Working at Height Scenario (10) AS

Question.
1Outline the factors to be considered while deciding the control measures for a
working at height scenario (10) AS
AS 1
Question 2.Outline the precautions to be taken in order to ensure the safety of a nurse who is
undertaking home visits alone as part of her duties (10) AS
AS 2
Question 1 (a) An extremely flammable liquid is being transferred from a road tanker to a bulk
storage tank.
Outline the control measures which would reduce the risk of ignition of the associated vapour
due to static electricity. (10)
(b) Tanker drivers are routinely required to work on top of road tankers during transfer
operations.
Outline the factors that should be considered when assessing the risk for work on top of the
road tanker. (10) AS
AS 3
Question 1. 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) PDF1
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Question 2. Outline the main design features of a workplace designed to reduce the risk of injury
associated with INTERNAL TRANSPORT. (10) PDF1
OR.
Outline the main design features of a ware housing operation design to reduce the risk of injuries
associated with INTERNAL TRANSPORT. (10) PDF1
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Question 3. 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. (10) PDF1
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Question 4. 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) PDF1.
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Question 6. With examples of actual incidents, describe the principles and effects of a BLEVE –
boiling liquid expanding vapour explosions. (10) PDF1.
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Question 7. 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. (5)
(b)For each of principles identified, suggest control measures which are based upon the principle.
(5) PDF1.
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Question 8. 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 (5) PDF1.
(b)Outline the technical failings that contributed to this major accident(5) PDF1.
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Question 9. 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 (a) Describe how corrosion occurs in buried LPG metal
pipework (10)
(b) Outline how buried LPG metal pipework can be protected against corrosion (5) PDF1.
(c) Excluding corrosion protection, outline additional factors to consider in preventing a
recurrence of an explosion in similar LPG pipework installations (10) PDF1.
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Question 10. 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. (10) PDF1.
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Question 11. 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 (10) PDF1.
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Question 12. 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
(a)Review, with valid reasoning, the systems that might be installed in the building to detect,
suppress and warn of fire (10)
(b)Describe the design features of the building to assist in the safe evacuation of persons in the
event of fire (10) PDF1.
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Question 14. 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. (10) PDF1.
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Question 15 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) PDF1.
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Question 16. 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) PDF1.
Or 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 liter drums(10) PDF1.
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Question 17. 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. (10)
(b)Give, with reasons, additional precautions for the safe storage of LPG in cylinders. (10) PDF1.
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Question 18. 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(10)
II. The main duties of safety advisors in relation to the transport of dangerous goods (10)
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Question 19. 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 (10)
(b)Describe, with the aid of sketches, the main features of a storage facility that would be
appropriate for the storage of such drums (10)
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 (10) PDF1.
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Question 20. 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 (10)
PDF1.
(b)Outline the range of measures that would be necessary to mitigate the effects of such an event
(10) PDF1.
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Question 21. 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) PDF1.
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Question 22. (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. (10)
b) Review the measures that may be needed to prevent the structural failure of pressure vessels
(10) PDF1.
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Question 23. 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) PDF1.
(NEBOSH diploma syllabus: Seven modes of failures- Ductile, brittle, metal fatigue, buckling,
corrosion, Wear and creep)
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Question 24. 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 (10) PDF1.
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Question 25. 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 (10)
(b)List THREE factors which can contribute to such a failure and for each factor describe one
circumstance in which it may occur (10)
(c)Describe the measures that could have been taken to minimize the likelihood of such a failure
(10) PDF1.
Question
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Question 26. 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:
All to write
A weld repair to a high pressure steam pipeline requires gamma radiography to be performed to
assess the quality of the repair
(a)Outline the principle of gamma radiography (5)
(b)Outline the advantage and disadvantages of this form of NDT (5) PDF1.
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Question Q27. Explain what is meant by a 'pressure system'.
(a)Describe common causes of structural failure in pressure systems.
(a)Outline the technical and procedural measures to minimize the likelihood of failures in pressure
systems. (5) PDF1.
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Question 28. a) Organizations may use a range of reactive and proactive strategies for plant
maintenance. Identify FOUR possible plant maintenance strategies AND outline the principles of
EACH strategy (10)
b) Outline the factors that you would advise the Engineering Department of an organization to
take into account in deciding on a maintenance strategy following the installation of an item of
process plant (10) PDF1.
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Question 29. A compressed air system is to be installed in a motor vehicle repair workshop.
Outline the safety requirements that should be met before the system is commissioned (10)
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Question 30. (a) Outline the features of computer controlled equipment (e.g. robots, Computer
Numerical Controlled (CNC) machines, and wireless operated lifting equipment) that may have
particular implications on safety. (10)
(b) Describe how the risk of injury to personnel working with such equipment may be reduced
(10)
Or, Identify the particular safety problems posed by industrial robots in a work place (10) PDF1.
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Question 31. A plastics injection moulding machine is supplied to your workplace.
Outline the moulding machine’s features that you would have expected to have been addressed
in order to demonstrate that the machine is safe (20) PDF1.
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Question 32. Describe the risks associated with the task of cutting sheet metal with guillotine
machines and the measures that should be taken to ensure the health and safety of operators.
The risks associated with the task of cutting sheet metal with guillotine machines (10) PDF1.
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Question 33. A new, self-contained air compressor is to be installed in an existing work shop
(a)Outline the built in protective devices that may be necessary in order to ensure its safe
operation (10)
(b)Identify the information that should be displayed on the air receiver in order to comply with the
best practices (10) PDF1.
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Question 34. A manually operated lathe/ milling machine is to be fitted with a computer numeric
control (CNC) system. Outline the additional risks that this may introduce and the measures
required to minimize such risk (10) PDF1.
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Question 35. Describe the principles of operation of the following interlocking methods used to
safeguard machinery
I. Captive key control system
II. Trapped key control system
III. A cam activated position (limit) switch operating in the positive (normally open) mode
(10) PDF1.
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Question 36. (a) Identify when a fixed guard would be an appropriate means of providing
protection against mechanical hazards.
(a)Outline the features of a ‘fixed guard’ in relation to machinery safety. (10)
(a)Outline the factors to be considered in the design and use of fixed guards that minimise risks to
workers (10) PDF1.
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Question 37. It is proposed to use an electro-sensitive safety system ('light curtain') to safeguard
the otherwise unguarded entrance to a fenced enclosure in which dangerous machinery operates
at high speed. Outline the safety considerations and specific design criteria that would need to be
addressed when assessing the acceptability of the proposal (10) PDF1.
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Question 38. The horizontally sliding gate at the bottom of a construction site hoist used for
raising and lowering both persons and materials is electrically interlocked.
(a) Illustrate, by means of a schematic diagram, a suitable interlocking arrangement and give
reasons for the level of protection shown.
(b)Outline the factors that could prevent effective operation of the interlocking mechanism and
the measures that would be needed to ensure continued effectiveness (20) PDF1.
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Question 39. Outline the factors that a competent person would need to take into account when
deciding the frequency of examination of lifting equipment (10) PDF1.
Outline the factors that a competent would need to take into account when deciding how
frequent the thorough examinations should be and Identify the documents the documents that
would be need for such an exercise(10) PDF1.
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Question 40. a) Describe the factors that may cause instability of a Mobile Crane. (cause of topple
/ overturning) (10)
b) Outline the measures that should be taken to reduce the likelihood of overturning during a
lifting operation (10) PDF1.
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Question 41. In order to inspect the insulation condition on pipework 4m above ground level, it is
proposed, in the absence of MEWP to utilize a personnel cage lifted to the required height by a
FLT.
Outline the factors to be considered to ensure safety in the performance of this task (10) PDF1.
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Question 42. The jib of a large mobile crane has failed during a lifting operation. Describe, with
sketches where appropriate, the range of issues and evidence that an investigation team will need
to examine in order to determine the reasons for the failure (20) PDF1.
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Question 43. Problem associated with the over hoisting of overhead cranes, whereby the crane
hook is hoisted beyond its upper limit and rope fails, have been recognized for many years.
Outline
I. The mechanism that are most likely to be associated with this kind of failure(10)
II. The technical and procedural control that can be implemented to prevent such failure (10)
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Question 44. A company is planning a move from premises containing a 'manual' warehouse to
one in which the warehouse contains automated order picking and automated guided vehicle
(AGV) goods transfer facilities. Identify And Describe the risks which might be reduced by such a
move, together with the new factors or increased risks which might arise from the changes (20)
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Question 45. (a)Outline the dangers against which protection is provided by a fuse in an electric
circuit and explain how such protection is achieved (10)
(b)With respect to UK mains voltage electricity, Describe the methods and devices other than
fuses designated to improve electrical safety (10)
(c)Describe the Precautions which should be taken when maintaining or repairing electrical
systems (10) PDF1.
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Question 46. Areas involving flammable gases and vapours are classified by legislation
surrounding the existence of Dangerous Substances and Explosive Atmospheres according to the
probability of occurrence of flammable atmospheres.
(a)Explain the purpose of classifying areas in this way AND distinguish between each zone class.
(b)Describe the types and principles of protection required for electrical equipment in relation to
flammable atmospheres.
Part a requires the Explanation of the Zone Classification system contained in legislation (e.g. the
UK Dangerous Substances and Explosive Atmospheres Regulations 2002 (Regulation 7 and
Schedule 2) (20) PDF1.
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Question 47. Small electroplating companies often have poor standards of health and safety,
made worse by the presence of conductive and corrosive fluids, and humid corrosive atmospheres
(a)Describe the types of fault that may be found in fixed electrical systems under such conditions
(20) (b) Outline the information relating to fixed electrical systems that will be required prior to a
survey by a competent person (20) PDF1.
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Question 48 (a) Outline the factors related to construction work that can increase the risks from
electricity on a construction site (10)
(b)Describe the control measures that may be used to address the problems outlined in (10)
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Question 49. (a) Identify the particular aspects of a working environment that may increase
electrical risks. (10) PDF1.
Outline the means by which protection is afforded by, and the limitations of, the following:
I.INTRINSICALLY Safe Equipment; II. FLAME Proof Electrical Equipment (10) PDF1.
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Question 50. Outline the precautions required when work is to be carried out on an 11 kV
electrical supply transformer (10) PDF1.
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Question 51. Identify the factors that may determine appropriate intervals for the inspection and
testing of portable electrical equipment. It is good practice (law in some countries e.g. UK - The
Electricity at Work Regulations 1989) that all systems, including portable electrical equipment,
should be maintained so far as is reasonably practicable to prevent danger (10) PDF1.
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Question 52. Outline the key technical and procedural measures required to ensure the initial and
continued stability of an independent tied scaffold to be erected against a multi storey building in
a city Centre (10) PDF1.
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Question 53.Outline the design and procedural issues that are relevant to the safe use of a
scaffold hoist tower on a construction site (10) PDF1.
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Question 54. It has been found necessary to repair the explosion venting system at the top of a 15
meter high grain silo on a farm. Fixed external and internal access will be required for fitters /
welders. Prepare a summary of the essential precautions to be taken before and during the repair
work (10) PDF1.
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Question 55. An independent tied scaffold to a new ten-storey office block has collapse into a
busy street
(a)Outline the factors that may have affected the stability of the scaffold (8) PDF1.
(b)Describe the main principles of scaffold design, erection and use to ensure the stability of such
scaffold (12) PDF1.
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Question 56. A worker suspended in a fall protection harness is at risk of suffering from
suspension trauma with the potential for serious injury or death
Outline the precautions an employer could take to reduce the risks to the worker in this situation
(10) PDF1.
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Question 57. A three-storey building is situated with one side fronting on to a pedestrian
walkway. The building is to undergo extensive maintenance to the external fabric which includes a
sloping roof.
(a)Outline the safety aspects of the work that will need to be considered before work starts (12)
(b)Describe, with sketches, the means of providing safe working places for those working at height
(12) PDF1.
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Question 1 (a) Outline what might cause an agricultural tractor to overturn. (6)
(b) Outline control measures that could help reduce the risk of an agricultural tractor
overturning. (4)
Question 6 (a) Outline factors that might cause an agricultural tractor to overturn. (6)
(b) Outline control measures that should be considered in order to help reduce the risk of an
agricultural tractor overturning. (4)
Question 4 (a) Outline factors that might cause an agricultural tractor to overturn. (6)
(b) Outline measures that may be necessary to minimise the risk of a tractor overturning. (4)
Question 1 Outline: (a) the factors affecting the likelihood of an agricultural tractor
overturning; (6)
(b) the measures that may be necessary to minimise the risk, or limit the effects, of a tractor
overturning. (4)
ER-1
Question 2 An organisation can help ensure workplace transport safety by having safe vehicles
and a safe site.
(a) Outline control measures that should be considered to help ensure safe vehicles. (5)
(b) Outline control measures that should be considered to help ensure a safe site. (5)
and a safe site.
and a safe site.
Question 8 Outline the design features and procedural arrangements that may need to be
considered in order to minimise risks associated with movement of vehicles in the workplace.
(20)
ER-2
Question 8 Outline the features and arrangements that should be considered in order to
minimise risks associated with the movement of vehicles in the workplace. (20)
Question 1 Outline the arrangements in a motor fleet policy that will minimise the risk to a
multi-site organisation where workers drive vehicles between sites. (10
ER-3
Question 3 Large goods vehicles are loaded and unloaded at a distribution depot.
Outline hazards associated with these vehicles during this loading and unloading process that
should be considered in a workplace transport risk assessment. (10)
ER-4
Question 10 There has been a steady increase in the number of road traffic incidents causing
vehicle damage and injuries to engineers who work for a multinational organisation. The
engineers are required to provide technical cover to clients in a number of countries around the
world as part of the organisation’s global operations. To attend clients’ sites, engineers are
required to take scheduled air travel and then drive from the airport to the site in hired cars.
(a) Outline factors associated with this work that can increase the risk of road incidents
involving the engineers. (10)
(b) Outline practical ways of managing the work-related driving risk to the engineers. (10)
ER-5
Question 3 An excavation is required of an existing factory floor to repair a damaged water
main. (a) Outline hazards and corresponding risks that may be created by the excavation work.
(5)
(b) Outline control measures that should be considered to help ensure the safety of the work
activity. (5)
ER-6
Question 3 Large diameter concrete water pipes are being installed in a trench 2.5 metres deep
during excavation works. Temporary shoring is provided by the use of drag boxes.
(a) Outline workplace control measures that are necessary when drag boxes are used to
provide temporary shoring. (4)
(b) Other than temporary shoring, explain workplace control measures that could help reduce
the risk of collapse of the trench. (6)
ER-7
Question 10 During excavation there is a risk of striking underground cables.
Outline precautions that minimise the risk of striking underground electrical cables. (20)
ER-8
Question 3 A worker is carrying out a user check on an alternating current (AC) electric drill
which is to be used with a residual current device (RCD).
(a) Outline types of visible defect on the drill that may be found during the check. (8)
(b) Outline the importance of an RCD. (2)
ER-9
Question 3 Outline the practical control measures that can be taken to minimise risk when
operating a bench-mounted circular saw. (10)
ER-10
Question 9 With respect to an electricity supply operating at 240v:
(a) outline the factors that determine the severity of the effects of an electric
shock. (6)
(b) For each of the following protective devices describe their principles of operation:
(i) residual current devices; (3)
(ii) fuses; (3)
(iii) 110v center tapped to earth reduced voltage systems. (3)
(c) Outline other design features of electrical systems intended to improve safety. (5)
ER-11
Question 11 (a) Outline hazards when excavating near underground electrical cables. (4)
(b) Outline control measures that should be considered when excavating near underground
electrical cables. (12)
(c) Outline the effects of electric shock on the body. (4)
Question 8 (a) Outline hazards when excavating near underground electrical cables. (4)
(b) Outline control measures that should be considered when excavating near underground
electrical cables. (12)
(c) Outline the effects of electric shock on the body. (4)
ER-12
Question 8 A worker has received an electric shock from a 240 volt portable drill whilst
installing a set of wooden shelves.
(a) Outline the physical effects the worker may have suffered from the accident. (5)
(b) Identify the emergency action that should have been taken immediately after the accident.
(5)
(c) Outline the precautions that could have been taken to prevent the accident. (10)
Question 10 A worker has received an electric shock from a 240 volt portable drill whilst
installing a set of wooden shelves.
(a) Outline the physical effects the worker may have suffered from the accident. (5)
(b) State the emergency action that should have been taken immediately after the accident. (5)
(c) Identify the precautions that might have been taken to prevent the accident. (10)
ER-13
Question 3 A contractor is working on an electrical distribution board and proposes to carry out
live working.
Outline a safe system of work when working on the live electrical distribution board. (10)
ER-14
Question 4 Outline the precautions that should be taken when construction work is to take
place under or near overhead power lines that will remain live during the work. (10)
ER-15
Question 8 Construction work is to take place in a rural area where electrical power for the site
is to be gained from an existing 11kV overhead supply that cuts across the site on wooden
poles.
Outline control measures that should be taken to help reduce risks associated with the:
(a) overhead supply; (8)
(b) supply of electricity on the site. (12)
ER-16
Question 2 Outline suitable control measures that could help reduce electrical risks
from portable electrical equipment associated with tungsten inert gas
(TIG) welding. (10)
ER-17
Question 4 Mobile telescopic lighting towers are to be used on a busy highway to illuminate
roadworks. The towers extend to a height of 9 metres.
22kV electrical power cables cross the highway and are as low as 7.5 metres above ground in
some places.
(a) Outline specific training requirements for workers who are required to move telescopic
lighting towers in the vicinity of the live overhead cables. (3)
(b) Other than training, outline control measures that should be considered when moving
telescopic lighting towers in the vicinity of the live overhead cables. (7)
ER-18
Question 8 A small organisation manufactures products using electro-chemical processes. The
organisation has poor general standards of health and safety, made worse by the presence of
conductive and corrosive fluids and humid, corrosive atmospheres.
(a) Outline the types of fault that may be found in a fixed electrical system under such
conditions. (10)
(b) Outline the technical information that a competent electrician would require before
conducting an inspection of a fixed electrical system. (10)
Question 9 A small company manufactures products using electro-chemical processes. The

company has poor general standards of health and safety, made worse by the presence of
conductive and corrosive fluids and humid, corrosive atmospheres.
(a) Describe the types of fault that may be found under such conditions in a fixed electrical
system. (10)
(b) Outline the technical information a competent electrician would require before conducting
an inspection of a fixed electrical system. (10)
ER-19
Question 6 A competent electrical contractor is being asked to conduct a periodic inspection of
the fixed electrical installation in a large hospital.
Outline the information, relating to the fixed electrical installation, that the hospital will need
to provide for the electrical contractor. (10)
ER-20
Question 5 Direct contact with live parts of an electrical supply within a workplace can result in
serious injury or death.
Outline a range of control measures that may prevent or reduce the effect of such contact. (10)
Question 5 Direct contact with live parts of an electrical supply within a workplace can result in
serious injury or death.
Outline a range of control measures that may prevent or limit the effect of such contact. (10)
ER-21
Question 8 Workers are required to enter a sewer though a vertical shaft. The sewer and shaft
are classed as a confined space.
(a) Give the meaning of the term ‘confined space’. (2)
(b) Outline hazards that the workers could be exposed to when working in the sewer. (10)
(c) Outline what should be considered when developing emergency arrangements that will be
provided during this activity. (8)
Question 2 (a) Give the meaning of the term ‘confined space’. (2)
(b) Outline factors that should be considered in relation to emergency rescue arrangements for
confined space work. (8)
ER-22
Question 7 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 steps that should be considered in order to enter this confined space and to carry
out the work safely. (20)
ER-23
Question 1 A plastics manufacturer stores plastic beads in a tower silo. The plastic beads are
considered to be a free flowing solid.
Workers need to enter the silo to carry out essential maintenance.
(a) Outline the risks to workers from the free flowing solid when entering the confined space.
(4)
(b) Outline reasons that the silo atmosphere may be, or could become, oxygen deficient. (3)
(c) Outline possible effects that oxygen deficiency may have on a confined space worker. (3)
ER-24
Question 1 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. (10)
Question 1 A sewer 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 risks to those entering the sewer. (10)
ER-25
Question 4 Car park entry and exit is controlled by an automatic barrier of the rising arm type
shown below.
The barrier has a control system with sensors, actuators and electronic controllers.
Maintenance is occasionally required due to vehicle impact or storm damage.
(a) Outline mechanical hazards associated with automatic rising arm barriers. (4)
(b) Outline control measures that should be considered to help reduce risk before starting any
maintenance activity on the barrier. (6)
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shown below.
ER-27
shown below.
ER-28
Question 5 An electrical installation on a dairy farm needs replacing.
(a) Outline what may have caused the deterioration of the existing electrical installation. (5)
(b) Outline what should be considered when designing the replacement electrical installation to
help avoid future deterioration. (5)
Question 6 An electrical installation on a dairy farm needs replacing.
(a) Outline what may have caused the deterioration of the existing electrical installation. (5)
(b) Outline what should be considered when designing the replacement electrical installation to
help avoid future deterioration. (5)
Question 4 An existing electrical installation on a dairy farm is to be replaced.
(a) Outline factors likely to have caused the deterioration of the existing electrical installation.
(4)
(b) Outline factors that should be considered when designing the replacement electrical
installation. (6)
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Question 6 Outline what should be considered when developing a planned maintenance
programme for workplace machinery. (10)
Question 6 Outline what should be considered when developing a planned preventive
maintenance programme for safety-critical machinery. (10)
Question 6 Outline what should be considered when developing a planned preventive
maintenance programme for safety-critical machinery. (10)
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Question 5 A motor vehicle repair workshop has installed a new electrically powered,
compressed air system.
Outline the factors to be considered in developing a suitable planned preventative
maintenance programme. (10)
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Question 2 Outline what should be considered when preparing a scheme for the systematic
examination, testing and maintenance of portable electrical appliances. (10)
Question 6 Outline what should be considered when preparing a scheme for the systematic
examination, testing and maintenance of portable electrical appliances. (10)
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Question 6 Outline factors that a competent person would need to take into account when
deciding the frequency of examination of lifting equipment. (10)
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Question 3 A large food processing factory has a range of new and older production machines
of varying conditions.
Identify AND explain the three main maintenance strategies available to the employer. (10)
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Question 11 (a) Organisations may use a range of reactive and proactive strategies for plant
maintenance. Identify FOUR possible plant maintenance strategies AND outline the principles
of EACH strategy. (10)
(b) Outline the factors that you would advise the Engineering Department of an organisation to
take into account in deciding on a maintenance strategy following the installation of an item of
process plant. (10)
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Question 10 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)
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Question 9 The final process in the manufacture of office furniture involves spraying it with
solvent-based paint, in a custom-designed spray room. The solvent has a flash point of 15°C.
Assuming that a risk assessment has been carried out, outline control measures that could help
minimise the associated risk of fire and explosion with this spraying activity. (20)
Question 10 Workers in a vehicle maintenance workshop spray vehicles using a highly
flammable, solvent-based paint.
(a) Outline the factors that would need to be considered when assessing the risks with the
spraying activity. (4)
(b) Outline control measures that could minimise risk with the spraying activity. (16)
Question 7 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. (20)
Question 8 Workers in a vehicle maintenance workshop undertake spray-painting of vehicles

using a solvent based paint that has a low flash point.
Outline the measures to be taken to ensure that the risks associated with the spray-painting
activity are adequately controlled. (20)
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10 A steam boiler is a type of pressure system used in industry where loss of containment can
occur through mechanical failures such as overheating, creep and hydrogen embrittlement.
(a) Outline why a steam boiler is classified as a pressure system. (3)
(b) Identify THREE additional examples of mechanical failure to which a steam boiler is
susceptible AND, in EACH case, outline the mechanism of the identified mechanical failure. (9)
(c) Outline the content of a written scheme of examination form for the boiler. (8)
Question 11 A steam boiler is a type of pressure system used in industry where loss of
containment can occur through mechanical failures such as overheating, creep and hydrogen
embrittlement.
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Question 9 Failure of pressure systems can result in accidents.
(a) Identify workplace examples of pressure systems. (5)
(b) Outline a typical written scheme of examination for pressure systems. (5)
(c) Other than a written scheme of examination and the provision of safe equipment, outline
control measures that could help reduce the risk of pressure system failures. (10)

(a) Identify examples of pressure systems AND give a workplace example in EACH case. (5)
(c) Outline other control measures that could reduce the risk of pressure system failures. (10)

(a) Identify FIVE examples of pressure systems AND give a workplace example in EACH case. (5)
(c) Outline other control measures that could reduce the risk of pressure system failures. (10)
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Question 4 A dental surgery uses a small steam steriliser to disinfect dental instruments. The
steriliser is labelled with a CE mark, and has a written record with it in the form of a logbook.
(a) Outline why the steriliser would be considered a pressure system. (3)
(b) Outline the purpose of the CE mark. (2)
(c) Outline what records need to be contained in the logbook. (5)
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Question 3 A 50 litre compressed air receiver made of welded steel is used in a factory
pneumatic system. It is operating at a nominal pressure of 10 bar/1MPa. During a routine
operation, the compressed air receiver ruptured when the weld running along its length failed.
(a) Outline why the compressed air receiver is classified as a pressure system. (4)
(b) Outline possible technical and procedural causes for the failure of the compressed air
receiver during operation. (6)
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Question 8 A pressurised steam boiler requires an examination. At the same time a repair on an
electrically driven pump, associated with the boiler, is needed.
(a) Give the meaning of the term ‘relevant fluid’ in relation to pressure systems safety. (4)
(b) Outline the typical contents of a written scheme of examination form for the boiler. (8)
(c) Identify the practical measures that should be taken in order to carry out the pump repair
safely. (8)
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Question 11 An organisation operates a multi-storey care home.
(a) Outline what should be considered to help ensure an adequate means of escape in the
event of a fire. (12)
(b) Outline general requirements for fire doors that should be installed in the care home. (8)
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Question 1 A university has several students with a range of physical and mental disabilities. A
fire risk assessment needs to be completed.
(a) Explain why students with a physical or mental disability may be at increased risk. (4)
(b) Identify other categories of people especially at risk. (2)
(c) Outline control measures that may need to be included in a Personal Emergency Evacuation
Plan (PEEP). (4)
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Question 8 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 occupants
based in one area of the building failed to leave the building until a further four minutes had
elapsed.
(a) Outline what may have contributed to the delay in evacuation. (15)
(b) Outline reasons for conducting regular fire drills in workplaces. (5)
Question 11 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 occupants
based in one area of the building failed to leave the building until a further four minutes had
elapsed.
(a) Outline factors that may have contributed to the delay in evacuation. (15)
(b) Outline reasons for conducting regular fire drills in workplaces. (5)
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Question 9 You have been asked to plan an emergency evacuation drill for a large office
building.
Outline factors that should be considered before, during and after the drill to help ensure that
the emergency evacuation is conducted safely. (20)
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Question 7 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 despatch 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)
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Question 7 A conference centre is planning to extend its existing building to incorporate
childcare facilities on the ground floor and additional conference rooms to hire out to local
organisations on the upper floors.
Outline the range of factors that would need to be reviewed following completion of the
planned work to enable the conference centre’s fire risk assessment to be updated. (20)
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Question 7 A container port handles a wide range of ships’ cargo including dangerous
substances that are flammable, explosive and toxic.
Outline the on-site organisational arrangements that the Port Authorities need to make to
prepare for an emergency. (20)
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Question 6 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.
(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. (6)
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Question 7 Vehicles are repaired for the public in a motor vehicle repair workshop. The process
involves mechanical repair, preparation, spray painting and curing. The workshop is situated in
a single-storey building with only one means of escape.
Following a serious fire, the organisation needs to review the fire prevention and fire protection
measures in the workshop.
(a) Outline what should be considered when assessing the adequacy of the existing means of
escape. (12)
(b) Outline what should be considered when assessing the adequacy of the existing fire
detection and alarm systems. (8)
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Question 7 For a large supermarket with restaurant facilities:
(a) outline automatic fire protection systems that should be in place. (6)
(b) outline what should be considered when developing a safe means of escape for the
supermarket. (14)

(a) outline automatic fire protection systems that should be in place; (6)
(b) outline factors that should be considered when developing a safe means of escape for the
supermarket. (14)

(a) outline the automatic fire protection systems that should be in place; (6)
(b) outline the factors to be considered when developing a safe means of escape for the
supermarket. (14)
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Question 3 (a) In relation to automatic fire detection and alarm systems, outline the basic
principle AND operation of:
(i) heat detectors; (4)
(ii) smoke detectors. (4)
(b) Identify the circumstances in which EACH type of detector would be inappropriate. (2)
principle AND operation of:
principles of operation of:
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Question 6 A fire protection contractor has recommended the provision of portable water and
carbon dioxide fire extinguishers to be placed in a multi-storey office block.
(a) Identify the class of fire that the water extinguisher is designed for AND give an example of
a material that is included in this class. (2)
(b) Outline advantages of a carbon dioxide extinguisher. (2)
(c) Outline what should be considered in siting the extinguishers. (6)
Question 6 A fire protection contractor has recommended the provision of portable water and
carbon dioxide fire extinguishers to be placed in a multi-storey office block.
(a) Identify the class of fire that the water extinguisher is designed for AND give an example of
a material that is included in this class. (2)
(c) Outline factors to be considered in siting the extinguishers. (6)
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Question 5 Slips are a common cause of workplace accidents.
(a) Outline what contributes to slip accidents at work. (6)
(b) Explain TWO tests for measuring the slip resistance of surfaces. (4)
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Question 6 (a) Explain how features of floor design can help reduce the risk of slipping. (5)
(b) Explain how the coefficient of friction (CoF) is used in workplace floor design. (5)
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Question 2 (a) Identify features of floor design that may help to reduce the risk of slipping. (4)
(b) Outline THREE methods of reducing the slip potential of the floor in use AND give reasons
why EACH method would be effective. (6)
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Question 1 An airline has noticed a significant increase in the number of slips and trips
experienced by airline workers while boarding and leaving aircraft. These incidents have
occurred both inside the aircraft and on the metal steps leading to the aircraft.
(a) Outline possible reasons for an increase in the number of slip and trip incidents. (5)
(b) Outline practical ways in which the airline could reduce the risk of slips and trips to the
airline workers. (5)
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Question 7 A rainwater gutter at a height of five metres is leaking.
Explain how you would apply the work at height hierarchy of control to the repair of the gutter.
(20)
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Question 7 A number of lights in a storage warehouse have failed and need replacing. The lights
are at a height of 5 metres.
Outline what should be taken into consideration when replacing the lights to help reduce the
risk of work at height. (20)
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Question 2 Ladders are often the most practical solution to working at height for short
durations.
(a) Outline the hazards associated with working from ladders. (2)
(b) Outline control measures that minimise risk when working from ladders. (8)
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Question 10 The International Labour Organisation’s Standard R175 and its associated Code of
Practice sets out general principles for ‘Safety and Health in Construction’.Minor repairs need
to be carried out to the sloping roof of a large twostorey property. A scaffold is to be erected in
order to gain access to the work area. Using the guidance in R175, outline the precautions
necessary for carrying out the repairs. (20)
Question 10 The International Labour Organisation’s Standard R175 and its associated Code of
Practice sets out general principles for ‘Safety and
Health in Construction’. Minor repairs need to be carried out to the sloping roof of a large two
storey property. A scaffold is to be erected in order to gain access to the work area. Using the
guidance in R175, outline the precautions necessary for carrying out the repairs. (20)
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Question 11 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 material that may contribute to the risk of falls
through the roof. (5)
(b) Outline the measures to be taken to reduce the risk to those involved in the roof work and
those who may be affected by it. (15)
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Question 4 A scaffolder is lowering scaffold poles from the third floor of a scaffold tower to a
colleague below using a pulley wheel and rope. Next to the scaffold tower there is a shop
entrance. The scaffolder on the ground floor places the scaffold poles horizontally onto the
back of a vehicle parked on a busy road. The scaffolders have already received information,
instruction, training and suitable supervision.
Outline additional control measures that could help reduce the risk of injury to those who may
be affected by this activity. (10)
Outline the additional practical measures that could minimise the risk of injury to the
scaffolders and others who may be affected by this activity. (10)
Outline the additional practical measures that could minimise the risk of injury to the
scaffolders and members of the public during this activity. (10)
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Question 9 An independent scaffold is to be used as a working platform to carry out repairs to a
two-storey building.
(a) Outline factors that should be considered in order to confirm that the scaffold is safe to use.
(15)
(b) Identify the inspection requirements for the scaffold. (5)
Question 9 An independent scaffold is to be used as a working platform to carry out repairs to a
two-storey building.
(a) Outline factors which should be considered in order to confirm that the scaffold is safe to
use. (15)
(b) Identify the inspection requirements for the scaffold. (5)
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Question 7 You are the Safety Advisor to a company that installs satellite dishes. The dishes
need to be secured to the external walls of buildings and this involves work at height. Due to
limited access around these buildings and the typical heights involved (3 to 5 metres) ladders
are the only practicable way of carrying out the work. Workers are on their own when carrying
out the work.
(a) Describe the safety precautions that could reduce the risk of falls from height when using
ladders. (14)
(b) Outline the emergency procedures you would implement in the event of accident or illness
for this type of lone working. (6)
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Question 1 An organisation provides an overnight security guard service.
The duties of the security guard include locking the building at night, patrolling the perimeter,
conducting visual checks during the night and unlocking again in the morning.
(a) Explain why the security guard is at greater risk of harm as a lone worker in these
circumstances. (3)
(b) Outline what the organisation could provide to minimise the lone working risks of the
security guard. (7)
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Question 2 A lone worker is using a pallet truck to move pallets of frozen food products in a low
temperature store. The temperature of the store is controlled at -5˚ Celsius.
Outline control measures to help the worker escape if they are accidentally locked into this low
temperature store. (10)
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Question 8 (a) Outline hazards from the use of a scissor lift. (12)
(b) Outline control measures that would help protect members of the public when operating a
scissor lift in a supermarket during opening hours. (8)
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Question 1 (a) Identify the hazards associated with the use of mobile elevating work platforms
(MEWPs). (5)
(b) Outline the control measures that should be taken when using MEWPs. (5)
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Question 9 A storeroom is to be built for the storage of bulk stocks of palletised containers of
highly flammable paints and thinners.
(a) Outline what should be considered when designing and constructing the storeroom. (10)
(b) Outline what should be considered in the use of the storeroom. (10)
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Question 11 Outline the factors to consider with respect to the design, construction and use of
a storeroom that is to be used for the storage of bulk stocks of palletised containers of highly
flamm
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Question 9 An organisation is proposing to build a store room for stocks of flammable paints.
Outline factors to consider in the design, construction and use of the store room. (20)
able paints and thinners. (20)
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Question 8 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.
Outline the safety provisions required for:
(a) the design; (10)
(b) the operation; (6)
(c) the maintenance of the proposed storage facility. (4)
Question 10 As part of its water treatment system, a manufacturer is to install a plant suitable
for the reception and storage of a strong acid and a strong alkali, both of which will be
delivered in bulk tankers.
Outline the safety provisions required for the design, operation and maintenance of the
proposed plant. (20)
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Question 7 A golf course management team proposes to store 3.6 tonnes of a chemical
fertiliser, which is an oxidising substance, in a single-storey building. The chemical fertiliser is
delivered to the golf course in bags known as flexible intermediate bulk containers (FIBCs). Each
bag contains 600kg of chemical fertiliser.
(a) Outline properties of an oxidising substance. (3)
(b) Outline the effects of oxidising substances on fire and explosion mechanisms. (4)
(c) Other than fire and explosion, outline risks when storing the chemical fertiliser. (3)
(d) Outline principles of safe intermediate storage of chemical fertiliser in the single-storey
building. (10)
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Question 10 (a) Outline the effects of a fire in a workplace on the following structural
materials:
(i) steel; (4)
(ii) concrete; (4)
(iii) wood. (4)
(b) Outline precautions that could be taken to prevent failure of these materials in the event of
a fire. (8)
Question 7 (a) Describe the effects of a fire in a workplace on the following structural materials:
(i) steel; (4)
(ii) concrete; (4)
(iii) wood. (4)
(b) Outline the precautions that could be taken to prevent failure of these materials in the
event of fire. (8)
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Question 1 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; (3)
(ii) metal; (3)
(iii) plastic. (3)
(b) Identify which of these window frame materials gives the best overall fire resistance. (1)
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Question 1 (a) Outline structural features that protect a building from the spread of fire. (8)
(b) Outline the behaviour of plastics in the event of a fire. (2)
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Question 11 An external lift on a construction site has an interlocked guard to prevent the lift
operating when the gate is open. With reference to the diagram below:
(a) identify the two types of switch shown (Switch A and Switch
B); (2)
(b) identify the functional components associated with BOTH switches; (4)
(c) outline the normal sequence of operation for the electrically-operated, cam-activated
switch assembly when the gate opens and closes; (6)
(d) outline ways in which electrically-operated, cam-activated switches may fail to operate as
intended. (8)
operating when the gate is open. With reference to the diagram:
(a) identify the two types of switch shown (Switch A AND Switch B); (2)
(c) outline the normal sequence of operation for the electrically operated, cam-activated switch
assembly when the gate opens and closes; (6)
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intended. (8)
operating when the gate is open. With reference to the diagram below:
(a) identify the two types of switch shown (Switch A and Switch
B); (2)
(c) outline the normal sequence of operation for the electrically-operated, cam-activated
switch assembly when the gate opens and closes; (6)
intended. (8)
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Question 1 (a) Outline TWO zone classifications for explosive atmospheres with a flammable
solvent in air. (4)
(b) Outline control measures to help reduce the risk of an explosion with a flammable solvent in
air. (6)
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Question 2 The designers of a large item of machinery are intending to include an access
opening in the side of the machine to allow an operator to reach inside with a single arm to
manually open a drain valve. Outline ergonomic factors that would influence the design of the
access opening. (10)
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Question 3 An office building has a passenger lift to transport office workers between floors.
(a) Outline hazards associated with using passenger lifts in the office building. (5)
(b) Outline control measures to help reduce risks to passengers when using lifts in the office
building. (5)
Question 4 (a) Outline hazards associated with using passenger lifts in the workplace. (5)
(b) Outline control measures to help reduce risks to passengers when using lifts in the
workplace. (5)
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Question 5 Large quantities of aerosol canisters are stored in a warehouse. The canisters
contain liquefied highly flammable gases.
(a) Outline what could cause a fire and explosion in these circumstances. (5)
(b) Outline fire precautions that could be taken to limit the spread of any resulting fire and
explosion. (5)
Question 5 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, etc.
(a) Describe how a fire and explosion may occur when large quantities of these canisters are
stored in a commercial warehouse. (5)
(b) Outline the fire precautions that could be taken to limit the spread of any resulting fire and
explosion in such a warehouse. (5)
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Question 9 Workers are using lathes to make metal components.
(a) Identify FIVE types of mechanical hazard associated with lathes AND give a practical
example of EACH. (10)
(b) Outline control measures that help reduce risks associated with lathes. (10)
Candidates only need to relate answers to lathes and not computer numerically controlled
(CNC) lathes.
Question 9 Workers are using lathes to make metal components.
(a) Identify FIVE types of mechanical hazard associated with lathes AND give a practical
(b) Outline control measures that help reduce risks associated with lathes. (10)
Candidates only need to relate answers to lathes and not computer numerically controlled
(CNC) lathe
Question 10 Metal components are being manufactured by workers using metal turning lathes.
(a) Identify FIVE types of mechanical hazard associated with metal turning lathes AND give a
practical example of EACH. (10)
(b) Outline control measures that minimise risks associated with metal turning lathes. (10)
s.
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Question 10 A wood turning lathe is used to machine components.
(a) Identify mechanical and non-mechanical hazards of wood turning lathes AND, in EACH case,
give an example of the identified hazard. (12)
(b) The lathe is to be upgraded to a Computer Numerical Control (CNC) machine. The new CNC
machine has an enclosure to prevent access to the machining area.
(i) Outline the key features of the enclosure of the CNC machine. (5)
(ii) Outline why access to the machining area might be required. (3)
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Question 8 An airport has an automated baggage handling system. A part of the system is a
series of large vertical storage racks, where baggage is placed on to trays. These trays are then
put on and taken off the racking by baggage handling robots.
(a) (i) Identify FOUR principles of safety integration. (4)
(ii) Outline how principles of safety integration could apply to the robots. (4)
(b) Outline key features for the baggage handling robots to operate safely. (12)
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Question 1 Members of the public have been injured when collecting baggage from a baggage
conveyor at an airport.
(a) Identify typical mechanical hazards when the conveyor is in use. (4)
(b) Outline control measures that should be in place to reduce the risk of injury from the
mechanical hazards. (6)
(b) Outline the control measures that should be in place to reduce the risk of injury from the
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Question 9 (a) Outline the features of industrial robots that may have particular implications
for safety. (6)
(b) Outline how the risk of injury to personnel working with, or in the vicinity of, industrial
robots might be minimised. (14)
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Question 3 In order to install a large item of machinery such as a turbine rotor it is sometimes
necessary to perform adjustments while the rotor is in motion. These adjustments are
necessarily undertaken with the rotor in an unguarded condition.
Outline the elements of a safe system for such work. (10)
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Question 10 Construction work is due to take place to repair the footpath of a single
carriageway road. The road is near to a busy school in a residential area. Trucks and buses use
the road occasionally.
Outline control measures that should be put in place to help ensure the safety of members of
the public. (20)
Question 10 Construction work is due to take place to repair the footpath of a single
carriageway road. The road is near to a busy school in a residential area. Trucks and buses use
the road occasionally.
Outline control measures that should be put in place to help ensure the safety of members of
the public. (20)
Question 9 Construction work is due to take place to repair the footpath of a single carriageway
road. The road is near to a busy school in a residential area. Lorries and buses use the road
occasionally.
Outline control measures that you would put in place to help ensure the safety of members of
the public. (20)
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Question 11 A truck-mounted crane delivers bulk materials to a construction site. The materials
are stored in flexible one-tonne bags. The crane is operated from the ground with a pendant
controller.
Outline control measures for safe delivery of bulk materials using this crane. (20)
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Question 7 A mobile crane is to be used to erect a new telecommunications aerial on the roof
of a three-storey office building.
Outline precautions that should be taken to help reduce risks to anyone at ground level who
may be affected by the operation. (20)
Question 10 A mobile crane is to be used to erect a new telecommunications aerial on the roof
of a three-storey office building.
Outline precautions that should be taken to help reduce risks to anyone at ground level who
may be affected by the operation. (20)
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Question 11 As a Health and Safety Officer you are asked to give advice to a lift supervisor
regarding a proposed lifting operation. The lift requires the use of two cranes working together
(a tandem lift).
Outline the elements of a safe system of work that you would expect to see in order that the
lift may be conducted safely. (20)
Question 8 An organisation is planning to carry out a lift that requires the use of two cranes
working together (a tandem lift).
Outline elements of a safe system of work in order to carry out the lift safely. (20)
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Question 1 During a construction project, a number of different types of crane will be necessary
to carry out mechanical lifting operations.
Outline factors that would need to be considered when selecting cranes that are suitable for
the required lifting operations. (10)
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Question 2 A battery-powered lift truck is being used in a potentially flammable atmosphere.
(a) Outline sources of ignition from the battery-powered lift truck. (4)
(b) Outline the protection that should be applied to the battery-powered lift truck to help
minimise the risk of an explosion. (6)
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Question 6 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. (4)
(b) Outline the protection that should be applied to the engine to minimise the risk of an
explosion. (6)
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Question 2 An employer provides a multi-storey car park for its workers. The car park is made
of steel-reinforced concrete.
Following several major fires at similar car parks, a review is being conducted of the fire safety
arrangements.
(a) Outline ignition sources that could be present from the cars. (3)
(b) Outline combustible materials that could be present from the cars. (3)
(c) In the event of a serious fire, outline possible effects of fire on the building structure. (4)
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Question 5 An organisation uses a powered guillotine to trim paper to the correct size.
Outline control measures that can be taken to help minimise risk when operating the guillotine.
(10)
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Question 9 In relation to dust explosions:
(a) outline the conditions that must be present for a primary dust explosion to occur; (4)
(b) outline the additional conditions necessary for secondary explosions to occur; (4)
(c) identify FOUR factors that may affect the reliability of a nitrogen inerting system used in a
powdered aluminium process; (4)
(d) identify the design features that would minimise the likelihood and effect of a dust
explosion. (8)

(c) identify FOUR key features of a nitrogen inerting system used in a chemical process; (4)
(d) other than a nitrogen inerting system outline design features that would minimise the risk
of a dust explosion. (8)

(a) outline conditions that must be present for a primary dust explosion to occur; (4)
(b) outline additional conditions necessary for secondary explosions to occur; (4)
(c) identify FOUR key features of a nitrogen inerting system; (4)
(d) other than a nitrogen inerting system, outline design features that would minimise the risk
of a dust explosion. (8)
Question 9 (a) Outline conditions that must be present for a primary dust explosion to occur.
(5)
(b) Outline additional conditions necessary for secondary explosions to occur. (5)
(c) Outline design features that would minimise the likelihood and effect of a dust explosion.
(10)
ER-101
Question 4 A disused chemical process plant is to be demolished to allow for the development
of a large sports stadium.
Outline what should be considered in a pre-demolition survey for the site. (10)
ER-102
Question 5 The control of risk when using work equipment relies on having trained and
competent workers who are appropriately supervised.
(a) Explain the differences between training and competence. (4)
(b) A worker is being transferred to an unfamiliar machine.
Outline training that might be required. (3)
(c) Explain the relationship between competence and supervision. (3)
Question 4 The control of risk when using work equipment relies on having trained and
competent workers who are appropriately supervised.
(a) Explain the differences between training AND competence. (4)
(b) Outline circumstances when training is likely to be required. (3)
(c) Explain the relationship between competence AND supervision. (3)
ER-103
Question 11 On construction sites, outline the roles and responsibilities of the:
(a) principal contractor; (6)
(b) designer; (4)
(c) contractors; (5)
(d) client. (5)
ER-104
Question 1 (a) Outline specific occasions when the operation of safety interlock
switches should be tested. (5)
(b) Outline suitable features of safety interlock switches that would help to ensure effective
operation. (5)
ER-105
Question 3 (a) Outline the principles of an interlocked machine guard. (4)
(b) Outline the principles of operation of trapped key control systems. (6)
ER-106
Question 11 Construction workers need to use a range of unpowered hand tools.
(a) Outline the criteria for the selection of hand tools for construction tasks. (10)
(b) Outline how risks to health and safety in construction, from the use of hand tools, are
controlled. (10)
ER-107
Question 8 Following a number of driving at work incidents, an organisation decides to
implement driver assessment and training.
(a) Outline what may help determine which workers need training. (8)
(b) Outline contents of a typical driver training programme. (12)
ER-108
Question 10 (a) Outline the causes of instability in a forklift truck (FLT). (8)
(b) Outline the content of a training programme for FLT drivers who are to operate a variety of
forklift trucks. (9)
(c) Identify THREE situations in which refresher training for FLT drivers would be appropriate.
(3)
Question 11 (a) Outline the causes of instability in forklift trucks (FLTs). (8)
(b) Outline the content of a training programme for FLT operators who are to operate a variety
of forklift trucks. (9)
(c) Identify THREE situations in which refresher training for forklift truck drivers would be
appropriate. (3)
Question 11 A road tanker is to be filled with petroleum (gasoline) at an installation.

(a) Identify FOUR hazards associated with this operation. (4)
(b) Describe how a vapour cloud explosion could be generated in this situation. (4)
(c) Outline practical ways of minimising the risk of an electrostatic charge. (4)
(d) Outline control measures that could reduce risks with road tanker filling. (8)
Question 9 A road tanker is to be filled with petroleum (gasoline) at an installation.

(a) Identify hazards associated with this operation. (4)
(b) Outline how a vapour cloud explosion could be generated in this situation. (8)
(c) Outline control measures that could reduce risks with road tanker filling. (8)
Question 4 The transfer of an extremely flammable liquid from a bulk storage tank to a road
tanker may generate static electricity.
Outline the control measures which would reduce the risk of ignition of the extremely
flammable liquid vapour due to static electricity. (10)
Question 5 The transfer of an extremely flammable liquid from a bulk storage tank to
a road tanker may generate static electricity.
Outline control measures that could reduce the risk of ignition of the extremely flammable
liquid vapour due to static electricity. (10)
ER-109
Question 2 (a) Analysis of system failure methods can be reductionist or holistic.
Give the meaning of the following terms:
(i) reductionist; (2)
(ii) holistic. (2)
(b) Reliability calculations depend on having robust reliability data.
Outline typical sources of reliability data. (6)
ER-110
Question 5 (a) Outline the principles of a vapour cloud explosion AND give an example of a
major incident associated with a vapour cloud explosion. (8)
(b) Outline the effects of a vapour cloud explosion. (2)
Question 4 (a) Outline the principles of a vapour cloud explosion AND give an example of a
major incident associated with a vapour cloud explosion. (8)
Question 5 With examples of actual incidents, describe the principles and effects of a vapour
cloud explosion. (10)
Question 2 (a) Outline the principles of a Boiling Liquid Expanding Vapour

Explosion (BLEVE) AND give examples of actual incidents to support your answer. (8)
(b) Outline the effects of a BLEVE. (2)
ER-111
Question 11 In November 1984 the San Juanico gas storage facility near Mexico City exploded
with catastrophic consequences.
(a) Outline the circumstances of the disaster. (8)
(b) Outline how a Boiling Liquid Expanding Vapour Cloud Explosion (BLEVE) occurs with a gas
storage vessel constructed of metal. (8)
(c) Outline the immediate rescue and restoration measures that took place. (4)
ER-112
Question 11 A new log splitting machine has been purchased for timber to be processed in a
sawmill. The machine operates as a hydraulic press with a moving vertical wedge that splits
wooden logs (see diagram below). The machine has been purchased from within the European
Union (EU) and comes with a Declaration of Conformity Certificate and an operator’s handbook.
The moving vertical wedge operates by means of a two-handed control of a hold-to-run type.
(a) Outline information that should be contained in the Declaration of Conformity Certificate.
(6)
(b) Describe how the operator is protected while the machine is working. (7)
(c) Describe warning signs associated with the machine. (7)
ER-113
Question 5 Unless appropriate precautions are taken, chemical reactions in a batch
manufacturing process can give rise to conditions that can lead to a ‘runaway reaction’.
(a) Outline what is meant by ‘runaway reaction’. (2)
(b) Identify conditions that may give rise to such an event. (4)
(c) Outline the design and operational features of chemical processes that are necessary to
prevent such an event. (4)
Question 1 Chemical reactions in a batch manufacturing process can lead to conditions which
can cause a ‘runaway reaction’ unless appropriate precautions are taken.
(a) Describe what is meant by ‘runaway reaction’
AND identify the conditions that may give rise to such an event. (6)
(b) Outline methods of control of industrial chemical processes necessary to prevent or
mitigate runaway reactions. (4)
ER-114
Question 2 With the aid of labelled sketches, outline the characteristic features of, and factors
that promote, the following types of materials failure:
(a) brittle failure; (5)
(b) ductile failure. (5)
Question 4 Outline the characteristic features of, and factors that promote, the following types
of materials failure:
(a) brittle fracture; (5)
(b) ductile failure. (5)
Question 6 (a) Explain how metal fatigue occurs. (4)
(b) Outline factors that can promote the following types of material failure:
(i) brittle fracture; (3)
(ii) ductile failure. (3)
ER-115
Question 9 Materials can fail through various modes.
(a) Outline the meaning of ‘metal fatigue’. (6)
(b) Identify TWO factors which can contribute to such a failure AND, for EACH factor, outline
ONE circumstance in which it may occur. (4)
(c) Outline:
(i) the characteristics of electrolytic corrosion; (5)
(ii) factors which cause electrolytic corrosion. (5)
Question 9 Materials can fail through various modes.
(a) Outline the meaning of ‘metal fatigue’. (6)
(b) Identify TWO factors which can contribute to such a failure AND, for EACH factor, outline
ONE circumstance in which it may occur. (4)
(c) Outline:
(i) the characteristics of electrolytic corrosion; (5)
(ii) factors which cause electrolytic corrosion. (5)
Question 9 Corrosion is a major problem in many industrial processes.
(a) Outline the characteristics and causal factors of electrolytic corrosion. (8)
(b) Outline the strategies AND methods for identifying potential corrosion failures. (12)
ER-116
Question 3 Welded joints within safety critical pipework can be inspected by nondestructive
testing (NDT) methods.
Outline the principles of operation AND the advantages and disadvantages of:
(a) magnetic particle inspection; (5)
(b) ultrasonics. (5)
Question 4 (a) Outline the purpose of non-destructive testing (NDT) on items of plant. (2)
(b) Outline the principles, benefits and limitations of the following
NDT techniques:
(i) dye penetrant; (4)
(ii) radiography. (4)
ER-117
Question 7 A rectangular, steel-framed warehouse, measuring 40m x 100m and 18m high was
severely damaged in a storm. One of the long coated steel walls suffered catastrophic failure,
which in turn caused the flat roof of the warehouse to collapse and the other coated steel walls
to buckle.
(a) Outline the possible causes of this structural failure. (5)
(b) Outline the health and safety issues to be considered when planning the subsequent
demolition of the damaged warehouse. (15)
ER-118
Question 5 The 1963 International Labour Organisation’s Convention 119 (C119) concerns the
Guarding of Machinery. Part 1 considers general provisions; Part 2 concerns the sale, hire,
transfer and exhibition of machinery and Part 3 the use of machinery.
(a) Outline categories of machinery covered by Part 1 of the convention. (3)
(b) Give examples of transmission machinery (exposed moving parts) specified in Part 2. (2)
(c) Outline requirements for the use of machinery as specified in Part 3. (5)
ER-119
Question 3 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).
(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. (4)
ER-120
Question 5 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. (10)
Question 3 Coal is delivered by train to a power station and is transported by 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. (10)
ER-121
Question 6 A large manufacturing company wants to minimise its emission of greenhouse
gases.
Identify the activities of the company that may lead to the release of greenhouse gas emissions
into the atmosphere. (10)
ER-122
Question 8 (a) Outline the possible health and safety effects of inadequate workplace lighting.
(4)
(b) Outline the factors that should be considered to ensure that lighting in a workplace is
adequate. (16)
ER-123
Question 3 Outline the issues that should be included in a fire safety training session for
workers. (10)
employees. (10)
workers. (10)
ER-124
Question 7 Outline the advantages and limitations of the following types of fall protection
devices AND give an example where EACH could be used:
(a) safety harnesses; (5)
(b) safety belts; (5)
(c) safety nets; (5)
(d) air bags. (5)
Question 7 Outline the advantages and limitations of the following types of fall protection
devices, giving a suitable application for each:
(a) safety harnesses; (5)
(b) safety belts; (5)
(c) safety nets; (5)
(d) air bags. (5)
ER-125
Question 4 Environmental pollution is a major concern in many industrial processes.
A number of alternative strategies are available to organisations to manage these risks.
Give the meaning of:
(a) Integrated Pollution Prevention and Control (IPPC); (4)
(b) Best Practicable Environmental Option (BPEO); (3)
(c) Best Available Techniques (BAT). (3)
ER-126
Question 2 A vegetable packing plant employing 200 men and 60 women is about to open. The
plant will operate 24 hours a day on a three-shift system.
Outline the specific welfare arrangements that will be necessary prior to the factory opening.
(10)
ER-127
Question 5 A company produces waste in the form of a hazardous sludge and is concerned
about the increasing cost of using an approved contractor to dispose of the waste at a landfill
site.
Outline FIVE options that the company could consider to reduce the cost and environmental
impact of dealing with the waste. (10)
ER-128
Question 1 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 to
the initial explosion. (6)
ER-129
Question 4 (a) Outline the features of a ‘fixed guard’ in relation to machinery safety. (2)
(b) Outline the factors to be considered in the design and use of fixed guards that minimise
risks to workers. (8)
ER-130
Question 6 A worker suspended in a fall protection harness is at risk of suffering from
suspension trauma with the potential for serious injury or death.
Outline the precautions an employer could take to reduce the risks to the worker in this
ER-131
Question 4 The residents of a village have recently been affected by a fallout of dust on their cars and
property. They allege that the dust came from cement works situated a few miles away.
Outline the steps that should be taken by those responsible for the cement works in order to
investigate whether emissions from the works are the cause of the problem. (10)
ER-132
Question 2.The inside of a chemical mixing vessel is to undergo minor repairs by an operative
entering the vessel via an access hatch. Outline the measures that should be in place to ensure
that:
a) The vessel is safe to enter without the use of breathing apparatus
b) The operative can be rescued safely in an emergency (10) PDF2
PDF2 1
Question 3.With examples of actual incidents, describe the principles and effects of:
a) A boiling liquid expanding vapour explosion; and
b) A vapour cloud explosion. (10) PDF2
PDF2 1
Question 4.Describe the principles and the effects of a boiling liquid expanding vapour
explosion (BLEVE).
Give examples of actual incidents to illustrate your answer. (10) PDF2
PDF2 1
Question 5.Outline the precautions required when storing liquefied petroleum gas (LPG) in
cylinders (10) PDF2
PDF2 1
Question 6.a) Explain the purpose of non-destructive testing (NDT) on items of plant.
b) Other than visual inspection, outline the principles, advantages and disadvantages of TWO
NDT techniques. (10) PDF2
PDF2 1
Question 7.Describe the non-destructive testing techniques that could be used to test the
integrity of welded joints in a large pressure vessel, identifying the advantages and limitations
of each technique.
Outline the purpose of non-destructive testing (NDT) on items of plant. (10) PDF2
PDF2 1
Question 8.A new design of hydraulic press is intended for use within the European Economic
Area. Outline the 'essential health and safety requirements' that you would expect to have
been addressed in the technical file for the machine in order to demonstrate that it is in fact
safe(10) PDF2
PDF2 1
Question 9.Most national legislation specifies fixed intervals between thorough examinations
of lifting equipment and also includes an option for thorough examination to be carried out in
accordance with an 'examination scheme'.
Outline the factors that a competent person would need to take into account when deciding
whether less frequent examinations might be justified, identifying the documents that would
be needed for such an exercise. (10) PDF2
PDF2 1
Question 10.Outline the health and safety issues which should be identified during a lighting
audit of a factory which includes production, maintenance workshops and offices. (10) PDF2
PDF2 1
Question 11. (a) Outline the factors other than legislation that may have influenced the decline
in the number of power press accidents over the last 40 years. (10) PDF2
PDF2 1
Question 12.With reference to the mechanical hazards associated with the operation of a
hydraulic robotic arm on a production line, outline a range of measures aimed at minimising
the risk of injury. (10) PDF2
PDF2 1
Question 13.State the factors to consider when selecting and assessing the suitability of lifting
tackle to be used with a crane in a lining operation. (10) PDF2
PDF2 1
Question 14.Maintenance work on electrical distribution panels and control circuitry commonly
involves diagnostic testing and fault finding on live systems.
Outline the conditions that must be met, and the safety measures that should be in place,
before this type of work is undertaken. (20) PDF2
PDF2 1
Question 15.You are still at the college answering students’ questions on health and safety.
You have now asked for the last question of the session, and it proves to be an awkward one:
Which five categories of individuals are main duty holders under the UK Construction (Design
and Management) Regulations 2007, and Outline the answer you would give. (10) PDF2
PDF2 1
Question 16. (a) Outline the duties of designers when considering significant construction
projects (5)
(b) Explain the importance of the designer’s role to health and safety (5) PDF2
PDF2 1
Question 17.Describe the broad legal and practical requirements relating to the provision of
welfare and first-aid facilities on a civil engineering site where the work involves excavation of
contaminated land and on which a large number of persons will be working. (10) PDF2
PDF2 1
Question 18.Outline the health and safety issues to be considered when planning the
demolition of a two-storey detached house in a street of occupied houses. (10) PDF2
PDF2 1
Question 1 (a) Outline the principles of a vapour cloud explosion AND give an example of a major
incident associated with a vapour cloud explosion. (8)
EX IC 1
Question 2
A fire protection contractor has recommended the provision of portable water and carbon dioxide fire
extinguishers to be placed in a multi-storey office block.
(a) Identify the class of fire that the water extinguisher is designed for AND give an example of a
material that is included in this class. (2)
(c) Outline what should be considered in siting the extinguishers. (6)
EX IC 2
Question 3 Chemical reactions in a batch manufacturing process can lead to conditions which can
cause a ‘runaway reaction’ unless appropriate precautions are taken.
(a) Describe what is meant by ‘runaway reaction’ AND identify the conditions that may give rise to
such an event. (6)
(b) Outline methods of control of industrial chemical processes necessary to prevent or mitigate
runaway reactions. (4)
EX IC 3
(b) Outline the control measures that should be in place to reduce the risk of injury from the
EX IC 4
Question 5
(a) Outline TWO zone classifications for explosive atmospheres with a flammable solvent in air. (4)
(b) Outline control measures to help reduce the risk of an explosion with a flammable solvent in air. (6)
EX IC 5
(c) identify FOUR factors that may affect the reliability of a nitrogen inerting system used in a
powdered aluminium process; (4)
EX IC 6
Question 7 Vehicles are repaired for the public in a motor vehicle repair workshop. The process
involves mechanical repair, preparation, spray painting and curing. The workshop is situated in a single-
storey building with only one means of escape.
Following a serious fire, the organisation needs to review the fire prevention and fire protection
measures in the workshop.
(a) Outline what should be considered when assessing the adequacy of the existing means of escape.
(12)
(b) Outline what should be considered when assessing the adequacy of the existing fire detection and
alarm systems. (8)
EX IC 7
Question 8. A road tanker is to be filled with petroleum (gasoline) at an installation.
(a) Identify hazards associated with this operation. (4)
(b) Outline how a vapour cloud explosion could be generated in this situation. (8)
(c) Outline control measures that could reduce risks with road tanker filling. (8)
EX IC 8
Question 9. A steam boiler is a type of pressure system used in industry where loss of containment can
occur through mechanical failures such as overheating, creep and hydrogen embrittlement.
EX IC 9
Question 10 Metal components are being manufactured by workers using metal turning lathes.
(a) Identify FIVE types of mechanical hazard associated with metal turning lathes AND give a practical
(b) Outline control measures that minimise risks associated with metal turning lathes. (10)
EX IC 10
Question 11 With respect to an electricity supply operating at 240v:
(a) outline the factors that determine the severity of the effects of an electric shock. (6)
(b) for EACH of the following protective devices outline their principles of operation:
(i) residual current devices; (3)
(ii) fuses; (3)
(iii) 110v centre tapped to earth reduced voltage systems. (3)
(c) Outline other design features of electrical systems intended to improve safety. (5)
EX IC 11

Working at Height Scenario (10) AS

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Question.

Question 9 A small company manufactures products using electro-chemical processes. The

Question 7 Workers in a vehicle maintenance workshop spray-paint vehicles using a highly

Question 8 Workers in a vehicle maintenance workshop undertake spray-painting of vehicles

Question 11 Failure of pressure systems can result in accidents.

Question 10 Failure of pressure systems can result in accidents.

Question 7 For a large supermarket with restaurant facilities:

Question 7 For a large supermarket with restaurant facilities:

Question 10 In relation to dust explosions:

Question 11 In relation to dust explosions:

Question 11 A road tanker is to be filled with petroleum (gasoline) at an installation.

Question 9 A road tanker is to be filled with petroleum (gasoline) at an installation.

Question 2 (a) Outline the principles of a Boiling Liquid Expanding Vapour

Question 3 Coal is delivered by train to a power station and is transported by conveyors to a

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