UNIT IC: |. In 1988 a disaster occurred on the Piper Alpha platform In the United Kingdom. a) Identify mechanical failures that contributed to the initial explosion (4) 'b) Outline the systems failures associated with the permit-to-work system that contributed to the initial explosion (6) In answering part (a) of the question, candidates should have referred to 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. For part (b), good answers would have referred to 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 ‘raining 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. This question was poorly answered with most candidates unable to identify the mechanical failures that led to the incident for part (a), and, for the second part, referring to a lack of communication at shift change over but litle else. 2. Outline the issues that should be included in a fire safety training session for workers (10) Most candidates were able to outline a good range of 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 fon hearing the alarm; the location and use of fire fighting 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. 3. Coal is delivered by train to a power station and is transported by conveyors to a furnace. Conveyor workers check that the coal moves along the conveyors efficiently. These workers have received suitable information, instruction and training and are supervised. Outline additional control measures that could reduce risks to conveyor workers (10)For this question, candidates were expected to refer to 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 con 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. Most candidates referred to the need to provide guards for the conveyor but did not indicate the type and location of the protection required. Some concentrated on general working conditions such as exposure to dust and dirt and wrote of job rotation and welfare issues while a few who perhaps did not read the question, with sufficient care discussed traffic management and the use of forklift trucks rather than the hazards associated with the use of the conveyors. 4, (2) Outline the features of a ‘fixed guard’ in relation to machinery safety (2) (b) Outline the factors to be considered in the design and use of fixed guards that minimise risks to workers (8) In outlining the features of a fixed guard candidates could have referred to it as a guard with no ‘moving parts affixed in such a manner (e.g. 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 2 ‘machine during its normal operation. Some candidates outlined features which were more appropriate for an interlocked rather than a fixed guard. In outlining the design features of a fixed guard, candidates should have referred to factors 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 Answers to this part of the question were to a reasonable standard though there were a few suggestions that the guard should be interlocked to stop the machine if it was removed. 5. Direct contact with live parts of an electrical supply within a workplace can result in serious injury or death. ‘Outline a range of control measures that may prevent or limit the effect of such contact (10)In answering this question, 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. Answers provided were generally not to a good standard with many candidates referring to control measures more suited to portable equipment. 3. Aworker suspended in a fall protection harness is at risk of suffering from suspension trauma with the potential for serious injury or death. Outline the precautions an employer could take to reduce the risks to the worker in this situation. (10) In answer to this question, candidates were expected to outline 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. Only a few candidates appear to have knowledge of suspension trauma with others describing standard precautions for working at height in order to prevent workers arriving in a position where they were suspended. 7. Workers in a vehicle maintenance workshop spray-paint vehicles using a highly flammable solvent-based paint. Outline the measures needed to assess and control the risks associated with the spray painting activity (20)(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 @ 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. While candidates were generally able to identify many of the control measures necessary, they had more difficulty in suggesting how the risks associated with the process should be assessed. Some lost ‘marks because they produced lists rather than the outline required, 8. Outline the features and arrangements that should be considered in order to minimise risks associated with the movement of vehicles in the workplace (20) In outlining 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 @ 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. ‘The question was well answered by the majority of candidates though some again produced lists rather than the additional detail required to satisfy an ‘outline’ question. 9. An Independent scaffold is to be used as a working platform to carry out repairs to a two- storey building. (a) Outline factors which should be considered in order to confirm that the scaffold is safe to use (15) (b) Identify the inspection requirements for the scaffold (5)Factors to be considered in order to confirm that the scaffold is safe to use include that: it has been designed to carty 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 long 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. For part (b), 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. Answers to this question were generally to a good standard despite the fact that a few candidates included inspection requirements in their responses to part (a) and thus were left with nothing more to identify for the second part of the question. 10. Prevention of pipework failures is critical in preventing major leaks and incidents. The construction of a new chemical plant is nearly complete and some parts are being prepared for start-up. (2) Outline an inspection strategy that could prevent pipework fallures within this plant (20) (b) Outline the items that could be included on a checklist when inspecting pipework after construction (20) In answering part (a) of this question, candidates would first need to make the point that any current inspection would need to be more thorough than those which may have been carried out in the past. The strategy would involve the use of NDT techniques such as dye penetrant for the detection of surface faults and ultrasonic 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 on going 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 2 member of the start-up team who suffer most from the results of construction defects. For part (b), candidates were expected to outline items 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 ail 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. This was not a popular question and answers that were submitted were not to a good standard. For the first part, candidates produced little more than a list of different types of NDT while for the second; only vague and general descriptions of the items that could be checked were given. 11. In November 1984 the San Juanico gas storage facility near Mexico City exploded with catastrophic consequences. (a) Outline the circumstances of the disaster (8) (b) Outline how a Boiling Liquid Expanding Vapour Cloud Explosion (BLEVE) occurs with a gas storage vessel constructed of metal (8) (c) Outline the immediate rescue and restoration measures that took place (4) ‘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. In answer to part (b), candidates should have outlined that 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 2 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. ‘This question was not popular and was answered by only a few candidates. While many were able to give a reasonable description of the mechanics of a BLEVE it became obvious that they had little knowledge of the circumstances of the Mexico City incident. 12, (a) Identify the hazards associated with the use of mobile elevating work platforms (MEWPs) (5) (b) Outline the control measures that should be taken when using MEWPS (5)For part (a), candidates needed to identify hazards 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 obstruction and exposure of employees to adverse weather conditions. Having identified the hazards candidates were then required to outline the measures which would bbe required to reduce the risk when using the equipment. These include the selection and training of operators; guarding scissor mechanism to prevent trapping; correct positioning of the MEWP to prevent overreaching 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 whether condition; keeping with in the safe working limit; prohibiting the transfer of whether conditions; keeping with in the safe working limit; prohibiting the transfer of persons or ‘materials to or from the platform while it was in a raised positions; regular inspection and servicing of the equipment; preventing falls from the platform by the use of harnesses; controlling working areas by the use of barriers and signs and providing head protection where appropriate. 13. A vegetable packing plant employing 200 men and 60 women is about open. The plant will ‘operate 24 hours a day on a three ~shift system. Outline the specific welfare arrangements that will be necessary prior to the factory ‘opening (10) The specific welfare arrangement 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 hhot and cold or warm water ,soap or other means of trying; 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 for boiling water facilities for nursing mothers and means or procedure 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. 14. In order to install a large item of machinery such as a turbine rotor it is sometimes necessary to platform adjustments while the rotor is in motion .These adjustments are necessarily 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 described in the QUESTION include: the use of experiences 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 with no external pockets together with arrangements to ensure here are no other entanglement hazards present such as wearing of jewellery, pendants for exampleor long hair, the use of temporary guards on the isolation of parts of the machine which are in necessarily 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 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 lowest 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. 15. A company produces waste in the form of a hazardous sludge and is concerned about the increasing cost of using an approved contractor to dispose of the waste at a landfill site. Outline FIVE options that the company could consider to reduce the cost and environmental impact of dealing with the waste (10) In answering the QUESTION, candidates should have referred to options such as identifying recycling ‘opportunities at all stages of the process; substituting process materials for ones that give arise 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. 16. (a) In relation to automatic fire detection and alarm systems outline the basic principle of ‘operation of; (i) Heat Detectors (4) (ii) Smoke Detectors (4) (b) Identify the circumstances in which each type of detector would be inappropriate (2) For heat detectors candidates were expected to distinguish between 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 thermistor. ‘Smoke detectors are two main types: lonising and optical or photoelectric. The chamber of an jonising 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 in electrical current caused by the neutralisation of ions by the smoke particles. The optical type 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 chamber where light would not normally be detected.In answers for Part (b), candidates should have identified 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 in appropriate 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, 17. Itis proposed to inspect clean and repair the inside of a tank that is 6 metres in diameter and 10 metres high and which has previously been used for storing leaded petrol. Outline the steps that should be considered in order to enter this confined space and to carry out the work safely (20) Good Answers to this QUESTIONS were those that approached the proposed work in a logical and sequential way clearly outlining what would be required at each stage in order to ensure the work in was carried out in safe manner .in order to 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 atmosphere from the previous contents of 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 urge 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 ear thing arrangements. It heat were to be a foreseeable problem then consideration should be given to issues such as job rotation and fluid intake. Additionally consideration should be given to the prevention 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 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 18. Corrosion is a major problem in many industrial processes. (a) Outline the characteristics and casual factors of electrolytic corrosion (8) (b) 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 cathode metal isretarded, Characteristics of corrosion include pitting and erosion and its product may affect quality of product and may lead to a reduction in flow in pipe work. AA 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 plastics 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 ofa sacrificial anode made of a metal which is more active than the protected metal. The connection of an 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. 19. A worker has received an electric shock from a 240 volt portable drill whilst installing a set ‘of wooden shelves. {a) Outline the physical effects the worker may have suffered from the accident (5) {b) State the emergency action that should have been taken immediately after the accident (5) (©) Identify the precautions that might have been taken to prevent the accident (10) For part (a), candidates should have outlined 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 possibility of secondary Injuries such as those resulting from a fall. Part (b) was concerned with the emergency action to be taken immediately after the accident and it ‘was expected that candidates would refer to matters 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. Part(c), ought information on the precautions that might have been taken in order to have prevented the accident. More successful candidates were those who provided a structured answer by looking at equipment selection, technical precautions and organisational issues. in selecting equipment consideration should be given to the 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. Ensuring that equipment or system components (plugs, sockets, cables etc)are free from storage 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. 20. A company has been contracted to undertake maintenance work on the roof of a building which is partly constructed of fragile material. (a) Identify the characteristic of the fragile material that may contribute to the risk of falls through the roof (5) (b) Outline the measures to be taken to reduce the risk to those involved in the roof work and those who may be affected by it (15)In answering part (a) of the QUESTIONs, candidates should have referred to characteristics such as the age and condition of the material; the type of material such as fibre board asbestos or poly carbonate 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 For the second part of the QUESTION 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 Protection of @ method statement detailing the safe system of work to be followed ; this would describe the proposed to 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 safely 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 material 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. 21. 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) This QUESTION required candidates to outline the practical measures that should be taken to protect both employees and members of the public whilst the contractors repair work was in progress. 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 or and a method statement. Candidates however were expected to add to these general points and outline 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 unauthorised persons,22, 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) In writing 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 trading 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 evacuations 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 fight aid fire fighting provision and fire protection. 23. A catastrophic fire occurs in which stores a substance which gives of 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 and building. {a) Identify the environmental impacts related to this event giving a probable source of Each.(5) {b) Identify the range of design features that could prevent or mitigate the environmental impacts of such an event at these premises.(5) In answering the first part of the QUESTION candidates should have identified that the initial impact of the fire on the environment would be the release to atmosphere of greenhouse gases. (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 effect on flora and fauna. Unless precautions were taken fire fighting media could run off to flora and fauna. Unless precautions were taken fire fighting media could run off to watercourses whilst in the clean up after the fire waste the products and sludge could be deposited in land fill sites For part (b) ,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 fire proof coating on steelwork using impervious material in the construction of the floor; providing a flame proof 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 ware house ; Using fire water catch tanks or lagoons during the fire fighting operation and treating residual solids before consigning them to landfill sites. 24, Outline the practical control measures that can be taken to minimise risk when operating a bench -mounted circular saw. (10)‘This QUESTION was concerned with the application of machinery safety principles to a specific item of work equipment. Good answers included reference 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 machines 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 protective equipment such as goggles and hearing protection ; the provision of sufficient space around the machine which should be Kept free from obstruction ; the standards of lighting heating. and ventilation ensuring the stability of the machine and that guards were always in position. 25. Legislation relating to lifting operation 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 examination might be justified. (10) In answering this QUESTION examiners were looking to candidates to outline 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 manufactures 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. 26. Unless appropriate precautions are taken, chemical reactions in a batch manufacturing process can give rise to conditions which can lead to runaway reactions. (2) Describe what is meant by runaway reaction (2) (b) Identify the conditions that may give rise to such an event (4) {c) Outline the design and operational features of chemical processes that are necessary to prevent such an event (4) Candidates could have described ‘runaway reaction’ as: an uncontrolled exothermic reaction where the heat produced exceeds the heart removed; the surplus heat raises the temperature of the reaction mass and hence reaction rate resulting in a runaway reaction. Reference could also have been made to the fact that the rate of heat production is exponential is whereas the rate of the heat removals linear. Candidates could then have gone on for part (b) 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. For part (c) 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 systems; 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. Candidates could have outlined ‘operational features such as ensuring that: only a high calibre of operator was employed in such processes; that decision making requirement 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. 27. rectangular warehouse building (40m x 100 m ground area and 18m high) was constructed on a structural steel framework with a flat roof and coated stee! walls. During a storm the warehouse suffered a catastrophic failure of one of its long walls which in turn caused the collapse of the roof and buckling of the other walls. (a) Outline the possible causes of this structural failure (10) (b) Outline the health and safety issues to be considered when planning the subsequent. demolition of the damaged warehouse (10) Possible mechanisms of structural failure that could have been outlined in answering part (2) of tl QUESTION 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 the 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 calculation 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. For part (b), issues that should have been outlined were 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 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. 28. A pressurised steam boiler requires on examination; at the same time a repair on electricity driven pump, associated with the boiler is needed.{a)_ Define the term relevant fluid in relation to pressure systems safety (4) (b) Outline the typical contents of a written scheme of examination form for the boiler (8) (€) Identify the pra safety (8) 3 measures that should be taken to carry out the pump repair A relevant fluid means steam; any fluid or mixture of fluids which is at a pressure greater than 0.5, bar above atmosphere 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%; or a gas dissolved under pressure in a solvent contained in a porous substance without the application of heat. In their outline of the typical contents of a written scheme of examination form for the inspection of 2 boiler candidates were expected to refer to items such as :the identifications of the items of plant or equipment with in the systems the parts of the systems which are to be examined; the nature of ‘the examination required including the inspection and testing to be examined safety ; 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 systems ~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. For Part (c), candidates should have initially identified the 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 pipeline s by locking valves or inserting blanks; releasing stored energy de-pressurising draining and decontaminating the pump; allowing hot machinery to cool to at least 50c ; segregating the work by the use of barriers and signs and providing safe means of access for employees who were to be 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. 29. Small electroplating companies often have poor standards of health and safety made worse by the presence of conductive, corrosive fluids and humid corrosive atmosphere, (a) Describe the types of fault that may be found in fixed electrical systems under such conditions (20) {b) Outline the information relating to fixed electrical systems that will be required prior to a survey by @ competent person (10) The first part of this QUESTION sought to examine candidates’ knowledge of typical faults with in an electrical system and how a corrosive atmosphere may exacerbate the problems. Issues that should have been described included poor ear thing damaged sockets and switchgear covers missing from Junction boxes incompetent workmanship and inadequate excess current protection. Additional problems caused by the atmosphere include exposed by the ingress of fluids; corrosion of systems parts such as access grilles and transformer casings; and the unsuitability of the equipment for use in such wet and corrosive conditions.For part(b) the type of information required by 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 modification 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. 30. {a) outline the possible health and safety effects if inadequate workplace lighting (4) {b) Outline the factors that should be considered to ensure that lighting in a workplace is. suitable and sufficient (16) Better answers were able to identify 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 back ache 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 hazardous are not identified. Because of the use of the wrong type of lighting such as producing a stroboscopic effect and through human error in performing a task which may put others at risk For part (b) 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 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 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. 31. In relations to dust explosion: (a). Explain the conditions that must be present for a primary dust explosion to occur (4) (b) Explain the additional conditions necessary for secondary explosion to occur (4) (c) Identify four factors that may affect the reliability of a nitrogen inerting system used in a powdered aluminium process (4) (a) Identify the design features that would minimise the (8) inood and effect of a dust explosion In order for a 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 explosion to occur include the dislodgement of accumulated dust from horizontal surfaces with in 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 with in the affected areas. In answering part (c) candidates should have identified factors such as the number and location of sampling points, The type and calibration of the sensors, the presence of contaminants in the system which could interfere with readings. Inadequate provision of a safe means of shut down if oxygen levels are too high ; the adequacy of the supply of inserting gas; the number of locations where air ‘can enter the plant or process and the reliability of the electronic control system, 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 system together with systems for suppressing fire; using screw conveyors instead of pneumatic systems for moving ‘materials providing @ magnetic extraction systems for removing metal from product fed to the plant. Interlocking equipment to prevent overfilling of vessels and over pressurisation using instrument systems with emergency shutdown; using intrinsically safe electrical equipment and bonding all metal work to earth ; preventing dust build up in the plant by the use of sloping surfaces and introducing a mechanised system for the humidification of the air. 32. 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) In answering this QUESTION candidates would have done well to have structured their responses round the key elements described in HSE guidance note GS6. The initial precaution to be considered ‘would have been the possibility of rerouting the cables but if this was not possible then the local electricity supply company would need to be approached for advice on the precaution 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 follow 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. nally 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.‘Answers were generally to a reasonable standard though some candidates treated it as electricity rather than a construction QUESTION and wrote of the precautionary measures to be taken to deal ‘with the possible presence of buried cables. if Marks were lost it because candidates produced a list rather than the outline that was required. 33, In 1974 a plant in flixborough, United Kingdom, Producing highly flammable pressurised gas developed a leak on the fifth of six reactors. In order to continue production the fifth reactor was removed from service and a bypass assembly then installed between the fourth and sixth reactor. The bypass assembly subsequently ruptured and an unconfined vapour cloud explosion followed. {a) Describe the mechanism for an unconfined vapour cloud explosion (3) (b) 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 with in 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, in answering part (b) candidates should have described the absence of a professionally qualified mechanical engineer on site to overseas the modification between the fourth and fifth reactor. The plant modification took place without a full assessments being made of the potential consequences of its installation, There was an absence of drawings for the proposed modifications no reference was made to any recognised standard, The constructed assembly was of known 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 turning moment imposing lateral shear forces on the bellows nor an appreciation of a hydraulic thrust on them and consequently no calculation were undertaken for the dog leg line or the bellows to withstand these strains. No reference was made to the Designers guide s0 provided for the newly installed pipe work under working conditions, Finally and in short, those concerned with the design construction and layout of the modification did not consider the potential for a major disaster to occur instantaneously ‘Answers provided for this part of the QUESTION were particularly disappointing. Some candidates described what happened rather than why it happened and some appeared unfamiliar with flixborough. 34, (a) Outline the purpose of non ~destructive testing (NDT) on items of plant. (2) Outline the principles, benefits and limitations of the following NOT techniques; () Dye penetrant (4) (i) Radiography (4) The purpose of non-destructive testing (NDT) is to check for faults such as cracks in components before they develop into failure without affecting the integrity of the component.1m answering Part (b) of the QUESTION candidates were expected to outline that the use of the dye penetrates technique makes cracks visible as dye penetrates into them. It is a relatively cheap and simple operation but it does not detect subsurface faults. Is not totally reliable interpretation of the indication may be difficult. There is a possible element of toxicity involved and there is no permanent record available of the results ofthe test. With radiography x-rays or gamma rays are used to penetrate the item to leave on image on film. Any defects are shown up by the differences in the intensity of the radiation striking the film, The benefits of these techniques are that it detects internal defects and produces a permanent record of the test. However the operation is time consuming expensive and skilled radiographs. Additionally there is a danger of radiation exposure. In general answers to this QUESTION were to a good standard 35. A Scaffolder is lowering scaffold from the third floor of a scaffold assembly 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 fioor places the scaffold poles horizontally onto the back of a lorry parked on a busy road. The Scaffolder have already received information instruction, training and suitable supervision. Outline the additional practical measures that could minimise the risk of injury to the ‘Scaffolder and others that may be affected by 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 singling techniques and rigging on the scaffold poles and use guide ropes where necessary. Toe boards and handrails would need to be fitted on the upper platforms to protect both the ‘Scaffolder on that floor and the public below while belts or lanyards should also be worn by the ‘work man on the upper floor as fall protection. Attention should be given to nearby hazards such as obstruction 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 lorry. Finally both workmen should be provided with and wear high visible clothing, gloves and head protection. Whilst there were a number of reasonable answers provided for this QUESTION. There were a few who considered it to be predominantly 2 QUESTION dealing with scaffolding and wrote about ensuring that it was correctly constructed and was in no danger of falling over. 36. 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 practise prevention of Major industrial accidents 1991. In the event of an uncontrolled release: {2) Outline the need for emergency planning (3) (b) Outline the general emergency planning measures that should be taken by the competent authorities in association with the works management of the installation (7)For part (a) candidates should have outlined that 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 assistances from neighbouring industries act For part (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 arrangement for an off-site emergency plan to be drawn up by the local authority in conjunction with the installation 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 Many candidates found this QUESTION challenging in particular the second part with a number concentrating on legal requirements including those contained in the coma regulations. Examiners gained the impressions that candidates provided answers for the QUESTION they had anticipated and had practised rather than the one that actually appeared on the QUESTION paper. 37. (a) Give the meaning of the term ‘confined space’ (2) (b) Outline the factors that should be considered to ensure that emergency rescue arrangements for confined space work are suitable and sufficient (8) {An acceptable answer to part (a) of the QUESTION would have been that a “confined space” is any 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. Part (b) required an outline of 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 methods of raising the alarm to advise those outside to initiate rescue procedures, The type of equipment such as lifelines 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; precautions taken to counter the possibility of fire such as the services and supplying them with relevant information; the availability of first aid assistance until the arrival of professional medical help and ig oF refresher training for persons likely to be involved in emergency rescue ‘the provision of trai procedures.There were some vague definitions of a confined space given in answer part (a) while a number of candidates did not read the second part of the QUESTION with sufficient care and outlined the ‘normal control measures that should be put in place when carrying out work in a confined space. 38. As a health and safety officer you are asked to give advice to a lift supervisor regarding a n. The lift requires the use of cranes working together (a tandem Outline the elements of a safe system of work you would expect to see in order that the lift may be conducted safety (20) 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 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 excavation 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 BANKSMAN WOULD HAVE TO BE COMPETENT AND THERE WOULD NEED TO BE AN EFFECTIVE MEANS of communications between them using standard methods of signalling calculation 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. This was a popular QUESTION which produced a good standard of response although candidates failed to gain marks by producing lists rather than outlines. 39. Factory manufactures upholstery using fabrics and plastic pellets .These raw material are delivered to a warehouse, the fabrics and plastics pellets are machined to form furniture coverings and cushions. The plastics pellets have been sprayed with flame retardant. The finished product 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 fork lift trucks. The ‘company is located on the outskirts of a small town and employees 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 and 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 filings and structural issues such as the materials of construction of the premises themselves. Ignition sources world 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 contractor 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 systems in warehouses and an minimising the amount of stock kept on the premises and ensuring a good standard of house keeping with facilities provided for the segregating 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 consideration, the provision of normal and emergency signage and emergency lighting together with refuges for subsequent evacuation and the provision of assembly points in 3 place of safety. Finally the assessment would have to consider the management systems introduced for the ‘maintenance and testing of fie 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, Several candidates wrote about generic fire control measures and did not deal with the potential hazards involved in the operations carried out in the premises described in the QUESTION. A few limited their answers to the associated with the use of LPG fuelled trucks. 40. A plastics moulding machine is supplied to your work place. Outline the moulding machines features that you would have expected to have been addressed in order to demonstrate that the machine is safe (20) Features that should have been addressed to demonstrate 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 hazards maintenance and indicators .successful candidates structured their answers under these condition.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 use 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 and use take account of errors in logic; that control devices are visible ,identifiable, well positioned , logical and sufficiently robust ; that there was 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 vibration and the emission of dust and/ or gases, AS FOR MAINTENANCE MATTERS SUCH AS REMOTE ADJUSTMENTS AND LUBRICANTS, 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 instruction on the installation use ‘and warning devices, the provision of instruction 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. This was not a popular QUESTION and was not well answered with some candidates only offering advice on how to use the machine safety. 441. (a) DESCRIBE THE EFFECTS OF A FIRE IN A WORK PLACE ON THE FOLLOWING STRUCTURAL MATERIALS: {i) Steel (4) (ii) Concrete (4) il) Wood (4) (b)Outline the precautions that could be taken to prevent failure of these materials in the event of fire (8) In answering part (a) of the QUESTION, candidates should have recognised that steel expands on heating loses strength as the temperatures rises and tends to deform and buckle. It regains strength. fon cooling but its properties may have changed .concrete on the other hand exhibits limited expansion of steel reinforcement with in the concrete. The structural strength of concrete is lost on cooling and its 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 furnes 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 Part (b) was concerned with 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 in tumescent while for concrete the selection of the type of mix to improve fire resistance and increasing the thickness of concrete between the external face ad reinforcement bars would provide some protection. Failure of wood 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 heat transfer through long steel members should fire occur and the use of fire resistant surface claddings or flammable sacrificial cladding, 42, 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 provision required for: (a) The design (10) (b) The operation (6) (c) The maintenance of the proposed storage facility (4) Candidates who divided the QUESTION into its component parts ie. design operation and maintenance and dealt with the detail of these issues in turn achieved more success, Under the design issues it was expected that candidates would deal with the 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 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 tanks and the colour coding of pipe work ; the fitting of evel indicators and high level alarms to prevent overflling; 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. 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 equipment gloves and full face protection. In outlining the issues connected with maintenance candidates were expected to refer to 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 bunds and the provision of training to maintenance staff in emergency procedures. Answers provided for part (a) were generally better than those for the other two parts of the QUESTION. Some candidates provided very general responses without paying too much attention to the scenario described whilst others dealt with it as a QUESTION on highly flammable liquids with the potential for a BLEVE or unconfined vapour cloud explosion, 43. (a) Outline the principles of a vapour cloud explosion and give an example of a major incident with a vapour cloud explosion (8) (b) Outline the effects of a vapour cloud explosion (2) ‘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 source that exceeds the minimum ignition energy .unconfined vapour includes 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 clouds may travel a considerable distance before igniting or they may be dispersed to a concentration below the lower explosive limit depending on conditions <] Water Level column Te Valve found = Water For part (a) of the QUESTION candidates should have identified 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. {As for the events that could have led to an explosion since a valve on the water column was found to the closed. No water could enter the boiler and the column would give a false reading .the actual ‘water level would fall as steam was drawn on demand the crown would become exposed heat transfer in that area would be ineffective and a localised heat build-up would take place. The crown would start a yield as a result of internal pressure and a ductile failure followed by a rupture wouldoccur, There would be a loss of contaminant with an instantaneous change from water to steam and an explosion as stored energy was released. There was a great deal of misunderstanding of the possible sequence of events and of the failure modes involved. Candidates did not seem to appreciate the consequences of a reduced water level and there were several unique suggestions put forward as to how the boiler might have exploded, 46. (a) outline the factors that may cause an agricultural tractor to overturn (6) (bjOutline the measure that may be necessary to minimise the risk of a tractor overturning (4) For part (a) candidates should have transferred to factors affecting the possibility of overturning ‘such as the angle of slope and direction of travel on gradients ; uneven or soft ground ;speed on concerning ; track width; the condition and pressure of tyres; the effects of trailers and the level of competence of the driver; In their answers to part (b) they were expected to outline measures such as restricting the use of tractors on steep gradients and restricting thelr speed; increasing the width of the wheel track; fitting counterbalance weights ; introducing a regular maintenance system and pre-use inspection Particularly of the tyres; using shearing pins on coupling and providing training for drivers... {In general answers provided were to a reasonable standard through a number of candidates provided lists rather than the required outline. There were on occasions some extreme measures suggested for part (b) such as not allowing the tractor to be driven on soil or when it was raining, 47. The 1963 international labour organisations convention 119 concerns. The guarding of ‘machinery part 1 considers general provisions. Part 2 concerns the sale, hire, transfer and exhibition OF MACHINERY AND PART 3 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 @) {c) Outline the requirements for the use of machinery as specified in part 3 (6) In answering part (a) candidates were expected to outline categories of machinery such as power driven and manually operated 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. |n giving two example of transmission machinery could have chosen from a list containing belts and pulleys, fly wheels gearing chains and shaftin. For part (c) it should have been stated initially that 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 ‘compliances with the law’s requirements, As such an employer should not require a worker to use to machinery without guards. In position to make guards inoperative on machines that may be used by @ worker. The worker too has an obligation both to use and not misuse the guards provided.Many candidates were not prepared for this QUESTION and in fact several did not even attempt it. ‘Answers that were to a very poor standard and the categories of machinery were frequently confused and misprinted. 48, During a fire drill exercises 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) In answering part (a) of the QUESTION candidates might have found it useful to structure their responses under headings such as the fire alarm design the structural layout of the premises the deficiencies in the existing procedures and their execution and human factors 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 there 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 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 complex and difficult to understand with sufficient instruction given to workers on what action to take when the alarm was sounded. 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 responses 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 ing disabilities or apathy with the assumption that It was only another fire drill or a false For part (b) regular practise 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 provided a test of the integrity of the hardware systems such as the alarms and emergency lighting and ensures compliances with legal and insurance requirements. ‘This was a very unpopular QUESTION and produced few good answers. It required an outline but yet again many candidates did not provide the detail that is required to satisfy this requirement. 49, (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 tisk 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, ‘operation. Outline the factors that should be considered when assessing the risk for work ‘on top of the road tanker (10) in answering part (a) of this QUESTION candidates should have addressed 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 minimise the risk 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 through some candidates would have done better ifthey had noted the use of the word static in the QUESTION. For part (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 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 walk way and hand rails the consequences of falling which might include the need for the use of harnesses when on the top of the tanker or the Provision of fall mitigation equipment such as air bags; and the availability of an alternative existing work place 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 foot wear and gloves. ‘Answers to this part of the QUESTION might have been better if candidates had recognised that the ‘main risk for the drivers in the situation described is from falling and had addressed the precautions required when working at heights. 50. 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 has migrated into the building. a) Describe how corrosion occurs in buried LPG metal pipe work (6) b) Outline how buried LPG metal pipe work can be protected against corrosion (4) ©) Excluding corrosion protection outline additional factors to consider in preventing a recurrence of an explosion in similar LPG pipe work installations (10) For part (a) of the QUESTION in describing how corrosion occurs in buried LPG metal pipe work, candidates should have include 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 contaminates in the soil in the liberation and transfer of electrons .Candidates should have described the effects of corrosion on different metals such as cast iron , ductile iron and steel.For part (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 cathodes protection or a sacrificial anode. ‘Additional factors to be considered in preventing a recurrence of an explosion in a similar LPG installation 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 other installation and the extent of their existing protection. For Inspection and maintenance of the systems plans and drawings will be required together with record of previous maintenance .Evacuation may be required through 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 a systematic programme of replacement of metallic pipes with poly propylene and the condition of at risk systems will need to be monitored pending the replacement. ‘This QUESTION was unpopular and generally very poorly answered. 51. Outline the advantages and limitation of the following types of fall protection devices AND give a suitable application for EACH. a) Safety harness /fall arrest (5) b)_ Safety belts /fall restraint (5) ¢) Safety nets (5) d) Air bags (5) This QUESTION required candidates to outline 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 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 restriction on movement thei requirement for trained and competent users and the fact that they provide 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 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 a low to medium fall potential areas. They are most suitable for use over water or under fragile roofs. Finally 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 persons require a continuous power supply and may be used only in low fall potential areas such as short run construction projects or around work place transport. This QUESTION attracted some good answers though some candidates lost marks because they did ot produce a suitable example of the use of the devices. A few candidates misunderstood the reference to safety and air bags and thought they referred to their use in vehicles. 52. With respect to an electricity supply operating at 240v: {a) Outline the factors that determine the severity of the effects of an electric shock (6) (b) For each of the following protective devices outline their principles of operations (i) Residual current devices (3) (ii) Fuses (3) 110v centre tapped to earth reduced voltage systems (3) (c) Outline other design features of electrical systems intended to improve safety (5) In answering part (a) of this QUESTION credit was given for reference to factors including 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 on the body and the type of footwear worn , the route taken by the current through the body, the speed of action of any productive measures and the environmental conditions such as the floor material and the presence of water .Knowledge of OHIM’S law was useful IN RELATING THE SIZE of current to voltage and resistance. In answering part (b) candidates were expected to outline that a 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) conductor is detected, operating a switch to cut off the electrical supply to the apparatus and preventing severe electric shock. The device should operate within 40 milliseconds of the fault being detected. ‘A fuse is a device placed in the live side of a circuit designed to automatically cut off the power supply to the circuit within a given time when the current flow in the circuit exceeds a given valves. 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 IT'S SPEED OF OPERATION IS GENERALLY TOO SLOW TO PROTECT PEOPLE FROM ELECTRIC SHOCK. One of the better ways of reducing the risk features intended to improve 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. For part (c) candidates could have outlined 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 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. ‘This was a popular QUESTION. Answers to the first two parts were generally to a good standard through some candidates had difficulty in outlining the workings of a step down transformer. ‘Answers to Part (c) however were disappointing with many candidates apparently not noticing or ignoring the reference to design features and offering only training and safe systems at work. 53, With the aid of labelled sketches outline the characteristic features of and factors that promote the following types of material failure a) Brittle failure (5) b) Ductile Faure (5) For this question candidates as were expected to outline with the aid of labelled sketches the characteristic that promote the following types of materials a failure. A brittle fracture generally occurs without warning or prior of distress. It is 2 crystalline structure failure with minimal plastic or elastic deformation. There are generally characteristic chevron marks from the point of intimation 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 fracture generally has a smooth fracture surface with plastic deformation of the material before final fracture. There is evidence of necking and the final fracture is often brittle because there is insufficient material left to sustain a load. This type of failure generally occurs as the result of a single stress. Overload through other promoting factors include high temperatures cold work hardening and the plastically of the material. 54. a) Outline the principles of interlocked machine guard.(4) b) Outline the principles of operation of trapped key control systems. (6) For part (a) examiners were looking for answers that included the fact that an interlocked guard is linked to the machine control 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. In answering part (b) candidates may have become confused between a captive key system and a trapped. key system. In the first case as the name suggests the key is at al 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 mechanism. While power is on the key is held in the switch55. The residents of a village recently been affected by a fallout of dust on their cars and property. They allege that the 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) ‘This question presented a scenario involving allegations of dust contamination from residents of @ village situated a short distance away from a cement works. It involved a typical investigates process which would deal with the factors to be examined in order to confirm or dismiss them. {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 resident and a research prevailing 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 emission on site together with offsite back ground monitoring. Analysis of dust collected from the village would also help to establish whether it matched that produced at the alleged source. 56. 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 work place. (20) {In outlining the design features that should be considered in order to minimise risks associated with the movement of vehicles in the work place 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 vehicles that will use them; the elimination of sharp bends blind corners and steep gradients with the sitting of convex mirrors on those corners that cannot be avoided; the installation of a one way system to minimise the need 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 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 itors including a 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. 57. (a) Organisations may use of range of reactive and protective strategies for plant ‘maintenance. Identify four possible plant maintenance strategies and outline the principles of each strategy. (b) Outline the factors that you would advise the engineering department an organisation to take into account in deciding on a maintenance strategy following the installation of an item of process plant. In answering part (a) candidates could have identified strategies such as planned preventive maintenance (PPM) break down 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 or 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 parameters when ‘maintenance work needs to be undertaken and measuring continuously or to a schedule. Emergency maintenance includes maintenance undertake to prevent more serious consequences such as reinforcement to prevent failure or the use of temporary supports to prevent collapse, For part (b) candidates could have outlined 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 availabilty 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 manufactures 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, 58. A sewage drain has collapsed and it is necessary to inspect the damage prior to its repair. ‘The inspection requires entry into a confined space 10 meters deep Outline the possible risks to these entering the sewer. (10) In answering this question, candidates were expected to outline possible risks such as those associated with the presence of gases and vapours either toxic and/or flammable and an atmosphere that was deficient in oxygen which could lead to asphyxiation and/or suffocation; working on slippery surfaces and the presence of pipes, cables or tools which could result in falls; the possibility of the sudden ingress of water with the danger of drowning; the presence of chemical or biological contaminants either on the surface water or in the sludge deposited in the sewer with the risk of contracting illnesses such as Weil's disease; working in a restricted space with low headroom which might lead to musculoskeletal injuries; thermal issues such as heat exhaustion that might ‘occur when working in high temperatures; coming into entrapment which could be caused by the collapse of the sewer. ‘Answers were generally to a reasonable standard. Some candidates did not read the question with sufficient care and referred to hazards rather than risks and though reference to control measures was not required a few mentioned these often without detailing the risks they were supposed to control, Many candidates failed to provide the detailed required for an outline answer. 59. Outline what should be considered when preparing a scheme for the systematic ‘examination, testing and maintenance of portable electrical appliances. (10) In answering this question, candidates should have first considered the importance of producing an initial inventory of the equipment to be examined and tested including its source such as in-house, contractors or workers and ensuring that each item was provided with a unique means of Identification, That completed, it would then be necessary to determine the appropriate type andfrequency of inspection for each item based on factors affecting the level of risk, such as the type of appliance, any protective systems provide such as earthing, double insulation, or reduced voltage, the age and usage of the appliance, the environment in which it was used such as n a corrosive atmosphere where more frequent testing may be required, and the experience and competence of the user. Additionally, historical data and manufacturer's recommendations would need to be taken into consideration. Finally, criteria for each type of examination and test would have to be laid down which would include issues such as the competence of the tester, the calibration and maintenance of test equipment, the format of records to be kept on the results of the tests and examinations and systems to identify and take out of use equipment that was found to be faulty. Better answers included reference to published guidance from the appropriate regulator or professional institute. Many Candidates listed the parts of the equipment that should be checked and tested rather than what should be considered in the preparation of a scheme for examination and testing. A few identified faults such as loose wires and defective plugs while there were others who did not appear to possess the technical knowledge to deal with this type of question. 60. Members of the public have been injured when collecting baggage from a baggage conveyor at an airport. (a) Identify typical mechanical hazards when the conveyor is in use. (4) {b) Outline the control measures that should be in place to reduce the risk of Injury from the mechanical hazards (6) For part (a), candidates should have identified mechanical hazards such as trapping between the interlaced parts of the conveyor bed, between moving items of baggage or between the lip and trapped baggage; abrasion hazards from coming into contact with the moving belt; impact hazards from coming into contact with moving baggage which might have been inadequately stacked or in attempting to replace items of clothing or jewellery become caught in the moving conveyor. It might have been expected that most candidates would have had experience of collecting baggage from a conveyor at an airport and indeed most were able to identify the typical mechanical hazards from the moving conveyor though some were under the impression that dangerous parts were always exposed, others identified non-mechanical hazards such as electricity and noise while a few dealt with the hazards connected to the use of roller conveyors. For the second part of the question, control measures that should be in place include the control of the speed of the conveyor; a reduction in gaps in the belt at critical points such as turns; the replacement of worn conveyor parts; the use of E-stops in the event of blockage or other ‘emergency; the use of photo-sensitive detectors; using a klaxon or strobe warning lights in the case of an inadvertent start-up; using workers to assess the conveyors for blockages and to assist passengers when this is seen to be necessary and providing signage advising caution when removing baggage from the conveyor, on the action to be taken in the event of a blockage and warning against placing hands or feet on the conveyor. Whilst the hazards may have been identified for the first part of the question, outlining the control measures proved to be more difficult with some candidates suggesting the impracticable such as prohibiting passengers from wearing loose clothing or jewellery ‘and others demonstrating a lack of realism by suggesting that passengers should be kept away from the conveyors61. Environmental pollution is a major concern in many industrial processes. A number of alternative strategies are available to organisations to manage these risks. Give the meaning of: {a) Integrated Pollution Prevention and Control (IPPC); @ (b) Best Practicable Environmental Option (BPEO); 8) (€)_ Best Available Techniques (BAT). @) For part (a), candidates were expected to include that Integrated Pollution Prevention and Control applies to industrial installations and its main aim is to achieve a high level of protection of the environment taken as a whole. It takes into account the whole performance of the plant and as it is ‘integrated’ includes emissions to air, water and land, the generation of waste, the use of raw ‘materials, energy efficiency, noise, the prevention of accidents and the restoration of the site upon closure. For part (b), a good answer would have included that Best Practicable Environmental Option is the option which provides the most benefits or least damage to the environment taken as a whole at an acceptable cost and in the long as well as in the short term. The option includes a range of methods such as kerb side recycling and green composting. Best Available Techniques applies to certain polluting installations and its aim is to avoid or reduce emissions and their impact on the environment as a whole. T takes into account the balance between costs and benefits to the environment so that the greater the environmental damage that can be prevented, the greater the cost of the techniques that must be provided. ‘Available’ are those techniques that are readily procurable by any person, while ‘techniques’ include plants, systems, processes, monitoring measures and staff. 62. A motor vehicle repair workshop has installed a new electrically powered, compressed air system. Outline the factors to be considered in developing a suitable planned preventative maintenance programme. (10) The first stage in the development of a maintenance programme would be to consider the design life and expected reliability of the system, the manufacturer's specifications, the pattern of usage whether constant, periodic or only as a standby and the anticipated fault pattern based on experience gained in using similar equipment. Consideration could then be given to further factors such as the need for routine operations such as belt tightening, lubrication and filter changes, the need for regular replacement or critical parts to prevent breakdown and the availabilty of the component parts, the operations that would be required at specific times to counter corrosion, wear and fatigue and any statutory requirements or those required by insurance companies. Additionally, though should also be given to the available occasions when ‘shut-down’ maintenance might be performed; to the particular safety aspects of maintenance while equipment was running; to the need for safe systems of work such as permits or electrical isolation; and to the availability of, staff with the necessary skills and competencies to carry out the work. A written scheme of maintenance might then be prepared which would include the safety precautions that should betaken and the arrangements for recording details of the work carried out such as the results of inspections, the defects found, and the remedial action taken such as the replacement of parts. Answers were limited with many candidates producing a list of items to be checked and maintained rather than the factors to be considered in the development of a programme for planned preventive maintenance. Some considered the siting of the equipment and the training of workers while others did not recognize that a compressed air system isa pressure system and accordingly the condition of critical parts and safety aspects in carrying out maintenance were of paramount importance. 63. A diesel engine is being used to power a machine in a potentially flammable atmosphere. (a) Identify the sources of ignition from the diesel engine. (4) (b) Outline the protection that should be applied to the engine to minimize the tisk of an explosion. (6) In the first part of the question, candidates were asked to identify possible sources of ignition from a diesel engine. They should have referred to flames or sparks from the exhaust and inlet systems, sparks arising from the engine’s electrical system, sparks caused by the presence of static electricity, through over speeding or overloading of the engine and from friction or the surface temperature. ‘Answers were to a reasonable were likely sources of ignition and that the fuel was highly flammable. Part (b), required and outline of the protection that should be applied to the engine to minimize the risk of explosion. An initial protection measure would be the fitting of flame and spark arrestors to prevent flashback to atmosphere if flammable vapour was drawn into the inlet system and to prevent any flames from the exhaust system escaping into the air of the workplace. The engine and exhaust system should be designed to ensure that their surface temperatures were below the ignition temperature of the flammable substance and the fitting of a water jacket on the exhaust system together with thermal sensors and air cooling for ‘hot spots’ would provide addi protection. Electrical equipment on the engine should be suitable for zones 1 and 2, mechanical alternatives, as for example the fuel gauge, should be fitted where possible and electrical starters wired to a plug and socket in a safe area. The use of electrically conducting materials for parts such as tyres and drive belts would reduce static build up, while fitting speed limiters would help prevent over speeding or over loading of the engine. Finally it would be advisable to fit an air inlet shut-off valve to stop the engine if at any time vapour ingestion does lead to over-speeding. Answers to this part of the question were not to the same standard as part (a). 64, For a large supermarket with restaurant facilities: {a) Outline the automatic fire protection systems that should be in place(6) (b) Outline the factors to be considered when developing a safe means of escape for the supermarket,(14) For part (a), candidates were expected to outline automatic fire protection systems such as those for fire detection for example fire and smoke detectors; fire suppression systems such as automatic sprinkler systems or foam flooding systems which would need to be subjected to regular testing; a fire alarm system with adequate call points located at strategic points in the store and regularly tested before the store is opened to the public; a smoke control system comprising roof vents and automatic self-closing doors; and an automatic fire service call out. Candidates should also haveIndicated which of these systems were more suitable for the supermarket and which for the restaurant, This was a popular question and part (a) was well answered though a few candidates seemed to miss the reference to ‘automatic’ and concentrated on manual mean such fire extinguishers and hose reels. Factors which would need to be considered in developing a safe means of escape for the supermarket include the possible types and numbers of persons to be evacuated, the distance to fire ‘escape routes and the number of routes available; the arrangements for evacuating members of the public which would include the use of the public address system and the appointment of fire marshals who would need training in their responsibilities including ensuring that all areas have been cleared; ensuring that fire exit routes are kept free from obstruction and are clearly signed with the routes from the supermarket and restaurant being sufficiently separated to avoid crowding and confusion; the location of clearly marked assembly points which should be in a safe position away from the building and positioned where they would not obstruct access for the emergency services; the provision of emergency lighting in the event of failure of the main supply; arrangements for liaison with the emergency services; the allocation of clear responsibilities to worker for giving assistance to customers and particularly those who might be disabled; arrangements for disabling of lifts and for locking the tills to prevent the opportunities for theft; and the completion of regular fire drills at least at six monthly periods. Answers to this part of the question were reasonable but perhaps not as good as those provided for part (a). Only the better answer differentiated between the store and the restaurant. Others described the need for the building to be constructed of fire resisting material rather than the means to be provided to ensure people were able to leave it safely if fire did occur. 65. A small company manufactures product using electro-chemical processes. The company has poor general standards of health and safety, made worse by the presence of conductive ‘and corrosive fluids and humid, corrosive atmospheres. {a) Describe the types of fault that may be found under such conditions in a fixed electrical system. (10) (b) Outline the technical Information a competent electri before conducting an inspection of a fixed electrical system. (10) ian would require “The first part of this question sought to assess candidates’ knowledge of typical faults within a fixed electrical system and how a corrosive atmosphere may exacerbate the problems. Issues that should have been mentioned included poor earthing and a lack of earth continuity, damaged sockets and switchgear, covers missing from junction boxes, inadequate excess current protection such as the fitting of fuses with incorrect ratings, means of isol poor condition and badly sited and incompetent workmanship in the original installation. Additional problems caused by the atmosphere include exposed live conductors due to damaged or perished insulation, grilles and transformer casings, and the unsuitability of the equipment for use in such wet and corrosive conditions, For part 9b), the type of information required by a competent electrician prior to carrying out a survey would include; an inventory of the equipment with details of its type and manufacturer; the operating parameters of the system such as its voltage, current, number of phases and itsimpedance and/or resistance; its IP classification including the measure of protection against the ress of water; any circuit diagrams and/or manuals for the equipment with 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 ‘Answers to this question were to an acceptable standard with most candidates able to identify @ ange of faults that might be found. For part (a), some tried to explain the chemical reactions involved which was not required, and suggested the presence of a flammable atmosphere which was irrelevant. In their answers to the second part of the question, some candidates outlined the Precautions to be taken rather than the information that the competent electrician would require, 66. The International Labour Organization's Standard R175 and its associated Code of Practice sets out general principles for ‘Safety and Health in Construction’. Minor repairs need to be carried out to the sloping roof of a large two-storey property. A scaffold is to be erected in order to gain access to the work area. Using the guidance in R175, outline the precautions necessary for carrying out the repairs. (20) ‘The more successful candidates were those who organized their answers under the general headings of scaffolds, ladder access, roof edge protection and general workplace precautions. For Scaffolds, necessary precautions include ensuring that it is constructed of suitable and sound material, is of adequate size and strength and is erected and modified where necessary only by competent workers in accordance with any local regulations. The scaffold should be stable which may mean that it has to be tied in to the building. The working platforms must be provided with Buard rails and toe boards to prevent the fall of persons and materials and means should be Provided to restrict access when it is not in use. It is imperative has the scaffold is inspected prior to it being used for the first time, at regular intervals thereafter, after alternations or interruption in its Use and after exposure to extreme weather conditions. Where ladders are used for access, they should be secured and extend for a distance of at least one meter above the landing platform. Workers using the ladder should always ensure three points of contact whilst climbing and arrangements should be made for lifting tools and materials to the working area by means of hoist or gin wheel. Properly secured roof ladders should be used for work on a sloping roof with protection provided round those areas where fragile material may be present. Guard rails should be provided to protect workers from falling from eaves or roof edges. It is not practicable to provide guard rails, and workers could fall a distance of more than 2 meters, then other means such as harnesses or nets must be used. General workplace precautions include those to be taken when work is carried out near to overhead ower lines; the provision of chutes for the removal of debris or rubbish; the issue and wearing of Personal protective equipment such as hard hats, boots, eye protection, gloves and high visibility clothing, and the provision of adequate welfare facilities. This was a popular question though Examiners suspected that there were many candidates who had limited knowledge of R175 given the content of their answers. Some related to UK standards and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. All candidates found the second part of this questions challenging and whilst some did point to the need to prepare on -site and off - site plans, they did not specify who should be responsible for drawing up the plans or who should be consulted in their formation. 70. 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 meters) ladders are the only practicable way of carrying out the work. (a) Describe the safety precautions that could reduce the risk of falls from height when using ladders. (14) (b) Outline the emergency procedures you would implement in the event of accident or illness for this type of lone working. (6) 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 recognized standard of ladder, whether conventional or combination, which should be appropriate in length, strong enough to carry its intended load, provided with stabilizers 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 ladder 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 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 same 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 2 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 wht part these would play in reducing falls. Despite the specific reference in the question that workers were on their own when carrying out the task, one of the precautions mentioned was that the ladder should be footed, 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 2 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 ald provision in the area where the work was being carried out. Ina 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 opposition to make a call himself; the provision of means of communication such as mobile phone or radio and a routine requiring the worker to contact and report to base at set intervals. Whilst 2 number of candidates did succeed in mentioning many of the above procedures there were also a varlety of alternatives suggested such as the appointment of trained first aidpersonal, the use of emergency rescue teams and the introduction of procedures for informing the next of kin. 7A. Failure of pressure systems can result in accident, {) Identify FIVE examples of pressure system AND give a workplace example in EACH case.(5) (b) Outline a typical written scheme of examination for pressure systems. (5) (¢) Outline other contro! measures that could reduce the risk of pressure system failures. (10) This was not a popular ques ion and was not well answered by those who attempted it. For part (a) of the question, candidates could have identified examples of pressure systems such as Pressurized process plant and pipe work connected chemical processes; fixed or portable compressed air systems as used for painting or type inflation; pressure cookers in industry; refrigeration plant found in a food storage building; boller or steam heating systems providing General heating in workplaces; and autoclaves or equipment sterilizers used in cleaning laboratory glass ware, Candidates were unable to provide many workplace examples. Atypical written scheme of examination for pressure system would cover all procreative devices and would include all pressure vessels and pipe work that could give rise to danger if they failed. The ‘ype of examination would be specified such as, for example, as a result ofa statutory requirement, 5 would also the frequency with which the examination should be carried out. The scheme should stipulate the special measures needed in preparing the plan for examination and in case ofa fired or heated pressure systems, the need for them to be examined when cold and also when in operation with 2 final requirement that the examination should be carried out by a competent person. Many candidates obtained good marks for this part of the questions through there were some who seemed unfamiliar with written schemes of examination. {In answering the last part of the question, candidates could have grouped other control measures that might reduce the risk of pressure system failure under the heading of equipment, operating conditions, protective device, and the provision of maintenance and the provision of operator training. Under equipment, it would be imperative to ensure that installation are suitable for their intended Purpose, and are installed correctly with due regards to design conditions, installation standards and accepted codes of practice. Operation condition required a knowledge of the nature, and pressure and the temperature of the 28 oF liquid being pressurized or contained, the safe operating limits of the system and equipment linked with the system and the methods of operating within these limits, the availabilty of operating instructions of the system and equipment linked with the system and the accessibility by workers to instructions on what action to take in the events of the emergency. As for productive device, these should be suitable, adjusted to the correct settings and should function properly at all times,ir. The 75. A sewer has collapsed and it is necessary to inspect the damage prior to its rep inspection requires entry into a confined space 10 meters deep. Outline risks to those entering the sewer. (10) ‘This question required candidates to outline 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 and with needle stick injuries and contact with sharp objects when entering the sewer. Candidates who outlined the risks of entrapment, drowning and of sewer collapse also gained marks. Consequently, candidates who outlined control measures only, or who gave answers on confined spaces generally failed to get the full marks available ‘The command word ‘outline’ was missed by some candidates and simple lists or bullet points were not acceptable answers. ‘The answer to this question did not require any particular reference to status or legislation, although ‘an understanding of legal requirements would have assisted candidates in structuring @ good answer. QUESTIONS TO PRACTICE 1. Compartmentation in buildings consists of fire resisting doors, walls, floors, ceilings, windows. Window Frames are potentially a week point in this fire resistance. {2} Outline how window frames made with the following materials might behave in a fire () Wood (3) Metal (3) Plastics (3) (i (b) Identify which of these window frame mat resistance (1) gives the best overall fire 2, AScaffolder 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 @ vehicle parked on a busy road. The Scaffolder s have already received information, instruction, training and suitable supervision. Outline the additional practical measures that could minimise the risk of injury to the scaffolder and members of the public during this activity (10)3. You have been asked to investigate a boiler explosion at one of your company’s sites. The Maintenance manager has drawn you a sketch showing the position of the water column isolating valves at the time of the explosion (see below). {a) Describe the chain of events that could have led to an explosion due to the water column valve being closed (6) (b) Other than the safety feature on the water column, Identify FOUR other safety features that_you would expect to find on the boiler (4) 4, Outline the precautions that should be taken when construction work is to take place under or near overhead power lines that will remain live during the work (10) 5. Coal is delivered by train to a power station and is transported by belt conveyors to a furnace. Conveyor workers check that the coal moves along the conveyors efficiently. These workers have received suitable information, instruction and training and supervised. Outline additional control measures that could reduce risks to conveyor workers (10) 6. Alarge manufacturing company wants to minimise its emission of greenhouse gases. Identify the activities of the company that may lead to the release of greenhouse gas, emissions into the atmosphere (10) 7. A factory manufactures upholstery using fabrics and plastics pellets. These raw Materials are delivered to a warehouse. The fabrics and plastic pellets are machined to form furniture covering and cushions. The finished product is then stored in a despatch warehouse prior to distribution. The movement of goods around the premises is carried out by Liquid Petroleum Gas (LPG) fuelled forklift trucks. The company is located on the outskirts of a small town and ‘employees 230 people. Outline the range of factors that must be addressed to ensure an on-site fire risk assessment is made for the premises (20) 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 ina workplace is. inadequate (16) 9. Materials can fall 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 outlive ONE circumstances in which it may occur (4) (c) Outline: i. The characteristics of electrolytic corrosion (5) li, Factors which cause electrolytic corrosion (5) 10. Metal components are being manufactured by workers using metal turning lathes, a) Identify FIVE types of mechanical hazard associated with metal turning lathes AND give a Practical example of EACH (10) b) Outline control measures that minimise risks associated with metal tur ig lathes (10) 11. Aroad 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) (4) Outline contro! measures that could reduce risks with road tanker filling (8) 12. (a) Outline factors that a competent person world need to take into account when deciding. the frequency of examination of lifting equipment. (10) (b)Describe the main hazards and control measures assdciated with commonly encountered lifting equipment. (10)