Smoke extraction: through automatic roof vents and sprinklers
and auto shut off of the ventilation system in the event of fire. 30-IC3-10
The owners of a large distribution warehouse business have secured a
contract from a stationery manufacturer. Their insurers have
recommended that the proposed storage facility is sprinkler protected.
OUTLINE the design factors to be considered in providing an adequate
sprinkler system for the facility.  Protection of dust and voids: Also
protection of ducts and voids (in roofs and ceilings) to minimize and
content the spread of smoke; Fire dampers and breaks in ducting 
Protection against fire and smoke using fire doors in staircases and
corridors o Fire resistance closures at stairways and lift shafts o
Compartmentalization: would need to be considered, although difficult in
common areas in an open plan store, and o Fitting doors with intumescent
stripes 17 utual assistance between neighboring industrial activities.
July 2011 July, 2009
18. 18. 18 General emergency planning measures that should be taken by the
competent authorities include - The need: to establish arrangements for an
on-site emergency plan which should be drawn up by the management of
the installation; - To establish arrangements for an off-site emergency plan
to be drawn up by the competent authority in conjunction with the
installation’s management, which should be prepared following
consultation with various bodies such as the fire and police authorities
and the hospital and ambulance services and which should be consistent
with the on-site emergency plan; - to ensure that regular rehearsals were
carried out in order to keep the off-site plan in a state of readiness and
also - to ensure that information on safety was provided to members of the
general public. END OF UNIT 3
19. 19.  Regular cleaning of the bunds and The provision of training to
maintenance staff in emergency procedures July 2012 July 2009 Jan 2008
Jan 2008N Jan 2006N 33-IC4-R- SAQ3 32-IC4-11 BBB Same Q repeated IC8-
03 A road tanker is to be filled with petroleum (gasoline) at an installation.
(a) IDENTIFY FOUR hazards associated with this operation. Marks-4 (b)
DESCRIBE how a vapor cloud explosion could be generated in this
situation. Marks-4 (c) OUTLINE practical ways of minimizing the risk of an
electrostatic charge. Marks-4 (d) OUTLINE control measures that could
reduce risks with road tanker filling. Marks-8 Or, An extremely flammable
liquid is being transferred from a road tanker to a bulk storage tank. a.
OUTLINE the control measures which would reduce the risk of ignition of
the associated vapour due to static electricity. Marks-10 Jan 2012 July
 2008 July 2010 The completion of the flushing out of tanks and pipe work
and their isolation before the start of maintenance work;  The
arrangements for the examination and testing of safety critical plant; The
use of permit to work systems;  The provision of PPE such as chemical
suits, chemical resistant gloves and full face protection. During
Maintenance of proposed plant:  Providing training for the personnel
involved including tanker drivers in the risks associated with the operation
and the control measures to be followed and  The provision and
maintenance of a contingency supply of neutralizing and absorbent
materials and water;  The provision of drench showers and eyewash
stations and a good standard of lighting.  The introduction of a safe
system of work including emergency procedures to deal with spillages 
Measures to avoid the tanker being driven away whilst still connected and
During Operation( procedural req)of proposed plant:  Provision of earthing
and bonding for the tanker, connection and hoses  The provision of good
vehicle access including a hard standing for tankers with facilities for spill
containment  The fitting of level indicators and high level alarms to
prevent overfilling;  The erection of hazard warning signs clearly
identifying the contents of the tanks and the colour coding of pipe work; 
Bunding must be provided around the storage tanks – the bunds must be
capable of holding the entire contents of the tanks plus 10%;  The design,
positioning and marking of the delivery inlets to prevent connection being
made to the wrong tank;  The need for the storage tanks and pipe work
to be constructed of suitable chemical resistant material;  The design;
Marks-10 (b) The operation; Marks-6 (c) The maintenance of the proposed
storage facility. Marks-4 During Design ( Technical Req)of proposed plant:
19 Element IC4 Storage, handling and processing of dangerous
substances 32-IC4-03 BBB As part of a water treatment system, a
manufacturer is to install a plant suitable for the reception and storage of
sulphuric acid and caustic soda, both of which will be delivered in road
tankers. These substances are highly corrosive and can react violently
together. SULB Water treatment plant OUTLINE the safety provisions
required for:
20. 20. 20 Tanker drivers are routinely required to work on top of road tankers
during transfer operations. b. OUTLINE the factors that should be
considered when assessing the risk for work on top of the road tanker.
Marks-10 Or, Identify the safety features needed to protect against ignition
by static electricity of the vapour of an extremely flammable liquid while it
is being transferred from a bulk storage tank to a road tanker. 10, JUL
2008, Jul 2010 a. Practical ways of minimising the risk of an electrostatic
charge - The use of tankers and pipework with high conductivity; Earthing
the pipework and tanker and bonding to the same electrical potential. ;
Reducing the velocity of the filling or draining operation by controlling the
pump rate - Reducing constrictions by the smoother pipe unrestricted by
strainers - Avoid splash filling or water contamination in pipe; Increasing
the relaxation time by using longer pipework - Add anti-static additives ;
 Nitrogen blanketing of the road tanker to minimise the risk of explosion -
The uses of a vapour return system to improve containment.; The provision
of instrumentation to detect earth leakage - Using antistatic clothing and
footwear b. Control measures that could reduce risks with road tanker
filling - Preparation of written procedure and instructions; The
identification of specified entry and exit routes - High level of
communication and cooperation between tanker’s driver and the site
operator - The use of pumps, hoses and other equipment which are
suitable for the purpose, properly installed and regularly maintained -
Fitting devices such as a high level alarm to prevent overfilling - The
erection of barriers or the use of bollards and warning cones to prevent a
collision - Installing a system to prevent tanker driving away to prevent
the tanker driving away if hoses are still connected - Ensuring the tankers
are positioned correctly with wheel chokes and hand brake applied -
Ensuring hoses are coupled without submitting them to abnormal stress
and valves operated in accordance with lay down procedure - Switching
off electrical equipment which was not required for filling such as mobile
phone and bonding and equalizing the potential between the tanker and
fixed installation - Using bottom loading tankers in preference to those
which are top loaded but if this is not possible ensuring that the top
loaded tankers have a fill pipe which touch the bottom of the tanker and
handrails or fall arrest equipment is provided to prevent falls - Finally
preparing procedure to be followed in the event of the emergency and
ensuring that all workers are fully aware about
21. 21. 21 34-IC4-R- SAQ1 BBB A chemical company is involved in the bulk
storage and transport of concentrated solutions of sodium hydroxide.
OUTLINE the technical and procedural requirements needed to ensure the
safety of these activities. 10 marks Technical issues relate to Design of
Tanks, The Filling Operation with the tanker whereas - The presence of
corrosive alkali and therefore, the tank and tanker should be made of
suitable chemical resistant material that will not be corroded, such as
stainless steel. - Avoid incompatible substance such as ACID, the location
of Alkali storage should not be adjacent to any incompatible substance
(ACID). - Bunding must be provided around the storage tanks – the bunds
must be capable of holding the entire contents of the tanks plus 10%; -
Usage of double skinned tanks; The erection of hard standings for vehicles
and anti-collision barriers around the tank. - The fitting of level indicators
and high level alarms and possibly a trip system to prevent overfilling; -
Installing a system to prevent tanker driving away to prevent the tanker
driven away if hoses are still connected - The erection of hazard warning
signs clearly identifying the contents of the tank and tankers and the
colour coding of pipe work; Procedural Issues will include Emergency
Procedure, Training, PPE and Maintenance. - Chemical analysis prior to re-
stocking, to avoid filling with incompatible materials - There must
emergency procedures to deal with spillages or other emergencies - The
provision absorbent materials and water; - The provision of drench
 showers and eyewash stations and a good standard of lighting. - Providing
training for the personnel involved including tanker drivers in the risks
associated with the operation and the control measures to be followed -
The provision of PPE such as chemical suits, chemical resistant gloves
and full face protection. - Provision for maintenance of plant- PTW and
isolation of stored energy, vehicles and flexible pipe works - Since
materials are being transported by tanker, there would be a need for
safety advisor for dangerous goods. 35-IC4-R- SAQ2 With the aid of fully
labeled diagram, IDENTIFY the key safety features of a building to be used
as a facility for the storage of highly flammable solvents in 200 litre drums.
The storage facility - The building of the storage facility should be
constructed of non-combustible and fire resistant materials - An
impermeable / solid base to be constructed; - Bunding must be provided to
contain spills; Facility for collection / disposal of spillage - Light weight
roofs and blast panels / fire explosion vents to be ensured - High or low
level ventilation ; - Adequate separation distance from other buildings
22. 22. 22 - Adequate provision for access and egress, including emergency
escape and ramps to facilitate handling - Door locks and security – to
avoid arson ; suitable warning / hazard signs and instruction displayed -
Indication of zone classification; Facility for external electrical isolation.
Fire safety / precaution - Segregation of incompatible materials; Sprinkler
system or provision of fire extinguishers - Flammable vapour monitoring
system and alarm 36-IC4-05 OUTLINE the factors to consider with respect
to the design, construction and use of store room that is to be used for the
storage of bulk stocks of palletized containers of highly flammable paints
and thinners. 20 As far as design and construction of storeroom were
concerned the following factors such as – - The construction of storeroom
on an impermeable / resistant base with fire resistant materials with a
light weight roof or blast panels - The provision of buildings to retain any
spilled liquid; The provision of high / low ventilation - The provision of
adequate separation from occupied building ; Segregation from traffic /
evacuation routes with the use of fire walls if separation was not possible
- The stores should have at least two access points to allow a means of
escape - Ensuring that electrical installations were suitable for a zoned
area - The provision of fire / smoke detection system, sprinklers, fire
extinguishers - Adequate spacing between racking to allow the movement
of FLT and The provision for separate access for pedestrians and the
trucks. Use of the store room: - The control of source of ignition such as
the FLT and portable electrical equipment - The storing of paint and
thinner in a fire resistant containers away from source of heat and sun
light - Procedure for decanting which should be carried out outdoors or in
a separate area - Procedure for spillages where immediate clean up
required using spill kit - Ensuring a high standard of housekeeping for the
FLT routes and pedestrian walk ways - Regular inspection and
maintenance of the racking and pallets - Arranging the safe disposal of
wastages; Providing information and trainings to workers on necessary
 precautionary measures to be taken - Controlling access to the stores by
limiting it to authorized person only Jan 2011
23. 23. 23 37-IC4-08 The physical and chemical properties of liquefied
petroleum gas (LPG) dictate a number of precautions which should be
taken in the storage of LPG in cylinders. a) Select four of these properties
and explain how one of the precautions is related to each property. b)
Give, with reasons, additional precautions for the safe storage of LPG in
cylinders. a. The properties can be selected include: - LPG is a flammable
gas at standard temp and pressure; - It is denser than air; Escape clouds
cool and therefore are not buoyant on thermal diffusion; - Liquid releases
float on water; The lower explosive limit (LEL) is reached with small
concentrations of LPG; - It is slightly anesthetic and suffocating in high
concentrations b. Precautions for the safe storage of LPG in cylinders
include: - Preferably stored in the open air; Floors should be concreted; -
Noncombustible or fire resistant and Ventilated with an explosimeter
installed. - Minimise quantity; - Elimination of ignition sources: no smoking,
Provision of signage with 'extremely flammable' warnings; - Intrinsically
safe / flame proof electrical equipment; - Only electrical apparatus for use
in Zone 2 area should be allowed in storage area or within separation
distance; - Dry powder extinguishers at storage location; - Control of
combustibles; Removal of vegetation around storage area (not sodium
chlorate weed killers / other oxidizing agents); - Segregated from oxygen
cylinders (3m); Empty cylinders stored separately from full with valves
shut / cap; - Cylinders stored upright; Protective caps kept in place on
valves; - Storage compound should be protected from vehicle impact; -
Storage situation greater than 3m from - cellars, drains or excavations and
protected from the elements; - If more than 400 Kg store must have 2m
high mesh fence, 2 exits, with Cylinders at least 1.5m from fence; 38-IC4
-02 Workers in a vehicle maintenance workshop spray-paint vehicles using
a highly flammable solvent-based paint. OUTLINE the measures needed to
assess and control the risks associated with the spray-painting activity.
Marks-20 - Risk assessment to be carried out for - The activities involved
by using paints & solvents with hazardous properties (normally by
reference to safety datasheet). - The circumstances in which the work
was carried out. - Possible ignition sources and likelihood that a fire or
explosion could occur - The control measures - The workshop should be
constructed of fire resistant materials; An impermeable / solid base to be
constructed; - Possibilities to replace the paint with less flammable - An
external fire resistant storeroom to be provided for the paints and solvents
- A reduced quantities of paint and solvent to be maintained at the
workshop Jan 2010 July 2008
24. 24. 24 - The paint and solvent should be kept in non-spill containers with
lids. - Procedures to made and followed for the containment and clean-up
of spillages and for the cleaning of the spray guns - Provision for Local
exhaust ventilation - Safe electrical equipment with provisions of
flameproof switchboards. - Fire fighting equipment, means of escape
 route, emergency procedure to be drawn and communicated to the
workforce - Instruction, training on the risks involved in the operation and
the precautions to be observed 39-IC4-R- LAQ2 A road haulage company
which is an established carrier of nonhazardous bulk liquid, has been
invited to tender for a contract to transport significant quantities of bulk
flammable materials in tank containers. Advise the hauler company on i.
The requirements for driver training and for the appointment of safety
advisor 6 ii. The main duties of safety advisors in relation to the transport
of dangerous goods. 14 i. The drivers of the tank and tank container
carrying dangerous goods should – - Attend a vocational course of
instructions communicated for transportation of dangerous goods - Sit in
an assessment examination organized externally in order to obtain a
competency certificate which needs to be updated at specific intervals.
The Safety Officer appointed – must hold a vocational qualification where
he had been instruction about the type of the means of transportation
such as water, road and train and the type of dangerous goods to be
transported. ii. The safety officer should act as catalyst and advise on
Health, Safety and Environment matters in term of handling and
transporting dangerous goods to the management, other responsibilities
includes – - Developing a procedure for compliance with local rules
governing the identification of dangerous goods – such as HAZCHEM signs
- Developing procedure for purchasing vehicles – Complying the
requirements for transporting significant quantities of bulk flammable
material in tank container. - Procedure for checking equipment - Procedure
for conducting training and maintaining records of attendance -
Emergency procedure; accountabilities of employees during emergency -
Monitoring of compliance of all procedure through suitable techniques
such as HSE audit - Investigating incidents, accidents and Nearmiss -
Complying the control measures / preventive measures identified during
investigation to avoid recurrence - Prequalification and competency
evaluation for sub contractors - Ensuring the distribution of operational
procedures among the employees - Ensuring that the vehicles are
maintaining required documents and equipment - The implementation of
verification / inspection procedure to ensure the compliance with
legislation governing loading and unloading of dangerous goods - Preparing
annual performance report to the employer
25. 25. 25 40-IC4-R- LAQ3. IC04- 7 As the Health, Safety and Environment
Manager to a group of manufacturing companies, you have recently
discovered drums of a highly flammable solvent being stored on open land
at the rear of one of the group's factories. a) Draft a memorandum to the
Production Manager of the company concerned explaining why storage in
this manner is inappropriate. b) Describe, with the aid of sketches, the
main features of a storage facility that would be appropriate for the
storage of such drums. OR, With the aid of fully labeled diagram, identify
the key features of a building to be used as a facility for the storage of
highly flammable solvents in 200 l drums. a. Memo to the production
 manager: I have recently discovered that the drums of highly flammable
solvents are stored in an open area at the rear of one of our factory, which
is potential to cause any eventuality at the factory leading harm and loss. I
therefore, would like to bring the issue to your kind notice / attention and
set out the below reasons , why storing highly flammable solvents are
inappropriate in such manner – - The risk of ignition leading fire as the
drums are stored under direct sun - over heating from sun, on site ignition
source and malicious damage can be causes of such ignition. - There is
also significant risk of leaks or spillage which could lead to soil
contamination as well as water contamination. - The cost of cleanup could
occur if the drums got damaged resulting in leakage and spillage - The
solvents also presents health risks to anyone in the vicinity - Open area
storage are inviting arsons, theft and vandalism - Risk of drum handling
using FLT and associated reduced stability in such location - It is a non-
compliance of local regulation concerning the storage of flammable
materials, hazardous to health or environment. - Finally it is one of the
major breaches of insurance condition and environmental accreditation. b.
The storage facility - The building of the storage facility should be
constructed of non-combustible and fire resistant materials - An
impermeable / solid base to be constructed; Adequate separation distance
from other buildings - The storage facility to contain the drums of highly
flammable liquid should be provided with Bund to contain spills; - Facility
for collection / disposal of spillage or accumulated rain water - Door locks,
perimeter fencing and security – to avoid arson ; suitable warning / hazard
signs and instruction displayed - High or low level ventilation ; Indication
of zone classification; Facility for external electrical isolation. Fire safety /
precaution - Segregation of incompatible materials from the solvents such
as acids, oxidizing agents to kept separately ; - Sprinkler system or
provision of fire extinguishers - Flammable vapour monitoring system and
alarm - Adequate provision for access and egress, including emergency
escape and truck ramps to facilitate and handling drums ETA 31, Jan 2007
N
26. 26. 26 41-IC4-10 A petrol storage tank in a bund containing three other
similar tanks is overfilled during a transfer operation resulting in a large
spillage of petrol into the bund. The petrol vapor is ignited from a remote
source causing a catastrophic explosion and fire involving the whole of
the installation a. IDENTIFY the design and construction measures that
could have prevented such an event 4 b. OUTLINE the range of measures
that would be necessary to mitigate the effects of such an event 6 a.
Design and construction measures that could have prevented the incident
include: - Adequate segregation between adjacent tanks and the use of
separate bunding - an interlocked pumping system with high level alarms
with at least double redundancy of the alarm - level detection and vapour
detector monitoring systems fitted in the bund - the provision of remote
shut down systems - good standards or earthing and bonding b. The
measures that would be necessary to mitigate the effects of such an event
 - Provision of adequate fixed foam installations to spray the surface of
pools in the bunded areas - The installation of foam monitors capable of
reaching the tops of tanks July 2007
27. 27.  No place on the permit for the issuer to declare that the work had
been left in a safe condition - Inadequate written procedures for the permit
to work in that there was reference of locking off or tagging valves to
prevent inadvertent operation - A failure to check that the blank valve was
leak tight at the time before pressurizing it - A failure in communication at
shift handover with the absence of any written procedure for this event -
The absence of formal training for those with the responsibilities of
issuing permits - No attention drawn to the potential dangers associated
with the suspended of permits - Finally inadequate monitoring and auditing
by management of the permit to work procedure. January 2010 43-IC4-01
Unless appropriate precautions are taken, chemical reactions in a batch
manufacturing process can give rise to conditions which can lead to a
'runaway reaction'. a) EXPLAIN what is meant by 'runaway reaction' also
called thermal runaway and July 2011 Jan 2009 July 2007 Failure in
communication at the end of the working day with the suspended permit
returned to the control room but not displayed and not communicated to
night shift team  No cross reference of the two permits to indicate the
removal of pressure valve in the pump in each of the permit.  No mention
of the need to cross reference permits / or 27 - The erection of radiation
walls between adjacent bunds to prevent other tanks being heated - An
adequate supply of firefighting water - The installation of remotely
operated pumps and valves to empty affected tanks - Easy routes of
access for fire fighters - The provision of drainage interceptors to minimize
the environmental effects of fire water run off - Regular draining and
cleaning to remove rain water from bunds 42-IC4-04 In 1988 a disaster
occurred on the piper alpha platform in the united kingdom a. IDENTIFY
mechanical failures that contributed to the initial explosion - 4 b. OUTLINE
the systems failures associated with the permit to work system that
contributed initial explosion - 6 a. The mechanical failures that contributed
to the initial explosion- - The removal of PSV (pressure safety valve) for
service and its replacement with a blank flange (Blind flange) - The blank
flange was made of ordinary metal sheet (without any Lock or tag with
switch of pump) - The blank flange was fitted incorrectly and was not leak
tight - On the night A running (condensate) pump was tripped and a stand
by pump associated with blanked flange was operated by night shift
without knowing about incorrectly fitted blank flange. - The condensate
and gas escaped from the blanked flange that resulted in gas explosion b.
- There were two permits taken – one for two weeks maintenance in the
pump and other for the work on pressure valve of the same pump. - The
failure with the PTW which was in operation for the removal of the
pressure valve.
28. 28. 28 b) IDENTIFY the conditions that may give rise to such an event. c)
DESCRIBE the design and operational features of chemical processes
 necessary to prevent such an event. 2+4+4=10, a) An uncontrolled
exothermic reaction where the heat produced by the reaction exceeds the
heat removed. The surplus heat raises the temperature of the reaction
mass, which causes the rate of reaction to increase resulting in RUNAWAY
REACTION. Thermal runaway occurs because, as the temperature
increases, the rate at which heat is removed increases linearly but the
rate at which heat is produced increases exponentially. b) the conditions
that may give rise to such an event includes – - Presence of Strongly
exothermic reaction; - Inadequate provision, or failure in cooling of the
reaction, and - Presence of contaminant catalysis. - Excessive quantities
of reactants present in the reactor - The lack of sensitive temperature
detection and control - the insulation of the reaction vessel where solid
residues have build up on the internal walls of the vessel and mixer failure
with loss of agitation - Increase in pressure and temperature from reaction
serve to accelerate the reaction in accord with Le Chatelier’s principle. c)
Carrying out a hazard and operability study (HAZOP) on the reaction
process would be appropriate in this scenario; this may then have led to
the inclusion of design features such as: - High integrity temperature
detection being linked to the cooling / reactant addition system; - Pressure
rise detection linked to cooling / venting / auto shut-down; - Vessel
protected by correctly sized bursting disc. - Fitting of an agitation failure
alarm system Operational Features such as - Only high caliber of operator
required for such processes was employed; - The decision making
requirements by operators in response to adverse operating condition
were minimized - Ensure that maintenance activities / raw material
handling do not introduce potential catalysts into the reaction; - The rate
of addition of reactants was limited and that inappropriate scale-up or
fouling was avoided 44-IC4-01 A hot liquid was accidently and violently
discharged from the feed port of reactor vessel following the addition of a
chemical regent during a chemical manufacturing process; The
investigation suggested that the cause was a runaway exothermic
reaction. i. OUTLINE the factors that may have contributed to the event
and explain the principle involved. 10 ii. DESCRIBE the measures that
could be taken to prevent a recurrence 10 a) The factors that may have
contributed to the event scenario - It is likely that the incident was a
violent exothermic reaction, which caused a thermal runaway, with
subsequent rapid increase in temperature and pressure causing the
ejection of vessel contents. ETA 29
29. 29. 29 - The system was based on wrong procedures or incorrect
assumptions about the heat generation and dissipation from quantities of
chemicals used for the procedure. - Equipment failure, for example
automatic feed breakdown or a failure of critical component such as
stirrer and mixers; - Incorrect operating procedures such as the speed of
addition or the method of mixing was wrong - The vessel contents could
have been incorrect or the wrong materials have been added. -
Contamination or contact with other chemicals reagent acting as catalyst.
 - Design failure, commissioning failure if the plant was not build as per the
recognized specification - Human error – unauthorized modification. b)
Measures to prevent a recurrence include - The feed of material should be
controlled adequately, either manually or automatically to ensure correct
speed of delivery. - Any engineering controls provided for temperature,
pressure, level, quantities should be properly designed and maintained and
tested. - Pressure changes and other warnings and alarms and - Automatic
process shutdown if the feed of the reagents or the reaction exceeds the
pre-set parameters. - Designed emergency neutralization or discharge of
the process reactants if feed or the reaction exceeds the preset
parameter - To prevent contamination, Procedural control measures such
as quality control of feedstock purity and specification of supplied
materials should be closely monitored. Allied to this would be the
requirement for - Adequate training, instruction and information for
operators to reduce human error, - Close supervision for normal operation
and emergency conditions. - The use of laboratory or pilot plant trials and -
The use of hazard analysis techniques (hazop). END OF UNIT 4
30. 30. 30 IC 5 : Work Equipment With the aid of labelled sketches, outline the
characteristic features of, and factors that promote, the following types of
materials failure: (a) Brittle Failure; Marks-5 (b) Ductile Failure. Marks-5
July 2012 Jan 2008 45-IC 05 - 11 Coal is delivered by train to a power
station and is transported by belt conveyors to a furnace. Conveyor
workers check that the coal moves along the conveyors efficiently. These
workers have received suitable information, instruction and training and
are supervised. OUTLINE additional control measures that could reduce
risks to conveyor workers. Marks-10 Jan 2012 Jan 2010 46-IC 05 – 08
Materials can fail through various modes. (a) OUTLINE the meaning of
‘Metal Fatigue’. Marks-6 (b) IDENTIFY TWO factors which can contribute to
such a failure AND, for EACH factor, outline ONE circumstance in which it
may occur. Marks-4 (c) OUTLINE: (i) The characteristics of electrolytic
corrosion. Marks-5 (ii)Factors which cause electrolytic corrosion. Marks-5
Jan 2012 Jul 2008
31. 31. 31 47-IC 05 – R- LAQ 1 “A” a) IDENTIFY the possible modes of
structural failure of pressure vessels and, with reference to different types
of pressure vessel, describe the factors and conditions that may influence
the mode and likelihood. 14 b) Review the measures that may be needed
to prevent the structural failure of pressure vessels. 6 a. The possible
modes of failures are as below - Creep ; Corrosion ; Brittle failure; Ductile
failure; Metal fatigue The factors and conditions that may influence the
mode and likelihood of such failure include: - Temperature (Low)– is an
important factor with brittle failure, more likely to occur at low
temperature, for example in LPG vessels - Temperature (high) – Creep and
ductile failure are more likely to happened at high temperature for
example in steam boiler - Cyclical pressure variations are likely to
promote metal fatigue - Residual manufacturing stress, choice of
materials, poor repair, welding and heat treatment can influence the likely
 stress in the vessels. - The contents of the vessels will affect the
probability, extent and the type of any corrosion - Weak components such
as seems, welds and loose access plates may promote failure. -
Contamination – oil / grease in air receiver; Environment is also an
important factors – Corrosive / hot - Operating within design specifications:
o Overheating – low water level / scale formation; Over pressure – Safety
gauge / valve failure b. Measures that may be needed to prevent structural
failure - Designed safety feature – relief valves, sight gauge, level sensor
and choice of material used - Specified design standards – Quality control,
proof testing - Regular checks and test – servicing, maintenance and
inspections - Thorough examination by competent persons - NDT (Non
Destructive test) to identify the potential failure modes - Operating
procedures to keep within specified performance - Water treatment for
boiler and filters to remove contaminations. 48-IC 05 -04 “A” With the aid
of labeled sketches, OUTLINE the characteristics of, and factors that
promote, the following type of material failure a) Brittle Failure; b)Ductile
Failure a) Brittle Failure: A brittle fracture generally occurs without
warning or prior evidence of distress. It is a crystalline structure failure
with minimal plastic or elastic deformation. There are generally
characteristics ‘chevron’ marks from the point of initiation and the failure
is sudden from rapid stress loading. The factors promoting a brittle
fracture are - High tensile stresses,; Residual or locked in stresses;
Sudden loading which does not give the material time to deform
plastically, - Case hardening; Low temperatures and The degree of
brittleness of the material b) Ductile Failure A ductile fracture generally
has a smooth fracture surface with plastic deformation of the material
before final fracture. There is evidence of necking and the final fracture is
often brittle because there is insufficient material left to sustain a load.
July 2012 Jan 2008
32. 32. 32 This type of failure generally occurs as the result of a single stress
overload though other promoting factors including - High temperatures,;
Cold work hardening and - The plasticity of the material 49-IC 05 – R SAQ 2
“A” Describe, with practical examples and sketches the characteristics
features of and that factors that promote the following types of failures in
metal. i) Fatigue 10 ii) Creep 10 (NEBOSH diploma syllabus: Seven modes
of failures- D There is Little or no deformation but the failure surface
shows characteristics conchoidal marks Initiated at stress
concentration. These Extend under Fluctuating stress until the material
fails - The final failure may be ductile or brittle (when there is insufficient
material to sustain the load) uctile, brittle, metal fatigue, buckling,
corrosion, Wear and creep) i) Fatigue: Characteristics: o Cracks spreading
– repeatedly stressed, newly failed smooth surface o Beachmark – 90
degree to crackdown o Final failure ductile / brittle – insufficient material
to withstand the load Fatigue: Factors: o Area of high stress concentration
– corners, threads, holes o Cyclical loading ; Temperature, pressure and
forced vibration Fatigue: Example: Rotating; Reciprocating ; Vibrating
 parts ii) Creep: Characteristics: Yielding and extension; Continuously
loaded materials; plastic deformation Creep: Factors: unequal relaxation
of stresses; Excess temperature; Choice of materials (Low creep) Fatigue:
Example: Pressurised pipework; high speed rotating blades 50-IC 05 – R –
LAQ 2 “A” A report into the collapse of a passenger walkways at a ferry
port concluded that the immediate physical cause of collapse was a
fatigue failure of a weld securing a stub axle to the walk ways. The
walkways , which was designed and installed by contractor, was attached
to a floating pontoon at one end and was intended to accommodate the
movement cause by the rise and fall of the tide i) Explain the mechanism
of “Fatigue Failure” 5 ii) OUTLINE the design and maintenance procedure
that could have helped in preventing incident 10 iii) OUTLINE the steps
that the ferry port could have taken to ensure that the contractor was
competent to design and install the walkways 5 i. The mechanism of
fatigue failure such as - Microscopic progressive cracks (point of high
stress, variable loadings, little deformation)
33. 33.  Failed surface shows conchoidal beachmarks , which Progress as
narrow rings at low and extended at full load b) Factors which could give
rise to fatigue failure in practice such as: (only 3 factor with 1
circumstance) - High Fluctuating stress – Use outside the design criteria,
Relative to fatigue strength of material, - Stress concentration – sharp
corners, threads, holes, defects / flaws / cracks / impurities - Temperature
– heat induces stress, change of material properties - Residual stress –
imposed during manufacture and assembly and induced bending stress,
and ETA 38, Jan 2007 N The characteristic fracture pattern. - The final
failure may be ductile or brittle when there is insufficient material to
sustain the load  Fluctuating stress environments and  Crack
propagation from points of stress concentration, 33 ii. Design and
Maintenance procedure includes - Deputing the competent and
experienced designer - A peer review of the design considering the service
condition and loading - Tidal and the possibility of the corrosion should be
considered - Stress concentration should be minimized; Material with
suitable fatigue strength to be selected - Risk assessment should be
carried out at the design stage - Provision for maintenance and
inspections; Maintenance and inspection requirement should be specified -
Implementation of documented inspection and maintenance routine -
Training of personnel on maintenance requirements; Periodic thorough
examination by the competent person iii. Steps for prequalifying / ensuring
competency the contractors - Enquiries for experience in similar projects -
Verifications from recent clients – they could have provided the
information about the performance of the contractor - Details of design
personnel (qualifications, Experience etc.) - Quality control techniques -
The use of Risk assessments for design stages should be queried - The use
of third party checks / inspection on design to be queried - Finally the
contractors should prepare a detailed plan Outlining the construction
safety and installation arrangements 51-IC 05-14 – R – LAQ 3 “A” A serious
 accident occurred when a threaded steel rod in the braking mechanism of
a hoist broke. An investigation revealed that the cause of the breakage
was fatigue failure. a) DESCRIBE the mechanism and characteristics of
fatigue failure 6 b) List THREE factors which can contribute to such a
failure and for each factor describe one circumstance in which it may
occur 6 c) DESCRIBE the measures that could have been taken to
minimize the likelihood of such a failure 8 a) The mechanism and
characteristics of fatigue failure such as - Microscopic progressive cracks
(point of high stress, variable loadings, little deformation)
34. 34. 34 - Corrosion – stress concentrations in corrosion pits c) Measures to
minimize the likelihood of fatigue failures such as - Design, manufacture
and installation o Minimize stress concentration; specifying materials /
components to match the service condition o Quality assurance; Correct
assembly - The maintenance, inspection and examination (with NDT) o
Failure record ; Reliability data; Non Destructive test o Examination of
critical components o Replacements at planned intervals o Maintenance o
Statutory examination requirements - Provision of training and instruction
for those involved in the use and - The keeping of service history records.
52-IC 05 -12 “A” Prevention of pipework failures is critical in preventing
major leaks and incidents. The construction of a new chemical plant is
nearly complete and some parts are being prepared for start-up. a)
OUTLINE an inspection strategy that could prevent pipework failures
within this plant 10 b) OUTLINE the items that could be included on a
checklist when inspecting pipework after construction. 10 a. The
inspection strategies that could prevent pipework failures: - A thorough
inspection must be done on current basis, more detailed manner than
previous one. - The use of NDT techniques such as dye penetrate for the
detection of surface faults and - And NDT techniques such as ultrasonic or
radiography to detect those that were more serious - The engagement of
qualified personnel to interpret the results and management should resist
the temptation to use unqualified personnel for any type of pipe work
inspection. - Inspection should take place during and after the
construction has been completed and should be ongoing throughout the
life of the plant. - Those carrying out inspections should preferably include
a member from design team who will be able to detect departures from the
design intentions and also a member of the startup team who suffer most
from the results of construction defects. b. Checklist - Suitable material
such as specified grade of steel to be chosen for the construction of the
pipe work. - The required tests have been carried out - The pipes are not
secured too tightly and are free to expand - The flanges on liquid lines are
not located above cables - Temporary supports have been removed and
permanent supports correctly installed - Springs and hangers are not fully
compressed or extended; No sub standards joint exists - No screwed joints
have been used and ; All joints have been leak tested JAN 2010 Jan 2008
35. 35. 35 - Temporary branches, nipples and plugs have been removed and
replaced with welded plugs - Pipes do not touch the ground, are not laid
underground and do not pass through pits or depressions containing water
- Relief valve drain lines are not too close to the ground so that blocking
and freezing is avoidable - Reinforcement pads are vented; dead ends,
dead legs and water traps have been avoided - Bellows are not distorted
and support rings are not loose - Vibrating pipes have been avoided and all
pipe work has received hydrostatic testing 53-IC 05 – 15, R-SAQ 3 “B” a.
EXPLAIN the purpose of non-destructive testing (NDT) on items of plant. 2
b. Other than visual inspection, OUTLINE the principles, advantages and
disadvantages of TWO NDT techniques 8 IC 05 - 16 “B” (a) OUTLINE the
purpose of non-destructive testing (NDT) on items of plant. Marks-2 (b)
OUTLINE the principles, benefits and limitations of the following NDT
techniques: (i) Dye penetrant; Marks-4 (ii) Radiography. Marks-4 July 2011
July 2009 “B” OUTLINE the principles, advantages and disadvantages of:
(a) Dye penetrant; (b) Magnetic particle inspection; (c) Radiography; (d)
Ultrasonics as methods of non-destructive testing on the welded joints of
a safety critical vessel. Marks-20 July 2011 July 2007 ANS of all above 3
Questions The purpose of non-destructive testing (NDT) is to check for
faults (cracks etc) in components before they develop into total failure
without affecting the integrity of the component. The main NDT
techniques required are: Principle of NDT Techniques Advantages
Disadvantages The use of a dye penetrant method makes cracks visible as
dye penetrates into it. It uses the principle of brightly coloured or
fluorescent liquid applied to the surface of the component, which
penetrates into any surface cracks or cavities. Developer is then applied
which draws out the penetrant, so indicating cracks etc, that are not
normally detected It is relatively cheap and is a simple operation It
detects surface faults, It is quick and easy to use on large surfaces, It is
cost effective, allows complex geometries to be inspected and is a
portable technique (e.g. spray aerosol cans of penetrant can be used) it
does not detect sub-surface faults It is only suitable for non-porous
materials, There must be direct access to the surface of the component,
Surface finish and roughness can affect inspection sensitivity, It indicates
the length of the defect but not the depth and There are health and safety
considerations such as possible confined space and flammability.
Additionally, the penetrant used may have toxic