B

With the aid of labelled sketches, outline the characteristic features of, and factors that promote the
following types of materials failure:
Brittle failure; (5)
Ductile failure. (5)
A brittle failure generally occurs without warning or prior evidence of distress. It is a crystalline structure failure with
minimal plastic or elastic deformation. There are generally characteristic “chevron” marks from the point of initiation
and the failure is sudden from rapid stress loading. The factors promoting a brittle fracture are high tensile stresses,
residual or locked in stresses, sudden loading which does not give the material time to deform plastically, case
hardening, low temperatures and the degree of brittleness of the material.
A ductile failure generally has a smooth fracture surface with plastic deformation of the material before final
fracture. There is evidence of necking and the final fracture is often brittle because there is insufficient material left to
sustain a load. This type of failure generally occurs as the result of a single stress overload though other promoting
factors include high temperatures, cold work hardening and the plasticity of the material.

B
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.
(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)
As for the events that could have led to an explosion, since a valve on the water column was found to be closed the
column would give a false reading. The actual water level would fall as steam was drawn on demand, the crown
would become exposed, and heat transfer in that area would be ineffective and a localised heat build-up would take
place. The crown would start to yield as a result of internal pressure and a ductile failure followed by a rupture would
occur. There would be a loss of containment with an instantaneous change from water to steam and an explosion as
stored energy was released.
There was a lack of understanding of the possible sequence of events and of the failure modes involved. the
consequences of a reduced water level and wrote about boiler tubes, reaction vessels and flammable vapours with
the occasional suggestion that a BLEVE had occurred.
(b) safety features such as pressure and temperature indicators, a pressure relief valve, a low water level
alarm, a bursting disc or fusible plug, and an automatic control system incorporating a fuel cut-off.

B
(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.
(a) The main methods of avoiding the build-up of static electricity. These would have included: controlling the pump
rate and transfer speed; earthing and bonding the pipeline, the tanker and the storage tank to ensure all equipment
was at zero potential after allowing sufficient relaxation time; the provision of an interlock between the earthing
arrangements and the pump; the avoidance of splash filling and the selection of conductive/smooth materials for the
transfer system; elimination of possible contamination arising for example from the presence of water in the pipeline;
the use of a vapour return system; nitrogen blanketing of the road tanker barrel to minimize the risk of explosion; the
provision of instrumentation, for example, to detect earth leakage and the use of anti static clothing and footwear.
Answers were to a reasonable standard though some candidates would have done better if they had noted the use
of the word “static” in the question.
(b) The initial factor that should be taken into consideration is the need for access to be gained to the top of the
tanker. If this is found to be unavoidable, then the height of the tanker, the frequency of access required, the task to
be performed, for example valve or pipe connection or valve operation, and the normal duration of the work to be
carried out would again be important factors in assessing the risk of falls. Additional matters to be considered
include the means of access provided on the tanker, the condition of the tanker roof and the walkway and hand rails,
the consequences of falling which might indicate the need for the use of harnesses when on top of the tanker or the
provision of fall mitigation equipment such as air bags; and the availability of an alternative existing workplace such
as an overhead gantry. Other factors include the possible exposure of the driver to inclement weather, their
experience, competence, fitness and ability to work at heights and the personal protective equipment that should be
provided such as footwear and gloves.
B
In November 1984 the San Juanico gas storage facility near Mexico City exploded with catastrophic
consequences.
Outline the circumstances of the disaster. (10)
Outline how a Boiling Liquid Expanding Vapour Cloud Explosion (BLEVE) occurs with a gas storage vessel
constructed of metal. (10)
Outline the immediate rescue and restoration measures that took place. (10)
A major fire and a series of catastrophic explosions occurred at the San Juanico LPG terminal near Mexico City. As
a result of the incident, some 500-550 people died and the terminal destroyed. The terminal was supplied with LPG
from three refineries on a daily basis. On the day of the incident it was being supplied from a refinery some 400km
away. Two large spheres and 48 cylindrical vessels (torpedoes) were filled to 90% capacity and four smaller
spheres to 50% capacity. A drop in pressure was noticed in the control room but the operators were unable to
identify the cause of the pressure drop. An 8 inch pipe between a sphere and a series of cylinders had ruptured. The
gas accumulated around surrounding tanks and over an area measuring 150 metres by 200 metres. The gas cloud
drifted to a flare stack and exploded. A number of ground fires from the original point of fracture were directed at
adjacent cylinders. A series of BLEVEs occurred involving four of the six spheres and a number of the cylindrical
vessels. Injuries sustained were caused by radiated heat and burning droplets of LPG.
The gases such as butane and propane are stored under pressure in metal storage vessels. When the valve to the
vessel is opened, the resulting drop in pressure restores the LPG to the gaseous state. If, however, the vessel is
involved in a fire, the liquefied gas boils and the contents of the vessel will revert to the gaseous phase with a
resulting increase in pressure inside the vessel. The pressure relief valve opens and vaporised liquid escapes and
the liquid level drops. As there is less and less liquid left to absorb the heat, the vessel above the liquid level
absorbs the heat and the metal starts to change and weaken and ultimately ruptures as a result of ductile failure.
The remaining contents burst out and vaporise under atmospheric pressure sending debris from the vessel into the
surrounding area. The vapour cloud which includes gas droplets finds an ignition source and explodes.
Following the explosion, some 4,000 emergency workers were drafted into the terminal. The primary measures were
concerned with the temporary evacuation and transport of the injured. Further measures were aimed at the
prevention of an epidemic, the removal of debris and identification of those who had been killed. Fires were
extinguished, temporary shelters provided and arrangements made for the mass internment of those who had died.

B
Outline the practical control measures that can be taken to minimise risk when operating a bench-mounted circular
saw. (10)
the correct operation and/or adjustment of the top guard; ensuring the saw teeth below the sole plate are fully
enclosed; the use of a push stick to feed through the material being sawn and extending the machine table where
persons are employed to remove the material whilst the machine was in motion; the correct positioning of the riving
knife and the correct selection, maintenance and adjustment of the blade. Other measures that could have been
outlined related to the training and competence of the operators; the provision of a local exhaust ventilation system;
the provision and use of personal protective equipment such as goggles and hearing protection; the provision of
sufficient space around the machine which should be kept free from debris and loose material; the provision of an
emergency stop device, means of isolation and a braking device for the machine; ensuring good standards of
lighting, heating and ventilation; ensuring the stability of the machine and introducing procedures to ensure the
regular maintenance of the machine and that guards were always in position.

B
(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)
the process by which flammable gases (mainly liquefied petroleum gas) that are stored as liquids under pressure
are subjected to an external heat source. This heat has two effects. Firstly, in the liquid phase the heat is absorbed
and leads to the liquid phase boiling and an increase in pressure in the vessel. Secondly, the gas phase absorbs
less of the heat and energy is absorbed by the metal structure leading to thinning of the material and eventual
rupture. This loss of containment causes a sudden drop in pressure inside the vessel leading to large quantities of
liquid boiling off. The expanding vapour is ignited by the external fire or heat source leading to the explosion.
Suitable examples were the San Juanico disaster, Mexico City (1984), The Los Alfaques tanker explosion in
Alcanar, near Tarragona, in Spain (1978) and tanker explosion in a tunnel near Palermo, Italy (1996). Other relevant
examples were acceptable.
flying debris but few understood the thermal radiation effects or the overpressure effects on the surrounding area.
References to fireballs, debris and missiles, thermal radiation and shockwave.
C
Give the meaning of the term ‘confined space’. (2)
Outline the factors that should be considered to ensure that emergency rescue arrangements for confined
space work are suitable and sufficient. (8)
“Confined space” is any enclosed or partially enclosed place such as a chamber, tank, vat, silo, pit, trench, pipe,
sewer or flue or other similar space in which, by virtue of its enclosed nature, there arises a reasonably foreseeable
specified risk such as a lack of oxygen or the possibility of drowning in free flowing solids.
The specific factors that would have to be considered in ensuring that arrangements for emergency rescue from a
confined space were suitable and sufficient. The factors would relate to the nature of the confined space, the risks
identified and how an emergency rescue might take place and could include methods of raising the alarm to advise
those outside to initiate rescue procedures; the type of equipment such as life lines, lifting equipment and breathing
apparatus that would be required; the means provided for emergency access/egress; the precautions taken to
protect rescuers from the risks to health and safety identified in the assessment; the identification of plant in the
vicinity that may need to be shut down during an emergency rescue; the number and competence of those who
would be involved in the rescue; precautions taken to counter the possibility of fire such as the provision of fire
extinguishers; means provided for contacting public emergency services and supplying them with relevant
information; the availability of first aid assistance until the arrival of professional medical help and the provision of
training or refresher training for persons likely to be involved in emergency rescue procedures.

C
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.
Develop a safe system of work, a full risk assessment would have to be carried out when consideration would need
to be given to the likelihood of flammable atmospheres from the previous contents of the tank, the possibility of air
contamination from the cleaning or repair methods used and the build-up of heat within the tank. The assessment
would also need to look at other issues from the work to be carried out including working from height and the toxic
effects of lead.
Completion of the risk assessment would point to appropriate precautions such as the need to purge the tank with
an inert gas, the use of forced ventilation, atmospheric testing before entry and while the work was being carried out
and the provision of personal protective equipment possibly including air-fed breathing apparatus. Attention would
also need to be paid to the requirements for electrical equipment (for example intrinsically safe or flameproof) and
earthing arrangements. If heat were to be a foreseeable problem, then consideration should be given to issues such
as job rotation and fluid intake. The prevention of falls from height and the means of access and egress in the event
of escape and rescue. Procedural arrangements would centre on the implementation of an entry permit system,
limiting the number of people working in the tank, communication with standby personnel and drawing up
emergency arrangements.
The emergency arrangements to be considered would include issues such as the provision and maintenance of
cutting equipment, hoists, fire-fighting equipment, personal protective equipment such as breathing apparatus, first
aid facilities including resuscitation apparatus and liaison with the emergency services. Additionally, arrangements
should be in place to ensure that all personnel involved in the operation had received sufficient training in the work
methods, the precautions needed and the emergency procedures with emergency rescue team.

C
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.
Those relating to the sitting of the equipment (protection from vehicles, protection of the public, separation from
flammable atmospheres, noise, etc); system design issues such as capacity, materials of construction and layout of
features; and installation issues such as the fitting of pressure gauges, relief valves and drain lines, the marking of
safety-related information (e.g. safe working pressure) and suitable guarding. There would also be a need for the
establishment of maintenance procedures and a written scheme of examination, for a competent person to
undertake a pre-commissioning check, and for providing information to operators on safety features, limits and the
correct operation of the system.
C
The residents of a village have recently been affected by 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)
In order to investigate whether the dust causing the problem emanated from the cement works, management would
first need to carry out a desk study involving contact with the residents and a research into historical records, weather
patterns, possible links with the prevailing wind direction and the existence of other potential sources of dust in the
area.
They would need additionally to check the plant for obvious faults and carry out continuous monitoring of the
emissions on site together with off site background monitoring. Analysis of dust collected from the village would also
help to establish whether it matched that produced at the alleged source.

C
Corrosion is a major problem in many industrial processes.
Outline the characteristics and causal factors of electrolytic corrosion. (8)
Outline the strategies AND methods for identifying potential corrosion failures. (12)
Electrolytic corrosion is an electrochemical process in which one metal corrodes preferentially when in electrical
contact with a different type of metal and both metals are immersed in an electrolyte. The metals have different
electrode potentials and the electrolyte provides a means for ion migration whereby metallic ions can move from the
anode to the cathode. This leads to the anodic metal corroding more quickly than it otherwise would whereas the
corrosion of the cathodic metal is retarded. Characteristics of corrosion include pitting and erosion and its products
may affect quality of product and may lead to a reduction in flow in pipe work.
A strategy to prevent corrosion would aim to interrupt the formation of a corrosion cell by the removal of electrical
contact or the removal of the electrolyte. Removal of electrical contact can be achieved by insulation using plastic or
a similar insulating material, or by the use of protective coatings such as galvanising or painting. Additional methods
of preventing corrosion include the use of a sacrificial anode made of a metal which is more active than the protected
metal; the connection of an electrical power supply to oppose the corrosive current and the use of water treatment
and/or purification techniques. The use of visual inspections and NDT are a means of identifying the effects of
corrosion as is also checking for the presence of contaminant in the product and the use of corrosion measure
currents.
The maintenance and the arrangements for the examination and testing of safety critical plant; the use of permit to
work systems; the completion of the flushing out of tanks and pipe work and their isolation before the start of
maintenance work; regular cleaning of the bunds and the provision of training to maintenance staff in emergency
procedures.

C
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.
Describe how the risk of injury to personnel working with such equipment may be reduced.
The features of computer controlled equipment that may have particular implications on safety include sudden, rapid
and forceful movements, aberrant behavior, software faults, dangers during teaching and maintenance, stored
energy and leaking hydraulic and pneumatic fluid.
Risk of injury to personnel working with such equipment may be reduced by carrying out a risk assessment which
identifies the hazards and those at risk, restricting access ie 2m high fencing, interlocks and pressure mats, lock off
procedures during maintenance, mechanical restraints, pre-startup warning signals, software checks and remote
diagnostics. Further controls would include emergency stops, training of relevant people on the hazards and controls
associated with CNC machines and planned maintenance.

C
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 businesses on the upper floors.
Outline the range of factors that would need to be reviewed following completion of the planned work to
enable the company’s fire risk assessment to be updated.
Following completion of the planned work the additional risk factors would include small children; worried and
possibly panicking parents if a fire was to occur; persons under the influence of alcohol following events held in the
conference facilities ; the possible hazards of allowing smoking in the conference rooms and the potential number
of extra people to be evacuated. This would call for additional precautions in terms of escape routes, holding fire
drills for the children and delegates; an extension to the existing alarm system with additional call points; and
additional equipment such as emergency lighting, fire fighting appliances and the notices and signage that would
be required. It would also be necessary to consider the appointment of additional fire marshals particularly with the
likely presence of a number of vulnerable people (children) and to train employees in the revised procedures.
C
Outline the practical control measures that can be taken to minimise risk when operating a bench-mounted
circular saw.
The practical control measures that can be taken to minimise risk when operating a bench-mounted circular saw to
the need for the correct operation and/or adjustment of the top guard; the effective guarding of the blade beneath
the bench; the use of a push stick to feed through the material being sawn and extending the machine table where
persons are employed to remove the material whilst the machine was in motion; the correct positioning of the riving
knife and the correct selection, maintenance and adjustment of the blade. Other measures that could have been
outlined related to the training and competence of the operators; the provision of a local exhaust ventilation system;
the provision and use of personal protective equipment such as goggles and hearing protection; the provision of
sufficient space around the machine which should be kept free from obstruction; the provision of an emergency stop
device and means of isolation; ensuring good standards of lighting, heating and ventilation; ensuring the stability of
the machine and introducing procedures to ensure the regular maintenance of the machine and that guards were
always in position.

C
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)
i) As far as wooden frames are concerned, some varieties of timber are more fire resistant than others, for example,
those which have been treated. Thin sections promote fire, generating fumes and smoke although the charred
surfaces may act as an insulator providing protection for the inner timber. Timber frames tend to maintain their
shape and will have limited distortion with the smoke seal and level of fire resistance being maintained.
ii)Metal window frames expand and distort leading to a reduction in fire resistance and the escape of smoke with the
possibility that the window unit as a whole will become unseated and fall out. The metal conducts heat, will regain
strength on cooling but may remain permanently deformed.
iii)Plastic window frames expand, distort and melt at relatively low temperatures producing toxic fumes and smoke
with molten plastic flaking off and falling to the area below the window. The frame will suffer a complete loss of
integrity leading to a reduction in fire resistance and the escape of smoke with permanent deformation on cooling.
It was not sufficient to decide only whether the three materials burn or not. Material maintained its shape and
integrity and continued to provide a barrier against the spread of smoke and fire.

C
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)
Additional control measures such as ensuring suitable guarding was in place for the conveyors for example fixed
guards on the conveyor drums, nip guards between the belts and rotating rollers and enclosures or distance guards
to prevent access to the conveyors; edge guards or rails to prevent the coal from falling off the conveyors; trip wires
or emergency stops that were clearly visible to enable the belts to be stopped in the event of an emergency; the
provision of adequate space between the conveyors; positioning the conveyor belts at a convenient height to
facilitate the loading and unloading of the coal; carrying out maintenance on the conveyors on a regular basis by
competent personnel; carrying out a noise assessment and providing the workers with hearing protection if this was
found to be necessary; monitoring the presence of dust and ensuring a good level of general ventilation together with
suppression sprays; providing a level of lighting that will enable work to be carried out safely and importantly
introducing procedures for inspecting the machinery at the beginning of each shift to ensure that the guards and
safety devices were in position and installing a start up warning device.
D
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.
The most obvious control measure that should have come to mind would have been the possibility of isolation with
the supply locked off to enable ‘dead’ working. If this were not possible, then contact with live parts might be
prevented by the complete insulation of live parts such as cables, bus bars and connections. Contact might also be
prevented or at least deterred by placing barriers across the usual direction of access or enclosures to prevent
contact from any direction. There are also occasions when contact is unintentional where consideration should be
given to positioning live parts of the supply out of reach taking into account activities which might include the use of
ladders or long metal tubes. In addition to the above measures, in the event of contact, its effect might be limited by
the use of residual current devices (RCDs) while other possible control measures include the use of fuses or circuit
breakers to protect against over current, procedural measures such as permits to work and physical measures such
as mats and the use of appropriate tools.

D
Outline the principles, advantages and disadvantages of:
Dye penetrant;
Magnetic particle inspection;
Radiography;
Ultrasonic’s
as methods of non-destructive testing on the welded joints of a safety critical vessel.
The principles of use of dye penetrate i.e. a liquid penetrant is sprayed onto the test piece, the excess is wiped off
and an absorbent powder is then sprayed on which draws to the surface any penetrant that has seeped in to any
cracks which will then highlight any defects. The advantages are that the use of a dye penetrant method is relatively
cheap and is a simple operation. The disadvantages are that it does not detect sub-surface faults, is not totally
reliable and interpretation of the indications may be difficult (although enhancement can sometimes be achieved by
using a fluorescent penetrant with a UV source). Additionally, the penetrant used may have toxic properties.
Magnetic particle inspection involves coating the joint to be tested with magnetic particles that may be in powder
form or within a liquid. It is a simple and quick operation that is very sensitive to surface cracks and, in certain
circumstances, can detect sub-surface defects. Its drawback is that the interpretation of results may be difficult,
particularly on the inside surface of a pressure vessel.
Radiography x-rays or gamma rays are used to penetrate the welded joint to leave an image on film. Any defects are
shown up by the differences in the intensity of the radiation striking the film. The benefits of this technique are that it
detects internal defects and produces a permanent record of the test. However, the operation is time-consuming,
expensive and requires bulky equipment and skilled radiographers. Additionally, there is the danger of radiation
exposure.
Finally, using an ultrasonic technique, short pulses of high frequency ultrasound are used on welded joints, with the
reflected waves being detected and shown on an oscilloscope or digital display. This technique detects both surface
and sub-surface defects, requires access to one side of the joint only and takes little time with portable equipment
that can be used in most environments. The limitations of the technique are that it requires a high level of expertise
and coupling the equipment probe onto rough surfaces can be difficult.

D
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)
The design features that should be considered in order to minimise risks associated with the movement of vehicles
in the workplace, candidates should have referred to matters such as the provision of traffic routes with a smooth
and stable surface and of sufficient width and headroom for the types of vehicle that will use them; the elimination of
sharp bends, blind corners and steep gradients with the siting of convex mirrors on those corners that cannot be
avoided; the installation of a one way system to minimise the need for reversing; the inclusion of passing places for
vehicles; the introduction of speed limits and the provision of speed retarders; the provision of a good standard of
lighting for the routes and particularly for the transition areas between the inside and outside of buildings; the
segregation of vehicles and pedestrians including separate access and egress and the provision of clearly marked
crossing places.
D
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)
primary dust explosion to occur, the dust must be combustible, must be capable of becoming airborne and mixing
with air and its particle size and distribution must be capable of propagating flame. Additionally the concentration of
dust must fall within the explosive limits, an ignition source of sufficient heat energy must come in contact with the
dust and the atmosphere must contain sufficient oxygen to sustain combustion. Additional conditions necessary for
secondary explosions to occur include the dislodgement of accumulated dust from horizontal surfaces within the
affected building by the pressure wave and consequent air turbulence created by the primary explosion and the
airborne suspension of combustible dust throughout the affected area which is ignited by the original primary
explosion ignition source or by the combustion of products from the primary explosion or by any other ignition source
with sufficient heat energy within the affected area. Reasonable answers were provided for this part of the question
though some candidates failed to refer to the dislodgement of accumulated dust or to identify possible ignition
sources.
In identifying factors that might affect the reliability of a nitrogen inerting system,
chosen from the location and number of sampling points; the type and calibration of the sensor; the possibility of
contaminants in the system interfering with the readings; an inadequate supply of inserting gas; the number of
locations where air might enter the plant or process; the safe means of shutdown if oxygen levels become too high;
and the reliability of the electronic control system.
the number and location of sampling points and the type and calibration of the sensor.
In identifying design features that would minimise the likelihood and effect of a dust explosion, candidates should
have referred to; the initial design of the ducting and equipment to withstand the effects of an explosion; the
importance of ensuring the ducting was dust tight; providing local exhaust ventilation at points of transfer; installing
explosion relief or suppression systems together with systems for suppressing fire; using screw conveyors instead of
pneumatic systems for moving materials; providing a magnetic extraction system for removing metal from product
fed to the plant; interlocking equipment to prevent overfilling of vessels and over-pressurisation; using instrument
systems with integral emergency shutdown; using intrinsically safe electrical equipment and bonding all metal work
to earth; preventing dust build up in the plant by the use of sloping surfaces and introducing a mechanized system
for the humidification of the air.

D
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:
the design;
the operation;
The maintenance of the proposed storage facility.
The design; need for the storage tanks and pipe work to be constructed of suitable chemical resistant material; the
design, positioning and marking of the delivery inlets to prevent connection being made to the wrong tank; the
positioning of the storage tanks in separate bunds with the bunds being capable of holding the entire contents of the
tanks plus 10%; the erection of hazard warning signs clearly identifying the contents of the tanks and the colour
coding of pipe work; the fitting of level indicators and high level alarms to prevent overfilling; the provision of good
vehicle access including a hard standing for tankers with facilities for spill containment; provision of earthing and
bonding for the tanker, connection and hoses; measures to avoid the tanker being driven away whilst still connected
and the provision of drench showers and eyewash stations and a good standard of lighting.
The operation; a safe system of work including emergency procedures to deal with spillages and the provision and
maintenance of a contingency supply of neutralising and absorbent materials and water; providing training for the
personnel involved including tanker drivers in the risks associated with the operation and the control measures to be
followed and the provision of personal protective equipment such as chemical suits, chemical resistant gloves and
full face protection.
The maintenance of the proposed storage facility the arrangements for the examination and testing of safety critical
plant; the use of permit to work systems; the completion of the flushing out of tanks and pipe work and their isolation
before the start of maintenance work; regular cleaning of the bunds and the provision of training to maintenance staff
in emergency procedures.

E
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.
The company could consider to reduce the cost and environmental impact of dealing with the waste ; substituting
process materials for ones that give rise to non-hazardous waste; improving production efficiency in order to
produce less waste; treating waste on site to reduce quantity, for example by de-watering; treating waste to reduce
hazardous properties; mixing the waste with other waste streams to neutralise hazardous properties; selecting
waste contractors who can process the sludge; seeking opportunities to exchange waste streams with companies
that can use waste as raw material; exploring other means of disposal such as incineration, or directing liquefied
waste to a sewer and exploring the possibility of becoming approved to save costs.
E
Legislation relating to lifting operations and lifting equipment often specifies fixed intervals between
thorough examinations of lifting equipment but 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. (10)
The factors which the competent person would need to take into account such as the age of the equipment and its
history including the extent of use, the loads lifted and the environments in which it has been used and its current
and anticipated future use. Other factors which should also be considered include: the standards and specifications
to which the equipment had been designed and manufactured and the quality conformance of materials at the time
of manufacture; the manufacturers’ recommendations on testing, inspection and maintenance and whether they
have been adhered to (by reference to records); the equipment’s accident, breakdown and repair history; records of
modifications and the fitting of replacement parts; the records of previous thorough examinations; the typical
performance history of similar items of equipment and any insurance company requirements

E
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.
Describe the types of fault that may be found in fixed electrical systems under such conditions.
Outline the information relating to fixed electrical systems that will be required prior to a survey by a
competent person. (10)
The types of fault that may be found in fixed electrical systems under such conditions and how a corrosive
atmosphere may exacerbate the problems. included poor earthing, damaged sockets and switchgear, covers
missing from junction boxes, incompetent workmanship and inadequate excess current protection. Additional
problems caused by the atmosphere include exposed live conductors due to damaged or perished insulation; short
circuits caused by the ingress of fluids; corrosion of system parts such as access grilles and transformer casings;
and the unsuitability of the equipment for use in such wet and corrosive conditions.
A competent electrician prior to carrying out a survey would include: the type of equipment and its rating (eg
operating voltage and current); its IP classification (including the measure of protection against the ingress of water);
any circuit diagrams and/or manuals for the equipment and details of any modifications made; means of isolation
and its location; earthing arrangements; the type and size of cables; details on the operation of protective devices
and copies of previous inspection reports

E
A worker has received an electric shock from a 240 volt portable drill whilst installing a set of wooden
shelves.
Outline the physical effects the worker may have suffered from the accident. (5)
State the emergency action that should have been taken immediately after the accident.
Identify the precautions that might have been taken to prevent the accident. (10)
Physical effects the worker may have suffered from the accident such as fibrillation of the heart muscles with
possible cardiac arrest, respiratory failure, muscular contraction or spasm, involuntary grip that can prolong current
flow, burns to tissue and ultimately death. There is also the possibility of secondary injuries such as those resulting
from a fall.
The emergency action that should have been taken immediately after the accident such as isolating the source of
power or using a non-conductive instrument to push the victim clear; wrapping the victim in insulating material and
checking for breathing and pulse; administering mouth-to-mouth resuscitation if needed; placing the victim in the
recovery position and contacting the emergency services.
The precautions that might have been taken in order to have prevented the accident. In selecting equipment, use
of reduced voltage, battery-powered and/or double-insulated tools and conformity with standards. Technical
precautions include the use of residual current devices, ensuring earth integrity (where appropriate), using correctly
rated cables and fuses, and ensuring that equipment or system components (plugs, sockets, cables etc) are free
from damage, where water is present in the space , suitable plug / socket connectors will be used and protected by
residual current devices (RCDs) suitable for protection against electric shock, while organisational issues relate to
maintenance arrangements, inspection and testing of portable appliances and electrical systems, housekeeping
standards, and the provision of information, instruction and training – particularly in relation to systems of work and
pre-use checks.
E
With respect to an electricity supply operating at 240v:
outline the factors that determine the severity of the effects of an electric shock. (6)
For each of the following protective devices describe their principles of operation: residual current devices;
(3) fuses; (3) 110v centre tapped to earth reduced voltage systems.(3)
Outline other design features of electrical systems intended to improve safety. (5)
The voltage, the nature of the current (whether alternating or direct), the body resistance of the individual with
reference to age, gender, the amount of moisture (perspiration) on the body and the type of footwear worn, the route
taken by the current through the body, the speed of action of any protective measures and the environmental
conditions, such as the floor material and the presence of water. Knowledge of Ohm’s Law was useful in relating the
size of current to voltage and resistance.
Residual current device is designed as a shock limiting device and not for system protection. It operates on an
earth leakage fault. Any differential in the current passing through the line (neutral) and phase (live) conductors is
detected, operating a switch to cut off the electrical supply to the apparatus and preventing severe electric shock.
The device should operate within 30 to 50 milliseconds of the fault being detected.
A fuse is a device placed in the live side of a circuit, designed to cut off automatically the power supply to the circuit
within a given time when the current flow in the circuit exceeds a given value and produces sufficient heat to melt the
fuse which is designed to do so at a predetermined temperature. It prevents the overload of an electrical system and
overheating of electrical wiring. However, its speed of operation is generally too slow to protect people from electric
shock. One of the better ways of reducing the risk from electricity is to reduce the voltage, achieved by the use of a
step down transformer.
A common reduction is to 110 volts and a transformer used to attain the reduction is described as centre tapped to
earth in that the secondary winding of the transformer is earthed to its centre thus ensuring that the maximum
voltage from live to earth involved in an electric shock will be 55 volts.
Other design features intended to improve safety such as the selection of suitable cables and placing them out of
reach wherever possible; the provision of effective means of isolation to ensure the secure disconnection and
separation of electrical equipment from every source of energy; the use of earthed systems and Class 1 equipment
or double insulated Class 2 equipment; the use of circuit breakers and the introduction of earth free zones.

E
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)
(a), effects such as fibrillation of the heart muscles with possible cardiac arrest, respiratory failure, muscular
contraction or spasm, involuntary grip that can prolong current flow, burns to tissue and ultimately death. There is
also the possibility of secondary injuries such as those resulting from a fall. The possible physical effects on the
worker seemed to be well known.
(b) was concerned with the emergency action to be taken immediately after the accident and it was anticipated that
candidates would refer to matters such as isolating the source of power and using a non-conductive instrument to
push the victim clear; wrapping them in insulating material and checking for breathing and pulse; administering
mouth-to-mouth resuscitation if needed or the use of a defibrillator; placing the victim in the recovery position and
contacting the emergency services.
(c) sought information on the precautions that might have been taken in order to have prevented the accident, and
there were many that could have been mentioned.
In selecting equipment, consideration should be given to the use of reduced voltage, battery powered and double-
insulated tools and conformity with standards. Technical precautions include the use of residual current devices,
ensuring earth integrity (where appropriate), using correctly rated cables and fuses, and ensuring that equipment or
system components (plugs, sockets, cables etc) are free from damage, while organisational issues relate to
maintenance arrangements, inspection and testing of portable appliances and electrical systems by a competent
person and pre-use inspection by the user, housekeeping standards particularly for cable management, and the
provision of information, instruction and training – particularly in relation to systems of work and pre-use checks.
E
As Health, Safety and Environment Manager at a hazardous installation you are responsible for emergency
planning. The site is regulated under the International Labor Organization (ILO) Code of Practice ‘Prevention
of Major Industrial Accidents’ 1991. In the event of an uncontrolled release:
Outline the need for emergency planning; (3)
Outline the general emergency planning measures that should be taken by the competent authorities in
association with the works management of the installation. (7)
In the event of an uncontrolled release, there would be a need for emergency planning to localise the release and if
possible, contain it; and to minimise the harmful effects of the release on people, property and the environment both
inside and outside the installation by the use of safety systems, alarm systems and the emergency services. Clear
and well defined plans should be made available for quick and effective use and where emergency equipment and
manpower are limited, provision should be made for mutual assistance from neighbouring industrial activities.
general emergency planning measures that should be taken by the competent authorities include the need: to
establish arrangements for an on-site emergency plan which should be drawn up by the management of the
installation; to establish arrangements for an off-site emergency plan to be drawn up by the local authority in
conjunction with the installation’s management, which should be prepared following consultation with various bodies
such as the fire and police authorities and the hospital and ambulance services and which should be consistent with
the on-site emergency plan; to ensure that regular rehearsals were carried out in order to keep the off-site plan in a
state of readiness and also to ensure that information on safety was provided to members of the general public.

F
Outline the features of a ‘fixed guard’ in relation to machinery safety. (2)
Outline the factors to be considered in the design and use of fixed guards that minimise risks to workers.
The features of a fixed guard as a guard with no moving parts affixed in such a manner (eg by screws, nuts,
welding) that it can only be opened or removed by the use of tools or destruction of the affixing means. It provides
appropriate protection against mechanical hazards when infrequent or no access is required to dangerous parts of a
machine during its normal operation.
The factors to be considered in the design and use of fixed guards that minimise risks to workers such as: the
material of construction, which should be sufficiently robust to withstand the rigours of the workplace and be able to
contain any ejected material, but still allow sight of the process when required; the method of fixing, usually requiring
the use of a special tool for the guard’s removal; the need to ensure that any necessary openings in guards are such
that they do not allow access to the dangerous parts (a function of the size of any opening in relation to the distance
to the hazard); and the need to address the possibility of the guard reverberating and exacerbating a noise problem.
Most candidates recognised that a tool would be required for the removal of a guard but then wrote about hazards
rather than outlining the essential properties of the guard. Factors to be considered in the use of fixed guards include
monitoring and supervision to ensure that the guard is not compromised; safe systems of work for carrying out
maintenance operations with the guard removed and the provision of information and training for both operators and
maintenance staff.

F
(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)
There are two type heat detectors, the fixed temperature type and the rate of rise type. A fixed rate heat detector has
a sensing element fixed at a particular temperature. By means of a thermocouple or similar arrangement, it detects
when the predetermined temperature is reached. A rate of rise heat detector detects abnormally fast temperature
rises by means of electronic resistors or thermistors.
Smoke detectors are of two main types: ionising and optical or photoelectric. The chamber of an ionising type has
two plates set apart, one charged negatively and the other positively. A small radioactive source is used to ionise the
chamber into which smoke may enter in the event of fire. The detector reacts to the change in electrical current
caused by the neutralisation of ions by the smoke particles. The optical type of detector has a number of variants but
chiefly responds either to the obscuration of a focused light ray or to the scattering of light from an optical ray. It
therefore reacts either to a reduction in light at a receiver or, more commonly, to the sensing of light by an optical
sensor placed in the chamber where light would not normally be detected.
(b), firstly that a smoke detector would be inappropriate in situations where smoke, steam or vapour might normally
be expected such as in kitchens while a heat detector might be considered inappropriate in situations where sudden
temperature changes might be experienced in normal circumstances or in situations where slow burning materials
are involved which would have an effect on the speed of response. Some candidates did not read the question with
sufficient care and identified the circumstances in which the use of each type of detector would be appropriate – the
opposite of that which was required.
F
Outline the issues that should be included in a fire safety training session for workers.(10)
The issues to be covered in a fire safety training session for workers which would include: the consequences of fire
such as the effects of smoke inhalation on those involved the potential costs to the business; the principles of the fire
triangle; the basic elements of fire prevention such as the storage of flammable materials, good housekeeping and
the need to prevent the accumulation of rubbish; the action to be taken on discovering a fire such as raising the
alarm, the procedure for calling the fire service and the action to be taken by personnel on hearing the alarm; the
location and use of firefighting equipment with practical training for selected workers; the escape routes and exits
from the premises together with the assembly points and the roll calls that would have to be carried out; the
arrangements for the evacuation of people with disabilities and for assisting visitors and members of the public; the
identity and role of fire wardens and marshals; the importance of fire evacuation practices and drills and issues
directly concerned with personal behaviour such as refraining from re-entering the building after evacuation until
instructed to do so.

F
A catastrophic fire occurs in a warehouse which stores a substance which gives off toxic products. The
warehouse has an integral asbestos roof and it is situated near to a densely populated area. The fire burns
for a day and completely destroys the building.
Identify the environmental impacts related to this event, giving a probable source of EACH.
Identify the range of design features that could prevent or mitigate the environmental impacts of such an
event at these premises. (5)
The initial impact of the fire on the environment would be the release to atmosphere of greenhouse gases (including,
eg carbon dioxide, methane and ozone), smoke and particulates such as soot. Additionally, asbestos fibres could be
carried by air and contaminate the locality. There would also be the possibility that toxic products could enter sewers
and water courses and also soak into the soil causing a detrimental effect on flora and fauna. Unless precautions
were taken, fire fighting media could run off to watercourses whilst in the clean-up after the fire, waste products and
sludge could be deposited in landfill sites.
Design features that could have prevented or mitigated the impact on the environment include the initial construction
of the building with non-combustible materials and introducing compartmentalisation; using a roofing material other
than asbestos; providing protective fireproof coatings on steelwork; using impervious material in the construction of
the floor; providing a flameproof storage container for the critical toxic substances; installing a fixed fire detection
and protection system; fitting interceptors to the drains; constructing a bund round the warehouse; using fire water
catch tanks or lagoons during the fire fighting operation and treating residual solids before consigning them to landfill
sites.

F
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
vapor due to static electricity.
The control measures which would reduce the risk of ignition of the extremely flammable liquid vapor due to static
electricity: controlling the pump rate and transfer speed; earthing and bonding the pipeline, the tanker and the
storage tank to ensure all equipment was at zero potential after allowing sufficient relaxation time; the provision of an
interlock between the earthing arrangements and the pump; the avoidance of splash filling and the selection of
conductive/smooth materials for the transfer system; elimination of possible contamination arising for example from
the presence of water in the pipeline; the use of a vapour return system; nitrogen blanketing of the road tanker barrel
to minimise the risk of explosion; the provision of instrumentation, for example, to detect earth leakage and the use
of anti static clothing and footwear.
F
During a fire drill exercise at a large multi-storey office premises, the majority of the occupants evacuated
the building in less than three minutes. However, all of the people based in one area of the building failed to
leave the building until a further four minutes had elapsed.
(a) Outline factors that may have contributed to the delay in evacuation. (15)
(b) Outline reasons for conducting regular fire drills in workplaces. (5)
(a) such as the fire alarm design, the structural layout of the premises, the deficiencies in the existing procedures
and their execution and human factors and outlined how each may have contributed to the delay in evacuation. In
considering the alarm signal, it might have been too quiet and thus inaudible in some parts of the premises because
there were too few sounders with those that did exist set at too low a volume. Additionally, even though the alarm
could be heard, there was a possibility that it was not distinctive enough and was similar to other alarm systems thus
causing confusion. As for the layout of the premises, escape routes might have been complex, lengthy and
inadequate; some may have been blocked or locked with others lacking an adequate standard of lighting. The
existing procedures might have been too complex and difficult to understand, with insufficient instructions given to
workers on what action to take when the alarm was sounded. The number of fire marshals appointed would have to
be questioned as would the adequacy of the training they had been given. During the actual exercise there were
obviously workers who did not follow the procedures and delayed their response to the alarm by finishing a
particular item of work, or gathering their belongings together or attempted to investigate the reason for the
sounding of the alarm. Finally the alarm might have been caused by human factors such as hearing disabilities or
apathy with the assumption that it was only another fire drill or a false alarm.
(b), regular practice of evacuation procedures allow for smooth and rapid evacuations when the need arises and for
workers to be familiar with the alarm signal, the evacuation procedure and their own duties, to react to future alarms
in a calm and orderly manner, and to be familiar with the escape routes. It also provides a test of the integrity of the
hardware systems such as the alarms and emergency lighting and ensures compliance with legal and insurance
requirements.

F
(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)
Causes of both lateral and longitudinal instability. They outlined cornering at speed, uneven ground, incorrect
positioning of the load on the forks and driving on slopes.
Too few candidates took a logical approach to training content within basic training, specific training and
familiarisation training and whether this training was carried out off the site or on the site. They failed to understand
that after basic training, local onsite rules and systems of work needed to be included in any training as should use
of forklift in workplace conditions.
Situations where refresher training would be appropriate, such as where forklift trucks have not been used for some
time and where there have been accidents.

F
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)
There are a number of factors which may cause fire and explosion where large quantities of aerosol canisters
containing highly flammable materials are stored in a warehouse. The canisters may have suffered damage for
example to the valve or body of the canister, leading to loss of containment and the formation of flammable vapours
which if between the upper and lower flammable limits can be ignited by a heat source, perhaps a nearby fire or hot
work and even by direct sunlight. The canisters may then be propelled from their original position as projectiles as
the radiant heat from the initial fire causes boiling of the contents of adjacent canisters.
This causes the release and ignition of additional vapour sources resulting in multiple BLEVEs.
Fire precautions that can be taken to limit the spread of any resulting fire and explosion in a similar type of
warehouse include the segregation of the canisters from other flammable products; the separation of high
flammability canisters by physical barriers; using compartmentation within the warehouse with fire resistant
partitions; the provision of containment cages to prevent projectiles; the installation of automatic fire detection and
alarm systems; the use of automatic extinguishing systems and venting and explosion reliefs. With this part of the
question, candidates again did not take the time to consider exactly what was required. It was concerned with
precautions that might be taken to limit the spread of fire but some wrote at length about fire drills, the appointment
of fire marshals and emergency action procedures without indicating how these would have limited the spread of
fire.
F
Outline the characteristic features of, and factors that promote the following types of materials failure:
(a) brittle fracture; (5)
(b) ductile failure. (5)
This question was assessing IC6.2 Describe with examples the principal generic mechanical and non-mechanical
hazards of general workplace machinery.
Structural and component integrity is an essential part of Unit IC.
Some candidates provided sketches, perhaps imitating previous variants of this question that did require sketches.
Whilst sketches do not fully meet the command word for this question („outline‟), they certainly help to provide a
prompt for an „outline‟ answer.
In part (a), the characteristics of brittle failure it was a crystalline structure failure, with chevron marks radiating from
the point of initiation. Some candidates understood that low temperatures and shock loading were a factor promoting
brittle failure. Very few candidates mentioned a failure line at 90 degrees to the principal axis of loading.
When answering part (b), most candidates had a complete misunderstanding of the characteristics of ductile failure
and failed to mention necking and plastic deformation before final fracture. Although some candidates understood
that high temperatures may promote ductile failure, too few understood the significance of overstress above the
elastic limit.

G
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.
Activities that may lead to the release of greenhouse gas emissions to the atmosphere include the combustion oil,
LPG, gas and coal for heating and cooling systems; emissions from transportation by road, rail or air; the
consumption of electricity generated from fossil sources; the use of fossil fuels in various processes and the removal
of ‘greenhouse sinks’ through peat consumption and deforestation.
Examples of processes or activities that may cause the emission of greenhouse gases to the atmosphere include
construction work which will require the use of diesel driven cement mixers; the use of chemicals derived from fossil
fuel sources such as the production of paint; processes resulting in the emission of hydro fluorocarbons and
chlorinated hydrocarbons; the leakage of methane from natural gas facilities, coal mines and oil well drilling; and the
disposal of waste either by incineration causing carbon dioxide emissions or to land-fill leading to methane
emissions.
The range of commercial, industrial and business activities that can have an impact on the environment. The use of
road vehicles and air travel while others referred to spray painting and the use of aerosols without indicating why
these might be relevant. It was only the better answers that referred to the disposal of waste by incineration or by the
use of land-fill.

G
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 the categories of machinery covered by Part 1 of the convention. (2)
(b) Give TWO examples of transmission machinery (exposed moving parts) specified in Part 2. (2)
(c) Outline the requirements for the use of machinery as specified in Part 3. (6)
(a), categories of machinery such as power driven and manually operated machinery, machinery which is new or
second hand, road and rail vehicles during locomotion with the safety of the operators in mind and agricultural
machinery with respect to the workers connected with the machinery.
In giving two examples of transmission machinery, candidates could have chosen from a list containing belts and
pulleys, fly wheels, gearing, chains and shafting.
(c), the requirements of Part 3 of the Convention apply to an employer and/or his/her prescribed agent who should
be aware that using machinery without guards is prohibited by law and there is therefore an obligation on them to
secure compliance with the law’s requirements. As such an employer should not require a worker to use to use
machinery without guards in position nor make guards inoperative on machines that may be used by a worker. The
worker, too, has an obligation both to use and not misuse the guards provided.
H
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)
The fire evacuation procedures for the hospital, factors to be considered include: the various activities involved such
as wards, theatres, offices, outpatients and visitors; the number of patients and staff to be evacuated; the mobility of
the patients including their medical condition and age; reviewing current and normal evacuation procedures including
escape routes, assembly points and fire brigade access and identifying temporary procedures and routes such as
the availability of operational lifts for bed-ridden patients; consideration of a two stage evacuation procedure; the
provision of training to hospital and construction staff in the temporary arrangements; ensuring that escape routes
and assembly points are kept clear of construction materials; the provision of emergency lighting and signage;
considering the possibility of emergency zoning and classification for example for full or partial evacuation; assessing
the effect of construction work on the existing detection, alarm and fire-fighting systems and on the possibility that it
might increase the risk of fire; and assessing the need for first aid fire fighting provision and fire protection.

H
Outline the advantages and limitations of the following types of fall protection devices AND give a suitable
application for EACH:
(a) safety harnesses/fall arrest; (5)
(b) safety belts/fall restraint; (5)
(c) safety nets; (5)
(d) air bags. (5)
the advantages and limitations of four types of fall protection devices and to indicate a suitable application for each
type. Safety harnesses may be used in high fall potential areas where full arrest is required, when carrying out short
duration work and when it would be impracticable to provide more sophisticated measures. Their limitations include
the need for secure anchoring points, their restrictions on movement, their requirement for trained and competent
users and the fact that they provide individual protection only. A suitable application for this device would be in
construction work such as for roof work or steel erection.
Safety belts, too, can be used in high fall potential areas for short duration work where the provision of more
sophisticated measures would be impracticable. However, this device offers restraint rather than fall arrest, again
requires anchoring points, provides individual protection only and may need to be supplemented with collective
measures. A suitable application for this device would be to gain access to a pole or pylon.
The advantage of safety nets is that they can provide collective protection (for the fall of persons and materials) for
long term work where full arrest is required. Their installation, however, takes time and needs to be undertaken by
competent persons. They can be used only in low to medium fall potential areas. They are most suitable for use over
water or under fragile roofs.
air bags can provide collective protection for falls and have the advantage of being available in different sizes. They
do, however, provide only small areas of protection, need installation by competent personnel, require a continuous
power supply and may be used only in low fall potential areas such as short run construction projects or around
workplace transport.

H
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.
The precautions such as the initial selection of the harness, particularly with respect to its shock absorbency and its
construction to a recognised standard; to implementation of plans to prevent prolonged suspension in the fall
protection harness but if prolonged suspension were to occur, to the drawing up of procedures for carrying out
rescue and providing treatment as soon as possible.
There will also be a need for workers wearing harnesses and those performing rescue operations to have training in
determining if the harness is properly fitted and correctly worn and performs as intended; how suspension
trauma/orthostatic intolerance occurs together with the procedures that should be followed in a rescue operation
and the methods of reducing risks while suspended. The procedures for rescue should contain contingency based
actions such as if self or prompt rescue is impossible, the worker should be trained to pump their legs frequently;
the need for rescue workers to elevate the worker’s legs and rescue them in the direction of gravity to avoid
negative hydrostatic force; the need for continuous monitoring of the suspended worker for signs and symptoms of
suspension trauma/ orthostatic intolerance; ensuring the worker receives appropriate first aid treatment once
rescued such as supplementary oxygen administered by trained personnel; the need to call for medical assistance
if the worker is unconscious in harness suspension and monitoring the worker after rescue and ensuring evaluation
by a healthcare professional. It is essential that the signs and symptoms of suspension trauma are recognised.
These include light headedness, palpitations, poor concentration, fatigue, nausea, dizziness, headache, sweating,
weakness, paleness, breathlessness, and unusually low heart rate and blood pressure.
L
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 you would expect to see in order that the lift may be
conducted safely.
A prime requirement would be that the proposed lifting operation should be planned by a competent person and be
closely supervised in accordance with the level of risk involved. A risk assessment would need to be carried out
which should address matters such as the weight, shape and centre of gravity of the loads and the availability of
lifting points; the positioning of the cranes and any available resting places for the loads; the number of times the
lifting operation will be carried out; the availability of the correct lifting equipment together with the availability of test
certificates and reports of statutory examination for the cranes; the precautions taken to cordon off the area for the lift
and the environment in which the lifting equipment will be used and the likely weather conditions. The cranes will
have to be positioned using outriggers and jacks to ensure stability, and sited on firm ground away from trench work
or other excavations and overhead and underground services. The lift should be under the control of a competent
person with knowledge of and training and experience in carrying out a tandem lift. Crane drivers and banksmen
would have to be competent and there would need to be an effective means of communication between them using
standard methods of signalling, Calculations should be carried out by a competent person to decide whether the
cranes would need to be de-rated and the lift should be carried out in such a way that the agreed individual safe
working load of either crane is not exceeded.

L
Outline factors that a competent person would need to take into account when deciding the frequency of
examination of lifting equipment. (10)
Describe the main hazards and control measures associated with commonly encountered lifting equipment.
Standards and manufacturers design criteria are factors to be taken into consideration by the competent person,

L
Outline the possible health and safety effects of inadequate workplace lighting. (4)
Outline the factors that should be considered to ensure that lighting in a workplace is suitable and sufficient.
(16)
The possible health and safety effects of inadequate workplace lighting as those relating to health and those relating
to safety. Health effects may include headaches, visual fatigue or eye strain and blurred vision and the effects of
adopting a poor posture, such as neck and backache in order to have an adequate view of the task being performed.
Safety implications include the likelihood of an increase in accidents due to trips, falls and striking against objects
because the hazards are not identified, because of the use of the wrong type of lighting such as those producing a
stroboscopic effect and through human error in performing a task which may put others at risk.
The factors to be considered in providing suitable and sufficient lighting include amongst others: the type of work to
be undertaken, the amount of precision required and whether the tasks require general, local or localised lighting; the
workplace layout giving attention to the effects of screens, furniture or racking and the shadows that might be cast;
the levels of lighting in adjacent areas in order to avoid the effects of moving from a strongly lit area to one which is
dimly lit and vice versa; the different types and levels of lighting required for stairs, corridors and outside security
lights; the level of natural light available; the individual needs of the employees whether on account of age or
disability; the possibility of glare on display screens and through reflection from other surfaces such as wall surfaces;
the colour and types of lighting fitted to prevent stroboscopic effects; the need for emergency lighting particularly for
fire escape routes; the need for portable lighting when work has to be carried out in confined spaces and the ease of
maintenance whether replacing spent bulbs or cleaning the light fittings.
L
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. (6)
(b) Outline how buried LPG metal pipework can be protected against corrosion. (4)
(c) Excluding corrosion protection, outline additional factors to consider in preventing a recurrence of an
explosion in similar LPG pipework installations. (10)
(a) Corrosion occurs in buried LPG metal pipe work, candidates should have included that this involved an electro-
chemical process and then included the need for the presence of a corrosion cell such as pitting of the metal pipe
for example, and the roles played by an anode, cathode and electrolyte, which in the scenario described was
moisture together with the possibility of contaminants in the soil, in the liberation and transfer of electrons. the
effects of corrosion on different metals such as cast iron, ductile iron and steel.
(b), buried LPG metal pipe work can be protected against corrosion by wrapping with protective tape; coating it with
bitumen; galvanising; sleeving with a dry envelope; and providing cathodic protection or a sacrificial anode.
Additional factors to be considered in preventing a recurrence of an explosion in a similar LPG installation would
involve identifying and prioritising at risk installations such as those where hazardous features arise from the design
and layout of the building; where there are inherent hazards in the layout or the condition of the installation and pipe
work such as the presence of unventilated voids; those which are least well maintained or located in the most
corrosive soils; and the older installations and the extent of their existing protection. For inspection and maintenance
of the systems, plans and drawings will be required together with a record of previous maintenance. Excavation
may be required, though it must be acknowledged that disturbing the pipe work may increase the risk of leaks.
There will also be a need for the introduction of a systematic programme of replacement of metallic pipes with
polypropylene and the condition of at risk systems will need to be monitored pending the replacement.

M
Outline the principles of an interlocked machine guard. (4)
Outline the principles of operation of trapped key control systems. (6)

The fact that an interlocked guard is linked to the machine controls by mechanical, electrical, hydraulic or
pneumatic means. The principles of operation are that the machine cannot become dangerous when the guard is
open and, when the machine is in an otherwise dangerous condition, either the guard cannot be opened or opening
the guard causes the machine to become safe.
The ‘key’ is at all times held captive in the guard locking mechanism that incorporates an electrical switch
connected to the power supply to the machine. It is therefore necessary to turn the key to open the guard and this
has the effect of switching off the machine (often in a two-stage process). With a simple trapped key system, the
guard lock and the switch connected to the power supply to the machine are separate. The key is removable but is
held in the guard locking mechanism until the guard is closed. On locking the guard, the same key can then be
transferred to the switch to allow power to the machine. While power is on, the key is held in the switch.

M
Outline the features and arrangements that should be considered in order to minimise risks associated with
the movement of vehicles in the workplace. (20)
The design features that should be considered in order to minimise risks associated with the movement of vehicles
in the workplace, the matters such as the provision of traffic routes with a smooth and stable surface and of
sufficient width and headroom for the types of vehicle that will use them; the elimination of sharp bends, blind
corners and steep gradients with the siting of convex mirrors on those corners that cannot be avoided; the
installation of a one way system to minimise the need for reversing; the inclusion of passing places for vehicles; the
introduction of speed limits and the provision of speed retarders; the provision of a good standard of lighting for the
routes and particularly for the transition areas between the inside and outside of buildings; the segregation of
vehicles and pedestrians including separate access and egress and the provision of clearly marked crossing places.
As for procedural arrangements, they would include the selection and training of competent drivers who would be
subjected to regular health screening; the provision of information on site rules for visitors including drivers visiting
the site; the introduction of procedures for the regular maintenance both of the traffic routes and of in-house
vehicles and for the reporting of defects; the rigorous enforcement of speed limits and the provision and use of high
visibility clothing by workers working in close proximity to traffic routes.
M
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)
There are a number of mechanical hazards associated with the use of metal turning lathes. For example, cutting or
severing by the cutting tools or swarf or that of entanglement when items of clothing, jewellery or hair comes into
contact with rotating parts of the machine. Other hazards include those of crushing or shearing, trapping between the
tool post and fixed parts of the lathe, stabbing, puncture, friction and abrasion.
Control measures that should be taken to minimise the risks associated with the lathes include the provision of
guarding for exposed rotating parts; using the correct size chuck; providing support for the work-pieces and securing
the tool post and cutting tool; using a tool board instead of placing tools on the headstock; ensuring that all controls
including an emergency stop are within easy access and are suitably marked and displayed; siting the lathe so that
there is adequate space for the operator and using barriers to prevent human and vehicular traffic from approaching
the machine; avoiding the wearing of loose clothing, gloves or jewellery; ensuring that there is a high standard of
lighting at the working position and keeping it clean and free from debris to prevent accidental slipping or tripping;
and providing personal protective equipment such as eye and foot protection.

M
Identify the hazards associated with the use of mobile elevating work platforms (MEWPs).
Outline the control measures that should be taken when using MEWPs. (5)
The hazards associated with the use of mobile elevating work platforms (MEWPs) such as falls from a height of
persons or materials, instability of the vehicle, being struck by other vehicles, trapping and impact hazards,
mechanical failure, contact with overhead lines or other obstructions and exposure of employees to adverse weather
conditions.
The control measures that should be taken when using MEWPs which would be required to reduce the risk when
using this equipment. These include the selection and training of operators; guarding scissor mechanisms to prevent
trapping; correct positioning of the MEWP to prevent over-reaching and proximity to dangers such as overhead lines;
maintaining stability by the use of fully extended and locked outriggers on firm ground; preventing the use of the
equipment in adverse weather conditions; keeping within the safe working limit; prohibiting the transfer of persons or
materials to or from the platform while it was in a raised position; regular inspection and servicing of the equipment;
preventing falls from the platform by the use of hand rails or harnesses; controlling working areas by the use of
barriers and signs and providing head protection where appropriate.

M
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)
a) Metal fatigue occurs because the accumulating effects of fluctuating loads promote slow changes in the
crystalline structure of a metal. Cracks appear at the point of high stress and extend until they reach a critical length.
There is little or no deformation prior to the failure which may be ductile or brittle. The failure surface shows
conchoidal marks which progress as narrow rings at low load but become extended at full load.
(b), the factors which could give rise to fatigue failure in practice such as stress concentration particularly at
sharp corners and holes; surface and sub-surface defects such as flaws, cracks, occlusions and impurities; design
and fatigue strength issues; residual stresses imposed during manufacture or assembly; and the effects of factors
such as corrosion or temperature. The majority offered only stress related factors and made no mention of issues
such as corrosion and the effects of temperature.
i) the characteristics of electrolytic corrosion include the presence of corrosion products consisting of metal oxides
which affect the quality of the product. The corrosion forms pitting round water droplets or condensate is found
especially on the underside of hot pipe work and ultimately can have an effect on the flow of product within the
pipework.
ii) As for the factors which cause electrolytic corrosion, candidates should have explained that it is an electro-
chemical process where a combination of moisture, oxygen and an electrolyte combine to promote the liberation,
transfer and consumption of electrons. The relative reactivity of metals is also a factor and environmental
contaminants such as sulphur or nitrous oxides may accelerate the corrosion. Reference should have been made to
the parts played by the anode and cathode and importantly to the need for an external source of electrical current.
N
(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)
a) The purpose of non-destructive testing (NDT) is to check for faults such as cracks in components before they
develop into total failure without affecting the integrity of the component. Most candidates managed to provide a
reasonable outline for this part of the question.
(b) the use of the dye penetrant technique makes cracks visible as dye penetrates into them. It is a relatively cheap
and simple operation but it does not detect sub-surface faults, is not totally reliable, interpretation of the indications
may be difficult, there is a possible element of toxicity involved and there is no permanent record available of the
results of the test.
With radiography, x-rays or gamma rays are used to penetrate the item to leave an image on film. Any defects are
shown up by the differences in the intensity of the radiation striking the film and the contrast in the images produced.
The benefits of this technique are that it detects internal defects and produces a permanent record of the test.
However, the operation is time consuming, expensive and requires a lot of space for the equipment involved. It also
requires skilled operators and there is a danger of radiation exposure.

O
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)
The initial precaution to be considered would have been the possibility of re-routing the cables but if this was not
possible then the local electricity supply company would need to be approached for advice on the precautions to be
taken. This would include advice on the maximum working heights and horizontal distances permitted near the
overhead lines. The next step would be to establish the maximum height and vertical reach of plant to be used on
site including those of sub contractors and those which could penetrate the safe distances would have to have
physical limiting equipment fitted. Safe routes where plant could travel and operate would have to be marked,
barriers and solid goal posts erected which would need to be monitored on a regular basis to ensure they remained
intact and in place, and appropriate warning signs displayed. Non-conductive equipment, for example wooden
ladders, would have to be used on site. Workers and sub contractors should be briefed on the hazards associated
with the work and the safe systems of work to be followed and drivers of visiting vehicles would also have to be
instructed on the routes to be followed. Procedures for dealing with an emergency would be necessary and
information on these procedures would again have to be passed on to workers. Finally, a high level of supervision
would have to be provided to ensure that there was strict adherence with the precautionary measures that had been
put in place.

O
Outline the organisational & personal factors that can contribute to the incidence of work-related stress 
The organisational factors, contribute to workplace stress such as negative workload, isolation, extensive hours
worked, toxic work environments, lack of autonomy, difficult relationships among coworkers and management,
management bullying, harassment and lack of opportunities or motivation to advancement in one’s skill level.
Personal factors, Stress-related disorders encompass a broad array of conditions, including psychological disorders
(e.g., depression, anxiety, post-traumatic stress disorder) and other types of emotional strain (e.g., dissatisfaction,
fatigue, tension, etc.), maladaptive behaviors (e.g., aggression, substance abuse), and cognitive impairment (e.g.,
concentration and memory problems). In turn, these conditions may lead to poor work performance, higher
absenteeism, less work productivity or even injury. Job stress is also associated with various biological reactions
that may lead ultimately to compromised health, such as cardiovascular disease, or in extreme cases death.
P
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
plastic pellets have been sprayed with flame retardant. 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 a suitable and sufficient fire risk assessment
is made for the premises. (20)
There are a number of factors to be considered in carrying out a suitable and sufficient fire risk assessment of the
premises described in the scenario and they may be grouped under the general headings of fuels, ignition sources,
people issues, preventive actions, mitigating actions, means of escape and management systems.
Factors connected with fuels which would have to be addressed include the LPG for the fork lift trucks, the flammable
covers and untreated fillings and structural issues such as the materials of construction of the premises themselves.
Ignition sources would include those connected with the use of electricity including the likely presence of static,
friction from machinery which may not be adequately maintained, “illegal” smoking by personnel, the controls (or lack
of them) introduced for maintenance which might include hot work, and the possibility of arson.
As for people issues, attention would have to be given to the number of persons to be evacuated in the event of a fire
including visitors and contractors with the needs of disabled workers being particularly addressed.
Preventive actions would include compartmentalisation for higher risk areas such as the plastics and LPG stores
with the latter being segregated, bunded and provided with a fixed sprinkler system; fixed protection systems in
warehouses and an adequate supply of water and/of foam; the use of fire resistant cover materials; minimising the
amount of stock kept on the premises and ensuring a good standard of housekeeping with facilities provided for the
segregation of waste.
Mitigating actions would be concerned with the sufficiency and appropriate nature of the fire fighting equipment
together with its location, smoke venting of warehouses and the provision of access for emergency services.
The assessment would need to give particular attention to the means of escape and there would have to be
assurance that these were continually maintained and that fire doors were correctly specified. Attention would have
to be given to travel distances including multi-storey considerations, the provision of normal and emergency signage
and emergency lighting together with refuges for subsequent evacuation and the provision of assembly points in a
place of safety.
Finally the assessment would have to consider the management systems introduced for the maintenance and testing
of fire precautions and mitigation equipment, the carrying out of fire drills and the training given to workers both in
evacuation procedures and the use of fire fighting equipment.
As for procedural arrangements, the selection and training of competent drivers who would be subjected to regular
health screening; the provision of information on site rules for visitors including drivers visiting the site; the
introduction of procedures for the regular maintenance both of the traffic routes and of in-house vehicles and for the
reporting of defects; the rigorous enforcement of speed limits and the provision and use of high visibility clothing by
employees working in close proximity to traffic routes.

P
In 1988 a disaster occurred on the Piper Alpha platform in the United Kingdom.
Identify mechanical failures that contributed to the initial explosion. (4)
Outline the systems failures associated with the permit-to-work system that contributed to the initial
explosion.
The removal of a safety pressure valve and its replacement with a blank flange assembly which was incorrectly fitted
and was not leak tight. A running condensate pump tripped and a stand by pump, associated with the blanked flange
was operated. Condensate and gas escaped from the blanked flange and the gas exploded.
The failures with the permit to work system which was in operation for the removal of the pressure valve including a
failure in communication at the end of the working day with the suspended permit returned to the control room but not
displayed and a failure to check that the blanked valve was leak tight at the time; a failure in communication at shift
handover with the absence of any written procedures for this event; the absence of formal training for those with the
responsibility of issuing permits; inadequate written procedures for the permit to work in that there was no reference
to locking off or tagging valves to prevent inadvertent operation, no mention of the need to cross reference permits,
no place on the permit for the issuer to declare that the work had been left in a safe condition, no attention drawn to
the potential dangers associated with the ‘suspension’ of permits, and finally inadequate monitoring and auditing by
management of the permit to work procedure.
P
A plastics injection molding machine is supplied to your workplace.
Outline the molding machine’s features that you would have expected to have been addressed in order to
demonstrate that the machine is safe. (20)
The safety of the plastics injection moulding machine could have been outlined under the headings of general
features, and those dealing with controls, protection against mechanical hazards, protection against other hazards,
maintenance and indicators.
The general features of the machine include the safety integration principles such as the control hierarchy applied,
foreseeable abnormal use and ergonomics anthropometry; the prevention of danger to the user from the materials
used in the construction of the machine or products created during its use such as coolants; the lighting provided
which gives adequate visibility without causing dazzle or producing stroboscopic effects; and the handling and
installation of the machine so that sharp edges are avoided and the machine is fitted with eyebolts.
With regard to controls and control systems, their safety and reliability should be addressed to ensure they can
withstand the rigours of normal use and take account of errors in logic; that control devices are visible, identifiable,
well positioned, logical and sufficiently robust; that there are adequate means for starting the machine by voluntary
actuation except where an automated cycle is in operation and a stopping device is fitted which disengages power to
the actuators and also an emergency stop which brings the machine to a halt quickly without creating additional risk;
that a failure of the power supply and/or control circuit does not allow the machine to start unexpectedly and the
protection devices remain effective, and that any interactive software fitted is user friendly.
The features concerned with the protection against mechanical hazards which should have been addressed include
the stability of the machine; the risk of break up during operation; the risks caused by falling or ejected objects; the
variations in speeds and risks from moving parts which should be designed to avoid hazards or provided with
protective devices; the choice and characteristics of guards and protective devices whether fixed, movable or
adjustable; and issues arising from working at heights.
Protection against other hazards would need consideration of electrical risks, those arising from fire and explosion,
extremes of temperature, noise and vibration and the emission of dust and/or gases. As for maintenance, matters
such as remote adjustment and lubrication, automatic cleaning, isolation, and means of access should have been
addressed, while finally for indicators, issues which should have been considered include the provision of
unambiguous and easily understood information and warning devices, the provision of instructions on the
installation, use and maintenance of the machine and its marking, in particular the CE mark, its serial number and
details of the manufacturer.

P
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.
Outline an inspection strategy that could prevent pipework failures within this plant. (10)
Outline the items that could be included on a checklist when inspecting pipework after construction.
Inspection strategy that could prevent pipework failures within this plant. The strategy would involve the use of NDT
techniques such as dye penetrant for the detection of surface faults and ultrasonics or radiography to detect those
that were more serious. The techniques would involve the use of qualified personnel to interpret the results and
management should resist the temptation to use unqualified personnel for any type of pipe work inspection.
Inspection should take place during and after construction has been completed and should be ongoing throughout
the life of the plant. Those carrying out the inspections should preferably include a member of the design team who
will be able to detect departures from the design intentions and also a member of the start up team who suffer most
from the results of construction defects.
The items that could be included on a checklist when inspecting pipework after construction , such as that: the
construction of the pipe work is from the grade of steel specified and the required tests have been carried out; the
pipes are not secured too tightly and are free to expand; the flanges on liquid lines are not located above cables;
temporary supports have been removed and permanent supports correctly installed; springs and hangers are not
fully compressed or extended; no sub-standard joints exist, no screwed joints have been used and all joints have
been leak tested; temporary branches, nipples and plugs have been removed and replaced with welded plugs; pipes
do not touch the ground, are not laid underground and do not pass through pits or depressions containing water;
relief valve drain lines are not too close to the ground so that blocking and freezing is avoided; reinforcement pads
are vented; dead ends, dead legs and water traps have been avoided; bellows are not distorted and support rings
are not loose; vibrating pipes have been avoided and all pipe work has received hydrostatic testing.
P
Failure of pressure systems can result in accidents.
(a) Identify FIVE examples of pressure systems AND give a workplace example in EACH case. (5)
(b) Outline a typical written scheme of examination for pressure systems. (5)
(c) Outline other control measures that could reduce the risk of pressure system failures. (10)
(a) the examples of pressure systems such as pressurised process plant and pipe work connected with chemical
processes; fixed or portable compressed air systems as used for painting or tyre inflation; pressure cookers normally
present in industrial kitchens; heat exchangers providing heating or cooling in industry; refrigeration plant found in a
food storage building; boiler or steam heating systems providing general heating in workplaces; and autoclaves or
equipment sterilisers used in cleaning laboratory glass ware.
b) A typical written scheme of examination for pressure systems would cover all protective devices and would
include all pressure vessels and pipe work that could give rise to danger if they failed. The type of examination
would be specified such as, for example, as a result of a statutory requirement, as would also the frequency with
which the examination should be carried out. The scheme would stipulate the special measures needed in preparing
the plant for examination and in the case of a fired or heated pressure systems, the need for them to be examined
when cold and also when in operation with a final requirement that the examination should be carried out by a
competent person.
c) other control measures that might reduce the risk of pressure system failures under the headings of equipment,
operating conditions, protective devices, the provision of maintenance and the provision of operator training.
Under equipment, it would be imperative to ensure that installations are suitable for their intended purpose, and are
installed correctly with due regard to design conditions, installation standards and accepted codes of practice.
Operating conditions require a knowledge of the nature, and pressures and temperatures of the gas or liquid being
pressurised or contained, the safe operating limits of the system and equipment linked with the system and the
methods of operating within these limits; the availability of operating instructions for the system and equipment
linked with the system and the accessability by workers to instructions on what action to take in the event of an
emergency.
As for protective devices, these should be suitable, adjusted to the correct settings and should function properly at
all times.
Maintenance is an important control measure and a programme should be drawn up for the whole system,
monitoring it for defects and for signs of corrosion and wear and ensuring that both the examination and any
necessary remedial work is carried out using safe systems of work and under competent supervision.
Finally, training would have to be provided for all operators, maintenance personnel, and those responsible for
carrying out inspections of the system to ensure they were in possession of the necessary knowledge and skills to
perform their duties.

P
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)
(a), the event of an uncontrolled release, there would be a need for emergency planning to localise the release and if
possible, contain it; and to minimise the harmful effects of the release on people, property and the environment both
inside and outside the installation by the use of safety systems, alarm systems and the emergency services. Clear
and well defined plans should be made available for quick and effective use and where emergency equipment and
manpower are limited, provision should be made for mutual assistance between neighbouring industrial activities.
(b), general emergency planning measures that should be taken by the competent authorities include the need: to
establish arrangements for an on-site emergency plan which should be drawn up by the management of the
installation; to establish arrangements for an off-site emergency plan to be drawn up by the competent authority in
conjunction with the installation’s management, which should be prepared following consultation with various bodies
such as the fire and police authorities and the hospital and ambulance services and which should be consistent with
the on-site emergency plan; to ensure that regular rehearsals were carried out in order to keep the off-site plan in a
state of readiness and also to ensure that information on safety was provided to members of the general public.
R
A company has been contracted to undertake maintenance work on the roof of a building, which is partly
constructed of fragile material.
Identify the characteristics of the fragile material that may contribute to the risk of falls through the roof.
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)
The characteristics of the fragile material that may contribute to the risk of falls through the roof; such as the age
and condition of the material; the type of material such as fibre board, asbestos or polycarbonate and its thickness;
the sheet profile; the span between roof supports; the design of the supporting structure such as the purlins; the
condition of the fixings; the slippery nature of the surface and the fact that the fragile material might well be
camouflaged by deposits of dirt and other material.
The measures to be taken to reduce the risk to those involved in the roof work and those who may be affected by it ,
an initial reference should have been made to the importance of completing a full risk assessment of the operation
to be carried out and the consequent production of a method statement detailing the safe system of work to be
followed. This would describe the proposed means of access to the area of work such as the provision of scaffolds
and crawling boards and the erection of edge protection to prevent the falls both of persons and materials from the
roof. It would also be necessary to identify areas of the roof containing fragile materials, to mark them with barriers
or signs and to prevent falls through them by the use of covers. An additional safeguard would be to provide safety
nets and/or air bags under the areas of the roof which contained fragile materials. For certain tasks, the use of
safety harnesses with adequate fixing points might also be necessary. Arrangements, such as a hoist, might be
needed to transport tools, equipment and materials to the roof, while the use of chutes should be considered for the
removal of rubbish. An important factor in carrying out this type of work is to ensure the use of competent personnel
fully briefed and aware of the risks involved and the precautions to be observed. Finally, measures would have to be
taken such as the erection of barriers and signs to prevent occupants of the building from passing beneath areas of
the roof where work was being carried out and also members of the public from passing in close proximity to the
building.

R
Chemical reactions in a batch manufacturing process can lead to conditions which can cause a ‘runaway
reaction’ unless appropriate precautions are taken.
Describe what is meant by ‘runaway reaction’ and identify the conditions that may give rise to such an
event.
Outline methods of control of industrial chemical processes necessary to prevent runaway reactions.
‘Runaway reaction’ as: a reaction rate increasing exponentially to the point where auto-ignition explosion or
catastrophic over-pressure occurs; or as: increases in pressure and temperature from reaction serve to accelerate
the reaction in accord with Le Chatelier’s principal.
Conditions such as: strong exothermic reactions; inadequate provision, or failure in cooling of the reaction, and
presence of contaminant catalysis. Carrying out a hazard and operability study (HAZOP) on the reaction process
would be appropriate in this scenario; this may then have led to the inclusion of design features such as: high
integrity temperature detection being linked to the cooling / reactant addition system; pressure rise detection linked
to cooling / venting / auto shut-down; vessel protected by correctly sized bursting disc. Operational features such as
ensuring that: only high calibre of operator required for such processes were employed; ensure that maintenance
activities / raw material handling do not introduce potential catalysts into the reaction.

R
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)
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)
Strategies such as planned preventive maintenance (PPM), breakdown maintenance, condition monitoring and
emergency maintenance. The principles of PPM include the need for planned maintenance and parts
replacement set against a schedule of time or running hours and driven by a record keeping system. Breakdown
maintenance, being reactive, means that maintenance is undertaken in response to reports of malfunction of
equipment and the maintenance activity is not required whilst the plant continues to operate effectively. Condition
monitoring requires monitoring of specified parameters, (for example, vibration levels or metal content of cutting
fluids, etc); specifying the level of each parameter when maintenance work needs to be undertaken and measuring
continuously or to a schedule. Emergency maintenance includes maintenance undertaken to prevent more serious
consequences such as reinforcement to prevent failure or the use of temporary supports to prevent collapse.
Factors such as statutory requirements including examples of the types of work equipment involved such as cranes
and air receivers, and the cost benefit analysis of PPM versus breakdown including the availability of spares,
competent staff, and the expected life-time of equipment. Additional factors that could have been included in the
advice to the Engineering Department are the outcome of risk assessments in terms of failure probability and
consequences; the history of failure with example sources such as incident reports and maintenance data; any
relevant manufacturer’s data or recommendations for the plant; the extent of and / or conditions of use; the
opportunity for downtime and the integration with existing systems such as condition monitoring.
R
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)
The measures that should be taken to reduce the risks to workers and members of the public. Selection and
subsequent monitoring of the contractor is an important factor as are the completion of risk assessments and the
development of safe systems of work and a method statement. The more specific measures required in this
scenario, such as the provision of appropriate means of access, the correct use of ladders, ensuring they were tied
and footed, and the provision of edge protection or other means to prevent falls of persons and materials. Safe
means of transporting tools and materials to and from the roof including enclosed debris chutes, the removal of
waste from the site, precautions when using LPG and the use of trained and competent employees, provided with
appropriate personal protective equipment such as gloves, boots, knee pads and masks are also crucial.
Consideration should also be given to the possibility of contact with hazardous substances such as tar or asbestos
and precautions taken to prevent exposure both of the contractor’s staff and members of the public.
Additional measures to improve the health and safety of the office staff and members of the public include the
erection of barriers and signs at ground level, safe arrangements for vehicle movement and security measures to
prevent access to the site by un-authorised persons.

R
Unless appropriate precautions are taken, chemical reactions in a batch manufacturing process can give
rise to conditions which can lead to a ‘runaway reaction’.
Describe what is meant by ‘runaway reaction’. (2)
Identify the conditions that may give rise to such an event. (4)
Outline the design and operational features of chemical processes that are necessary to prevent such an
event.
“Runaway reaction” as: an uncontrolled exothermic reaction where the heat produced exceeds the heat removed.
The surplus heat raises the temperature of the reaction mass and hence the reaction rate resulting in a runaway
reaction. Reference could also have been made to the fact that the rate of heat production is exponential whereas
the rate of heat removal is linear.
The conditions such as: the presence of a strongly exothermic reaction; inadequate provision of, or failure in cooling
of the reaction; the presence of contaminant catalysis; excessive quantities of reactants present in the reactor; the
lack of sensitive temperature detection and control; the insulation of the reaction vessel where solid residues have
built up on the internal walls of the vessel and mixer failure with loss of agitation
Carrying out a hazard and operability study (HAZOP) on the reaction process would be appropriate in this scenario.
This might then lead to the inclusion of design features such as: high integrity temperature detection being linked to
the cooling/reactant addition system; pressure rise detection linked to cooling, venting or auto shut-down; the
protection of the vessel by correctly sized bursting discs; and the fitting of an agitation failure alarm. Operational
features such as ensuring that: only a high calibre of operator was employed in such processes; that decision making
requirements by operators in response to adverse operating conditions were minimised; that maintenance and/or raw
material handling do not introduce potential catalysts into the reaction; that the rate of addition of reactants was
limited and that inappropriate scale-up or fouling was avoided.

R
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.
(b) Outline methods of control of industrial chemical processes necessary to prevent or mitigate runaway reactions.
(4)
a) “Runaway reaction” as: an uncontrolled exothermic reaction where the heat produced exceeds the heat
removed. The surplus heat raises the temperature of the reaction mass and hence the reaction rate resulting in a
runaway reaction. Reference could also have been made to the fact that the reaction rate is exponential whereas the
rate of heat removal is linear. Candidates could then have gone on to identify conditions such as: the presence of a
strongly exothermic reaction; inadequate provision of, or failure in cooling of the reaction; the presence of
contaminant catalysis; excessive quantities of reactants present in the reactor; the lack of sensitive temperature
detection and control; the insulation of the reaction vessel where solid residues have built up on the internal walls of
the vessel and mixer failure with loss of agitation. In general there were poor descriptions given of a runaway
reaction and of the conditions that would cause the event.
(b), the relevant control methods such as the installation of high integrity temperature detection linked to the
cooling/reactant addition system; pressure rise detection linked to cooling, venting or auto shut-down; the protection
of the vessel by correctly sized bursting discs; and the fitting of an agitation failure alarm. Operational features such
as ensuring that: only a high calibre of operator was employed in such processes; that decision making requirements
by operators in response to adverse operating conditions were minimised; that maintenance and/or raw material
handling do not introduce potential catalysts into the reaction; and that the rate of addition of reactants was limited.
R
A pressurised steam boiler requires an examination; at the same time a repair on an electrically driven
pump, associated with the boiler, is needed.
Define the term ‘relevant fluid’ in relation to pressure systems safety. (4)
Outline the typical contents of a written scheme of examination form for the boiler. (8)
Identify the practical measures that should be taken to carry out the pump repair safely.
A “relevant fluid” means steam; any fluid or mixture of fluids which is at a pressure greater than 0.5 bar above
atmospheric pressure and which fluid or mixture of fluids is a gas, or a liquid having a vapour pressure greater than
0.5 bar above atmospheric pressure when in equilibrium with its vapour at either the actual temperature of the liquid
or at 17.5°C; or a gas dissolved under pressure in a solvent contained in a porous substance at ambient temperature
and which could be released from the solvent without the application of heat.
The typical contents of a written scheme of examination form for the inspection of a boiler, such as: the identification
of the items of plant or equipment within the system; the parts of the system which are to be examined; the nature of
the examination required including the inspection and testing to be carried out on protective devices; the preparatory
work needed for the item to be examined safely; the maximum interval between examinations; whether an imminent
danger report is required to be given to the enforcing authority and/or the employer; the critical parts of the system –
if modified or repaired – which must be examined by a competent person before the system is used again; the name
of the competent person certifying the written scheme and the date of certification.
Need to issue a permit to work which would specify the control measures to be taken such as: the isolation and
locking off of the electrical power to the pump; the isolation of pipelines by locking valves or inserting blanks;
releasing stored energy, de-pressurising, draining and decontaminating the pump; allowing hot machinery to cool to
at least 50ºC; segregating the work by the use of barriers and signs and providing safe means of access for
employees who were to carry out the repair work. Other measures that should be taken include the use of skilled and
competent personnel to carry out the work; the provision and use of personal protective equipment such as head
protection, eye protection and gloves; the provision of a good standard of lighting and ventilation and finally ensuring
co-ordination with the person conducting the examination of the boiler.
As for procedural arrangements, they would include the selection and training of competent drivers who would be
subjected to regular health screening; the provision of information on site rules for visitors including drivers visiting
the site; the introduction of procedures for the regular maintenance both of the traffic routes and of in-house vehicles
and for the reporting of defects; the rigorous enforcement of speed limits and the provision and use of high visibility
clothing by employees working in close proximity to traffic routes.

R
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)
(a) the hazards such as over-filling, over-loading or spillage; the presence of incompatible or contaminated
products; the presence of fumes or vapour together with an ignition source such as static electricity or smoking
resulting in a fire or explosion; a vehicle collision or a vehicle driven away while the hoses are still attached; and the
risk of a fall from working at height. Many candidates were unable to provide four different hazards with few referring
to incompatible or contaminated products and vehicle movement.
(b), the fact that the explosion could be confined in a tank or vessel or be unconfined in the open air if large quantities
of vapour were present. It would be generated by the formation of a flammable mixture in air within the upper and
lower explosion limits, which would be ignited by a source with energy in excess of the minimum required. All three
elements of the fire triangle would need to be present for the explosion to occur.
c) Practical ways of minimising the risk of an electrostatic charge include the use of tankers and pipe work with high
conductivity; reducing the velocity of the filling or draining operation by controlling the pump rate; reducing
constrictions by the use of smoother pipes unrestricted by strainers; increasing the relaxation time by using longer
pipe work; earthing the pipe work and tanker and bonding to the same electrical potential; and using anti-static
clothing and footwear and anti-static additives in liquids.
(d), control measures such as the preparation of written procedures and instructions; the identification of specified
entry and exit routes for tankers together with a high level of communication and cooperation between the tanker
driver and the site operator; the use of pumps, hoses and other equipment which are suitable for purpose, properly
installed and regularly maintained; fitting devices such as a high level alarm to prevent overfilling; the erection of
barriers or the use of bollards and warning cones to prevent a collision between vehicles and installing a system to
prevent the tanker driving away if hoses are still connected to it; ensuring tankers are positioned correctly with wheel
chocks and hand brake applied; ensuring hoses are coupled without submitting them to abnormal stress and valves
operated in accordance with the laid down procedures; switching off electrical equipment which was not required for
filling such as mobile phones and bonding and equalising the potential between the tanker and the fixed installation;
using bottom loading tankers in preference to those which are top loaded but if this is not possible, ensuring that the
top loaded tankers have a fill pipe which touches the bottom of the tanker and that hand rails or fall arrest equipment
is provided to prevent falls; and finally preparing procedures to be followed in the event of an emergency and
ensuring that all workers are fully conversant with them.
R
(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)
This question was assessing IC6.2 Describe with examples, the principal generic mechanical and non-mechanical
hazards of general workplace machinery.
This was the least popular question in Section B. Candidates and accredited course providers are reminded that the
hazards associated with the use of robots remains on the syllabus.
Some candidates understood that robots were prone to sudden, unpredictable movements but too few referred to
the reasons for aberrant behaviour or the potential for the release of stored energy. Few candidates listed the
dangers arising from the work activity eg spot welding or from the dangers that arise during maintenance and
teaching activities.
Some candidates identified how risk could be minimised but failed to give sufficient detail to justify high marks. They
could have referred to restriction of access to operating areas by barriers, interlocked access, software checks and
the elimination of stray radio frequency interference. They were, however, unclear about how to minimise the risk
whilst maintaining robots and the use of such techniques as remote diagnostics.

S
An independent scaffold is to be used as a working platform to carry out repairs to a two-storey building.
Outline factors which should be considered in order to confirm that the scaffold is safe to use.
Identify the inspection requirements for the scaffold. (5)
Factors to be considered in order to confirm that the scaffold is safe to use include that: it has been designed to
carry all loads likely to be placed upon it including sheeting, chutes and nets and has been erected by a competent
person; it is constructed of sound materials and fittings and has been erected on firm level ground avoiding all voids
and drains; that the standards are supported on base plates on suitable sole plates with care being taking to ensure
joints are staggered; that longitudinal and diagonal bracing and ledger braces have been used; that the working
platforms are fully boarded, are wide enough for the work to be undertaken with the boards fully supported without
any overhang; that guard rails, toe boards and brick guards or sheeting have been provided; that there is safe
access to the scaffold with ladders extending to at least one metre above the working platform; that appropriate
methods for dealing with waste such as chutes have been fitted together with the means for raising and lowering
materials such as hoists or closed containers and that if the scaffold is erected in a position where there is likely to
be movement of vehicles, protection has been provided to prevent damage from any collision that might occur.
Inspection by a competent person is necessary following erection, at specified intervals, following any alterations or
damage or after a period of inclement weather. Records of the inspections should be retained and the scaffold
tagged as having been inspected.

S
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 the additional practical measures that could minimise the risk of injury to the scaffolders and members of
the public during this activity. (10)
The first option would be to investigate the possibility of using an alternative means of lifting such as a crane. If this
was not possible then there would be a need to ensure that the pulley wheel and rope were in good condition and
had been subjected to the required statutory inspections and that the safe working load of the equipment was not
exceeded. The workmen would need to adopt the correct slinging techniques and knot tying on the scaffold poles
and use guide ropes where necessary. Toe boards would need to be fitted on the upper platform to protect both the
worker on that floor and the public below while a harness should also be worn by the worker on the upper floor as
fall protection. Attention should be given to nearby hazards such as obstructions and power lines and signs and
barriers erected at ground floor level to prevent public access to the lowering area. There could be a danger from
passing traffic and the placing of cones would help to prevent a collision with the vehicle. Finally, a good means of
communication between the workers would be essential and it would be advisable to allow frequent breaks or to
introduce job rotation to avoid the possibility of upper limb disorders.
S
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)
The elements of a safe system of work for carrying out the operation: the use of experienced workers fully trained in
the systems to be adopted since this is not a task to be carried out by the young or inexperienced; the provision and
use of a single one piece close fitting overall with no external pockets together with arrangements to ensure there
are no other entanglement hazards present such as the wearing of jewellery, pendants for example, or long hair; the
use of temporary guards on or the isolation of parts of the machine which are unnecessarily exposed; where
practicable the use of jigs to ensure workers’ hands are distanced from the unguarded rotor; the provision of a “stand
by” man in direct contact with the person carrying out the work with means of immediate communication such as
telephone or radio to ensure an emergency response should the need arise; the provision, close at hand, of an
emergency stop or braking arrangements; the use of an inching device to minimise the free rotation period or using
the slowest speed possible consistent with the task; the provision of adequate lighting; the introduction of a permit to
work to formalise the establishment of the safe system of work and the erection of barriers and signs to prevent the
close approach of non-involved personnel.

S
Outline the advantages and limitations of the following types of fall protection devices, giving a suitable
application for each:
safety harnesses; (5)
safety belts; (5)
safety nets; (5)
air bags. (5)

Safety harnesses may be used in high fall potential areas where full arrest is required when carrying out short
duration work when it would be impracticable to provide more sophisticated measures. Their limitations include the
need for secure anchoring points, their restrictions on movement, their requirement for trained and competent users
and the fact that they provide individual protection only. A suitable application for this device would be in general
construction work.
Safety belts, too, can be used in high fall potential areas for short duration work where the provision of more
sophisticated measures would be impracticable. However, this device offers restraint rather than fall arrest, again
requires anchoring points, provides individual protection only and may need to be supplemented with collective
measures. A suitable application for this device would be to gain access to a pole or pylon.
The advantage of safety nets is that they can provide collective protection (for the fall of persons and materials) for
long term work where full arrest is required. Their installation, however, takes time and needs to be undertaken by
competent persons. They can be used only in low to medium fall potential areas. They are most suitable for use over
water or under fragile roofs.
Air bags can provide collective protection for falls and have the advantage of being available in different sizes. They
do, however, provide only small areas of protection, need installation by competent personnel, require a continuous
power supply and may be used only in low fall potential areas such as short run construction projects or around
workplace transport.

S
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)
One of the first measures to be taken in this situation would be to carry out an assessment of the risks involved in
carrying out the activity which would include the hazardous properties of the paints and solvents used ( normally by
reference to safety data sheets), the circumstances in which the work was carried out, possible ignition sources and
the likelihood that a fire or explosion would occur. The control measures to be taken would be firstly to ensure that
the workshop was constructed of fire resistant material, and then to give consideration to the possibility of replacing
the paint in use with one that was less flammable. An external fire resistant storeroom would have to be provided for
the paints and solvents with the quantities present in the workshop reduced to a minimum and kept in non-spill
containers provided with lids. Procedures would have to be put in place for the containment and clean up of spillages
and for the cleaning of the spray guns. Local exhaust ventilation would have to be provided in the workshop with
care taken to ensure all electrical equipment was to the standard appropriate for the conditions that might prevail,
such as flameproof or intrinsically safe. Fire fighting equipment would have to be provided together with adequate
fire escape routes and emergency procedures drawn up and communicated to the workforce who would also need
instruction and training on the risks involved in the operation and the precautions to be observed.
S
Describe the effects of a fire in a workplace on the following structural materials:
(ii) steel; (4)
(iii) concrete; (4)
(iv) Wood. (4)
Outline the precautions that could be taken to prevent failure of these materials in the event of fire.
Steel expands on heating, loses strength as the temperature rises and tends to deform and buckle. It regains
strength on cooling but its properties may have changed.
Concrete on the other hand exhibits limited expansion and has a tendency to spall and crack which can be
exacerbated by the expansion of steel reinforcement within the concrete. The structural strength of concrete is lost
on cooling and it loses structural integrity.
As for wood, while thin sections will burn and promote fire, the charred surface of thicker structural members may
act as an insulator to protect the inner timber. However, burning timber generates smoke and fumes and allows the
surface propagation of fire. Some varieties of timber are more resistant to fire than others while large timbers
generally tend to retain their structural integrity.
The precautions that could be taken to prevent failure of the materials in the event of fire. Steel might be protected
by the use of sprayed concrete or intumescent coatings, while for concrete, the selection of the type of mix to
improve fire resistance and increasing the thickness of concrete between the external face and reinforcement bars
would provide some protection. Failure of wood may be prevented by selecting fire resistant timber, increasing the
thickness used to allow for a charring outer layer or impregnating it with fire retardant. Other general precautions
include the provision of means such as compartmentalisation to prevent heat transfer through long steel members in
the event of fire; automatic means of applying water to structural members should fire occur and the use of fire
resistant surface claddings or flammable sacrificial cladding.

S
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.
(b) Outline the emergency procedures you would implement in the event of accident or illness for this type of lone
working. (6)
Safety precautions that could reduce the risk of falls from height when working from a ladder to install the dishes
include the use of a recognised standard of ladder, whether conventional or combination, which should be
appropriate in length, strong enough to carry its intended load, provided with stabilisers at the base, inspected at
regular intervals by a competent person and tagged to indicate its inspection date and should additionally be
inspected on a daily basis by the user before starting work. The ladders should be sited on firm and even ground, at
a 75 degree angle, and against a stable upper contact point. A safety rope should be attached to the ladder and
secured to a suitable anchor point on the wall. Another rope should be provided to enable the dish to be elevated to
the required height. Workers should be competent and trained in the safe use of ladders with emphasis being laid
on constantly maintaining three points of contact on the ladder, the dangers of overreaching, the wearing of
appropriate clothing, particularly foot wear, and the use of a tool pouch for carrying the necessary tools and
equipment. Many candidates did not seem to understand what was involved in installing a dish and suggested
eliminating lone working, employing a team of erectors, and using a scaffold or a MEWP. Some suggested the use
of personal protective equipment such as hard hats, gloves and goggles without indicating what part these would
play in reducing falls.
Emergency procedures to be implemented for lone working in the scenario described, would fall into two categories
– sources of help in non-life threatening circumstances and those where there was a threat to life. In the first
instance it would be sufficient to provide the worker with a help line number and the location of either walk-in
services or first aid provision in the area where the work was being carried out. In a life threatening situation, there
would need to be the introduction of procedures for contacting local accident and emergency departments; a list of
persons to be contacted in the event of such an emergency and carried by the worker in circumstances where he
would not be in a position to make the call himself; the provision of means of communication such as a mobile
phone or radio and a routine requiring the worker to contact and report to base at set intervals.

S
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)
the risks associated with this specific example of entry into a confined space.
For instance, it was necessary to outline the risk of oxygen depletion and asphyxiation, the risk of fire and explosion
from methane gas and the risk of inhaling toxic gases disturbed by walking in the sewer.
Risks associated with bio-hazards such as Weil‟s disease and leptospirosis. Candidates could also gain marks for
outlining the risks associated with needle stick injuries and contact with sharp objects when entering the sewer.The
risks of entrapment, drowning and of sewer collapse.
S
A rectangular warehouse building (40m x 100m ground area and 18m high) was constructed on a structural
steel framework, with a flat roof and coated steel walls. During a storm, the warehouse suffered a
catastrophic failure of one of its long walls which in turn caused the collapse of the roof and buckling of the
other walls.
Outline the possible causes of this structural failure. (10)
Outline the health and safety issues to be considered when planning the subsequent demolition of the
damaged warehouse. (10)
Possible mechanisms of structural failure that included: impact damage by moving plant creating initial weakness;
adverse weather conditions where the designed wind loadings were exceeded or low temperature resulting in brittle
failure; overloading of the structure by excess weight on the roof caused by snow or rain water; weakening of the
steelwork by corrosion through roof leaks or the in-operation of rain water drains; alteration to structural members
which had invalidated the original design calculations; subsidence or nearby excavation or tunnelling operations
creating instability and vibration caused by the volume of passing traffic or wind variation which would result in
fatigue.
The competence of the demolition contractor; the method to be used for demolishing the partially collapsed
structure to prevent premature collapse of the remainder and the preparation of a method statement to indicate the
systematic approach that would be taken; precautions to be taken to prevent falls of people or material; the
identification and isolation of buried services such as electricity, water and gas; the inspection, examination and
maintenance of plant and equipment to be used; issues associated with manual handling and the use of mechanical
equipment where this was possible; procedures for the removal of waste including categorised waste and the
contents of the warehouse; identification of the possible presence of asbestos or lead paint; protection of adjoining
property; the provision of appropriate personal protective equipment for the employees such as hard hats, boots and
eye protection; the protection of the public including the erection of barriers and the introduction of arrangements to
ensure site security; contaminated land issues and the need to introduce pest control.

T
A mobile crane is to be used to erect a telecommunications aerial on the roof of a three-storey office
building.
Describe the precautions that should be taken in order to minimize risks both to employees involved in the
work and to other persons who may be affected by the operation.
Precautions such as the selection of the crane with respect to its safe working load and reach and checking the
existence of current test certificates; ensuring ground conditions were appropriate for positioning the crane and that
outriggers were used; avoiding contact with overhead services and other buildings or structures; using adequate
lifting gear and ensuring that there were competent people in control of and involved in the lifting operation.
Additionally, with the scenario very much in mind, account would have to be taken of weather conditions and the
need to follow safe roof work practices such as the provision of edge protection or the use of harnesses.
The precautions needed in relation to the employees carrying out the work and others who might be affected by the
operation. Such precautions would entail providing sufficient personnel on site to control access of the public to the
area; the provision of adequate signing and traffic control; liaison with the local police and planning the lift for a time
of day when few people would be in the vicinity.

T
Outline: The factors affecting the likelihood of an agricultural tractor overturning; (6)
The measures that may be necessary to minimise the risk, or limit the effects, of a tractor overturning. (4)
Factors affecting the possibility of overturning such as the angle of slope and direction of travel on gradients;
uneven or soft ground; speed on cornering; wheel width; the condition and pressure of tyres; the effects of trailers
and other attachments including power take-off seizure and the level of competence of the driver. Measures such as
seat restraints and roll-over protection to mitigate the effects of an overturn. Other appropriate measures to
minimise the risk of tractor overturn include restricting the use of tractors on steep gradients; fitting counterbalance
weights; fitting wider tyres and maintaining them on a regular basis; fitting a power take-off torque limiter such as
shear pins and providing training for drivers.
V
With examples of actual incidents, describe the principles and effects of a vapour cloud explosion. (10)
A vapour cloud explosion may be confined for example in a tank or vessel or unconfined. Its key principles include
the presence of flammable vapour at a concentration between the upper and lower explosive limits and an ignition
source that exceeds the minimum ignition energy. Unconfined vapour clouds may travel a considerable distance
before igniting or they may be dispersed to a concentration below the lower explosive limit depending on conditions.
The effects of vapour cloud explosions include overpressure, thermal effects and the emission of debris. In confined
explosion cases, vessel or containment rupture may occur resulting in a rapid release of liquefied gas. In unconfined
explosion cases, damage to people and property may be caused by the pressure wave and thermal radiation.
Suitable examples could have included Flixborough 1974, Abbeystead 1984, Grangemouth 1987 and Buncefield
2005.

V
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.
The specific welfare arrangements that the company would have to provide include a sufficient number of sanitary
conveniences which should be separate for men and women (or capable of being locked from the inside) and which
should be adequately lit, ventilated and kept clean; washing facilities situated close to the sanitary conveniences and
changing rooms, provided with a supply of hot and cold or warm water, soap or other means of cleansing and
means of drying; a clearly marked supply of drinking water with cups; clothing accommodation and changing
facilities which should be separate for men and women and contain means for drying wet clothing and for separate
storage of contaminated clothing; decontamination facilities with showers and a clear division between clean and
dirty areas; rest and eating facilities including sufficient tables and seats, arrangements for preparing and heating
food and for boiling water, facilities for nursing mothers and means or procedures for preventing contamination of
the area where food and drink are taken; and adequate first aid facilities including trained personnel taking into
account the number of persons employed and the proximity of emergency services.

V
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 vapor cloud explosion followed.
Describe the mechanism for an unconfined vapor cloud explosion. (3)
Outline the technical failings that contributed to this major accident. (7)
The incident at Flixborough occurred following the uncontrolled release of a gas, cyclohexane, from a temporary
pipeline which had been used to bypass a reactor taken out of service for repair. On release the gas formed a
flammable mixture in air within explosive limits and the large vapour cloud either immediately came across a source
of ignition or travelled some distance to find one where it was quickly detonated causing rapid flame propagation.
The absence of a professionally qualified mechanical engineer on site to oversee the modification between the
fourth and fifth reactor. The plant modification took place without a full assessment being made of the potential
consequences of its installation. There was an absence of drawings for the proposed modification, no reference was
made to any recognised standard, the constructed assembly was of unknown strength and flow and pressure
calculations were undertaken on a straight bypass line and not a dog leg as subsequently fitted. Pneumatic tests
that were carried out were for leak testing and not in order to assess the strength of the assembly. There was
apparently no appreciation that the pressurised assembly would be subject to a turning moment, imposing lateral
shear forces on the bellows nor an appreciation of a hydraulic thrust on them and consequently no calculations were
undertaken for the dog leg line or the bellows to withstand these strains. No reference was made to the Designer’s
guide so that bellows were used out of line without adequate support, and insufficient support provided for the newly
installed pipe work under working conditions. Finally and in short, those concerned with the design, construction and
lay out of the modification did not consider the potential for a major disaster to occur instantaneously.

V
A vegetable packing plant employing 200 men and 60 women is about to open.
Outline the specific welfare arrangements that need to be provided before the plant opens. (10)
The specific welfare arrangements that the company would have to provide include a sufficient number of sanitary
conveniences which should be separate for men and women (or capable of being locked from the inside) and which
should be adequately lit, ventilated and kept clean; washing facilities situated close to the sanitary conveniences and
changing rooms, provided with a supply of hot and cold or warm water, soap or other means of cleansing and
means of drying; a clearly marked supply of drinking water with cups; clothing accommodation and changing
facilities which should be separate for men and women and contain means for drying wet clothing and for separate
storage of contaminated clothing; decontamination facilities with showers and a clear division between clean and
dirty areas and rest and eating facilities including sufficient tables and seats, arrangements for preparing and heating
food and for boiling water, facilities for nursing mothers and means or procedures for preventing contamination of
the area where food and drink are taken.
V
(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)
Vapour cloud explosion may be confined for example in a tank or vessel or unconfined. Its key principles include the
presence of flammable vapour at a concentration between the upper and lower explosive limits and an ignition
source that exceeds the minimum ignition energy. Unconfined vapour clouds may travel a considerable distance
before igniting or they may be dispersed to a concentration below the lower explosive limit depending on conditions.
The effects of vapour cloud explosions include overpressure, thermal effects and the emission of debris. In confined
explosion cases, vessel or containment rupture may occur resulting in a rapid release of liquefied gas. In unconfined
explosion cases, damage to people and property may be caused by the pressure wave and thermal radiation.
Suitable examples could have included Flixborough 1974, Abbeystead 1984, Grangemouth 1987 and Buncefield
2005.

W
(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)
a) The effects of inadequate lighting as those relating to health and those relating to safety. Health effects may
include headaches, visual fatigue or eye strain and blurred vision and the effects of adopting a poor posture, such as
neck and backache in order to have an adequate view of the task being performed. Safety implications include the
likelihood of an increase in accidents due to trips, falls and striking against objects because the hazards are not
identified, because of the use of the wrong type of lighting such as those producing a stroboscopic effect and through
human error in performing a task which may put others at risk.
(b), the factors to be considered in providing suitable and sufficient lighting include amongst others: the type of work
to be undertaken and whether the tasks require general, local and/or localised lighting; the workplace layout giving
attention to the effects of screens, furniture or racking and the shadows that might be cast; the levels of lighting in
adjacent areas in order to avoid the effects of moving from a strongly lit area to one which is dimly lit and vice versa;
the different types and levels of lighting required for stairs, corridors and outside security lights; the level of natural
light available; the individual needs of the workers whether on account of age or disability; the possibility of glare on
display screens and through reflection from other surfaces such as wall surfaces; the colour and types of lighting
fitted to prevent stroboscopic effects; the need for emergency lighting particularly for fire escape routes; the need for
portable lighting when work has to be carried out in confined spaces and the ease of maintenance whether replacing
spent bulbs or cleaning the light fittings.

W
Animals are kept at a zoo where managers are planning to write a waste management policy. For the solid
waste produced, outline the issues that should be addressed by such a policy and associated procedures.
The statement of intent would refer to the need to minimise the production of waste; to recycle as much as possible;
and to comply with environmental legislation without putting at risk the health and safety of workers, members of the
public, contractors or animals through the waste handling procedures.
Responsibilities for achieving these objectives would then have to be clearly defined and allocated to managers,
workers and contractors.
As for the practical arrangements, these would include the separation of different types of waste; the procedures to
be followed in handling the types of waste such as animal faeces, soiled animal bedding, animal carcases, sharps,
animal feed waste as well as paper and packaging, horticultural waste and waste from the catering activities. The
waste would have to be clearly labelled and safe storage provided for it on site with attention being paid to its safe
handling with manual handling and contamination risks in mind. A licensed waste disposal contractor would have to
be used and attention paid to ensure the final destination of the waste such as to a licensed landfill site or to an
incinerator.

W
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.
Under the design issues, it need for the storage tanks and pipe work to be constructed of suitable chemical resistant
material; the design and positioning of the delivery inlets to prevent connection being made to the wrong tank; the
positioning of the storage tanks in separate bunds with the bunds being capable of holding the entire contents of the
tanks plus 10%; the erection of hazard warning signs clearly identifying the contents of the tanks and the colour
coding of pipe-work; the fitting of level indicators and high level alarms to prevent overfilling; the provision of good
vehicle access including a hard standing for tankers with facilities for spill containment and the provision of a good
standard of lighting.
Operational issues should have included the introduction of a safe system of work including emergency procedures
to deal with spillages and the provision and maintenance of a contingency supply of neutralising and absorbent
materials and water; providing training for the personnel involved including tanker drivers in the risks associated with
the operation and the control measures to be followed and the provision of personal protective equipment such as
chemical suits, chemical resistant gloves and full face protection.
The maintenance and the arrangements for the examination and testing of safety critical plant; the use of permit to
work systems; the completion of the flushing out of tanks and pipe work and their isolation before the start of
maintenance work; regular cleaning of the bunds and the provision of training to maintenance staff in emergency
procedures.