Sl.

No Questions
Element IC 1: General Workplace Issue
1 a) Outline the possible health and safety effects of inadequate workplace lighting. (4)
b) Outline the factors that should be considered to ensure that lighting in a workplace is suitable and sufficient.
(16)

SUGGESTED ANSWER
a) The possible health and safety effects of inadequate work place lighting are:
 Health effects include: headache, visual fatigue , eye strain, blurred vision; -inadequate posture creating
neck and backache to get adequate VIEW for the tasks to be performed.
 Safety implications : likely to increase the incidents such as slip, trip and fall, striking with objects
because of insufficient lighting arrangements causing unidentified objects – wrong type of lightings
which are creating stroboscopic effects - Human error which may put others at risk.

Health effects Safety effects

Head ache Slips, trips & fall

Eye strain
Striking with objects

Blurred vision
Stroboscopic effects

Inadequate poster
Human error
b) Factors that should be considered: - The type of work to be taken - The amount of precision required and
whether tasks require general, local and/or localised lighting - The level of natural light available - The workplace
layout giving attention to the effects of screens, furniture or racking - the considerations of those objects casting
shadows - The different types and level of lightings required for stairs, corridors and outside security lights. - The
level of lighting in adjacent areas in order to avoid the effects of moving from a strongly lit area to one which is
dimly lit and vice versa; - The individual needs of the employee whether on account of age or disability - The
possibility of glare on display screen - The colour and type of lighting fitted o prevent stroboscopic effects - The
need for emergency lighting particularly for fire escape routes - The need for portable lighting when work has
to be carried out in confined space - The ease of maintenance whether replacing spent bulbs or cleaning the
light fittings for probable - All glazed windows and skylights used for the lighting of workrooms shall, so far as is
practicable, be kept clean on both the inner and outer surfaces and free from obstruction.

Type of
Glare Amount of
Stroboscopic work
precision
effects

Level of
Emergency natural
lighting light

Factors to be
Confined considered
Workplace
space
layout

Ease of
maintenance
Casting shadows
Individual
needs
2 A vegetable packing plant employing 200 men and 60 women is about to open. The plant will operate 24 hours a
day on a three-shift system.
Outline the specific welfare arrangements that will be necessary prior to the factory opening. (10).

SUGGESTED ANSWER
The specific welfare arrangements that will be necessary for vegetable packing plant are:
Sanitary Conveniences:
 Sufficient numbers of well-lit sanitary convenience and maintained in a clean & tidy condition.
 Provision of toilet paper, a coat hook – separate rooms or blocks for men & women (or capable of being
locked from inside if the sanitary conveniences in the same room.)
Washing Facilities:
 Sufficient numbers of well-lit and ventilated washing facilities - Changing rooms and Showers to be
provided and maintained in a clean, tidy condition - Supply of hot and cold or warm running water, -
Soap and a means of drying
Drinking Water:
 An adequate supply of drinking water with cups - Readily accessible, located away from sources of
contamination - Marked conspicuously
Accommodation for Clothing / Facilities for Changing Clothing:
 Clothing accommodation with a hook/peg located in a clean, warm, dry, ventilated place should be
provided for each worker to hang their own clothes if not worn during the working day.
 Changing facilities separate for men and women and contain means of drying wet clothing and separate
storage of contaminated clothing - Decontamination facilities with shower and a clear division between
clean and dirty areas

Facilities for Rest and to Eat Meals:

 Rest and eating facilities - Readily accessible, contain adequate seating and tables - Be
maintained in a clean condition - Arrangement for preparing and heating food and for boiling
water
 Means or procedure for preventing contamination of the area where food and drinks are taken.
 Rest rooms and areas should be arranged to ensure that non-smokers do not have to be exposed to
smokers –separate rooms/areas, prohibition.
 Adequate facilities for nursing mothers and pregnant women to rest.
  First aid facilities including trained personnel taking in to account the number of
persons employed and the proximity of emergency services.

Washing facilities
Sanitary Facilities Drinking facilities

First Aid facilities

Resting facilities
3 Outline the features and arrangements that should be considered in order to minimize risk associated with the
movement of vehicles in the workplace.
OR
OUTLINE the main design features of a workplace designed to reduce the risk of injury associated with INTERNAL
TRANSPORT.
OR
OUTLINE the main design features of a ware housing operation design to reduce the risk of injuries
associated with INTERNAL TRANSPORT.

SUGGESTED ANSWER
Features that could have been included are: -
1. SEGREGATION of vehicles and pedestrians. - Separate pedestrian access and egress; Inclusion of
passing places and refuges; barriers, guard rails, raised walkways and curbs to protect pedestrians,
and clearly marked crossing places.
2. TRAFFIC ROUTE should be sufficient width, on stable leveled ground, Suitable road surfaces; Design of
layout to avoid sharp bends and blind corners and to avoid the need to reverse, through use of one ways
systems. Provision Convex mirrors on blind corners to improve visibility; Route should have speed
limit, speed retarder and suitable road marking. Provisions of hazard signs – to warn blind corners,
crossings, low-head rooms or width restrictions.
All the routes should be well lit – including color balance, avoidance of glare & provision of good
standard lighting for the transitions area between inside and outside the buildings, -
3. VEHICLE Movements should be carried out in safe area with sufficient space and operatives provided
with high visibility clothings. Vehicle should be fitted with reverse alarm and flashing beacon lights.
Designated parking spaces to avoid congestion.
4. PROCEDURAL ARRANGEMENTS – control of visitors in the premises, training and certification for the
drivers, prevention of unauthorized use of vehicles; training and information to pedestrians on the risks,
selection for suitability and maintenance of vehicles , monitoring and reporting the defects, maintenance
of traffic routes, enforcement of speed limits and the use of banksman will further reduce the risks ,
provision of information on site rules for visitors including drivers visiting the site & provision of high
visibility clothing by workers working in close proximity to traffic routes.
Protection of racking or other vulnerable items, to reduce the likelihood of items falling and to avoid from
collision with moving vehicles. Provision of suitable and sufficient
 Avoid creation of blind
bends if unavoidable Segregate
install wall mounts mirror pedestrians from
(convex) to improve vehicles with the
Direction of vehicle visibility use of fixed barriers
movement control
e.g.. force one way
traffic Separate access &
egress points for
vehicles/pedestrians

Where possible
Design features to reduce
design routes such to
risk of vehicle/pedestrian Introduce safe crossing
eliminate/reduce the
collision
need for reversing points e.g.. zebra
crossing

Allow sufficient space

for vehicles to operate Create Safe
Passing Places

Ensure lighting is Where possible re-route Consider automated

adequate and pedestrians away from system (robotic to almost
suitable for tasks vehicle movement area e.g.. eliminate pedestrians
carried out elevated corridors requiring access
4 A rectangular warehouse building (40m x100m ground area and 18m high) was constructed on a structural steel
framework, with a flat roof and coated steel walls. During a winter storm, the warehouse suffered a catastrophic
failure of one of its long walls which in turn caused collapse of the roof and bucking 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)

SUGGESTED ANSWER
a) The possible causes of this structural failure are:
1. Exceeded the designed wind loading due to adverse weather.
2. Overloading of structure by excess weight on roof due to accumulation of snow or rain water.
3. Alteration to the structural members which had invalidated the original design calculations.
4. Collapsing or nearby excavations and tunneling operations creating instability
5. Vibrations caused by the volume of passing traffic
6. Wind variations which would result in fatigue.
7. Poor workmanship - Even superior quality materials, if used imperfectly, may not successfully serve the
planned function, or be as durable as designed.
8. Faulty Construction- occurs when inappropriate material is used for construction. Faults that result in
structural failures include bad welds, improper torque used on nuts and bolts, sand that is too salty for concrete,
bad riveting and inferior steel.
9. Bad Foundation - cause displacement which alters the stress distribution of the building so the construction
and design are changed and no longer meet the necessary specifications
b) The health and safety issues to be considered when planning the subsequent demolition of the damaged
warehouses are:
1. Selection of Demolition contractor (competency).

2. Risk Assessments, SSW, method statements: The method to be used for demolishing the partially
collapsed structure to prevent premature collapse of the remainder. The preparation of a method
statement to indicate the systematic approach that should be taken.
3. Access and egress

4. Correct use of ladders

5. Edge protection / fall protections

6. Identifications / insulations of buried services (EWG):

7. Inspection, examination and maintenance of plants / equipment.

8 . Means for transporting tools, materials.

9. Garbage chute.

10. Competent employees.

11. Precautions while handling gas cylinders.

12. Identification, Precautions for possible contacts with hazardous substances such as lead paint,
asbestos.

13. Protections of adjoining property 12– PPE .

14 . Additional measures / protection of public: Barriers, Signs at ground, Arrangement for vehicle
movement – Restricted access / security, Traffic control / flagman.

Identification of competent
demolition contractors
Protection of nearby
If building partially collapsed buildings/business/properties
already devise method for
demolishing to avoid premature
collapse of the remainder

Site traffic management if

required
Welfare facilities provision e.g..
toilets, wash and rest facility
plus maybe lay down area for
Protection of public e.g..
contaminated clothing
barriers, signs, security

H & S issues to be considered

when planning demolition of
Control of noise
building Precautions to prevent
people or objects falling e.g..
scaffolds, edge protection

Identification of buried and/or

overhead services e.g.. power Notification of HSE
cables, gas pipelines under CDM 2007 regs

Selection of and Inspection,

Identification of hazardous
maintenance of plant and
materials, control of dust and safe
equipment to be used
removal of waste from site – use of
licensed carrier etc
PPE required for workers e.g.. hard
hats, ear protections safety boots,
protective clothing, eye protection
etc
5 It is proposed to inspect, clean and repair the inside of a tank that is 6 metres in diameter and 10 metres high and
which has previously been used for storing leaded petrol.
Outline the steps that should be considered in order to enter this confined space and to carry out the work safely.(20)
OR
Outline additional arrangements that should be considered in order to comply with the confined spaces Regulations
1997. (20)

SUGGESTED ANSWER
The relevant specified risks in this case relate to fire and explosion, and loss of consciousness due to asphyxiation
or high temperatures, works at height.
The steps that has to considered in order to enter a confined space which was used to store leaded petrol are:
 A SSW is required for entering confined space, to comply with confined space legislation and to carry out
work safely
 To develop a safe system of work a full RISK ASSESSMENT needs to be carried out considering the likelihood
of Toxic effects of lead, - Flammable atmospheres from the previous contents of the tank - Air
contamination from the cleaning or repair methods used - The build-up of heat within the tank.
 Hazard associated with Working at height - Completion of the risk assessment would point to appropriate
arrangements / preventive measures / precautions such as
 Initial Arrangements - The need to purge the tank with an inert gas, - The use of forced ventilation, -
Atmospheric testing before and during entry, and - The provision of PPE including air-fed breathing
apparatus - The requirements for electrical equipment (e.g. intrinsically safe, flameproof) and earthing
arrangements – If heat were to be a foreseeable problem, then consideration should be given to issues such
as job rotation and fluid intake.
 The physical arrangements for working at height would need to be considered in terms of both prevention of
falls from height and, means of access and egress in the event of escape or rescue.
 Procedural arrangements would centre on the - Implementation of an entry permit - Limiting the number of
people working in the tank, - Communication with standby personnel and - Drawing up the emergency
arrangements .
 The emergency arrangements to be considered would include issues such as The provision and
maintenance of cutting equipment, - Tripod / Hoists, - Fire-fighting equipment, - PPE (e.g. breathing
apparatus) - First-aid facilities including CPR apparatus and Liaison with emergency services.
 Additionally, Arrangements should also be in place to ensure that all personnel involved in the operation
have received sufficient training in the work methods, the precautions needed and emergency procedures

Key Factors/Regs
• Confined space regs
• Reg 4(1) Avoid
• Reg 4(2) If must SSOW to
be defined
• Reg 5 Define Emergency
rescue plan
Specified occurrence
• Fire or explosion
• Loss of
consciousness/asphyxiation from
gas, fumes or lack of oxygen
• Drowning
• Asphyxiation arising from free
flowing solid e.g.. mud slide
• Loss of consciousness arising from
high temperature
Reg 5 Emergency planning/Procedure
• Communication with workers in
vessel/space
• Raising the alarm
• Emergency rescue e.g.. tripod winch
• Provision of stand by man/first aider
• Means of fire fighting
• Provision of emergency escape sets
• Communication with emergency services
Reg 4(2) SSOW
Reg 4(1) Avoid if possible Risk assessment to consider
Consider other options • People conducting work e.g.. age,
• Cameras experience, training
• Cleaning lances • Likelihood of flammable/explosive
Robotic inspection atmosphere from previous contents
• Access/egress
• Contaminated air from previous
contents
• Build up of heat
• Duration of activity
• Lack of oxygen
CONFINED
• Working at height within CFP
SPACE ENTRY
• Ingress of solids/liquids
• Impact of other plant
• Outside environment Weather,
other activities
• Isolations required
• Emergency situation
Reg 4(2) SSOW cont.
Control measures
• Trained and experienced workers to conduct activity
• Entry procedures, use of equipment e.g.. BA
• Purge of space with inert gas e.g.. nitrogen
• Forced air ventilation
• Atmospheric testing e.g.. gas/oxygen level monitoring
• Suitable electrical equipment e.g.. intrinsically safe
• Earthing arrangements
• Job rotation e.g.. control of heat fatigue
• Appropriate access and egress e.g.. scaffold, ladders
• WAH provision, e.g.. scaffold internal of space
• Barriers to prevent unauthorised access
• Appropriate isolations as necessary
• Appropriate PPE e.g.. anti static clothing, BA, gloves etc.
6 Element IC 2: Principles of Fire & Explosion
A production uses a potentially explosive powder. Pressurised nitrogen is the transporting and inerting gas within
the plant.
a) Give the meaning of ‘inerting’ (2)
b) Outline practical reasons why inerting was considered necessary for the process. (3)
c) Identify the risks from inert atmospheres during maintenance. (2)
d) Outline control measures that reduce the risks from inert atmospheres during maintenance. (3)

SUGGESTED ANSWER
a) Inerting is the process of converting a substance from a flammable or reactive condition into a safe, non-
flammable or non-reactive state. This is done by adding an inert gas to replace atmospheric air containing
oxygen or moisture.

An inert gas does not interact directly with a compound or product. Nitrogen is the most commonly used gas for this
purpose, but carbon dioxide or argon is sometimes used.

Objectives of inerting:

 Increase product quality

 Boost safety

The different inerting processes are known as blanketing, purging, sparging, stirring and stripping.
 b) Inerting is necessary during the process of the prevention of explosion within the process and the avoidance
of flammable limits.

i) The prevention of air/oxygen being drawn with the process through the pipe work or holes in the
equipment.
ii) The possible existence of air/oxygen within the process due to start up condition or maintenance
and repair work.
iii) The negate possible ignition sources from friction or static electrical within the process.

c) The risks from inert atmosphere during maintenance are cold burns from cold nitrogen supplies hypoxia
anoxia are asphyxiation due to an a inadequate supply of oxygen . Direct and indirect injury from the release
of pressured gas or product from the plant.

d) The control that reduce the risks from inert atmosphere during maintenance

 The effective isolation of the plant by in connecting the supply of inert gas.
 The blanking/spading the supply pipe
 Measuring and monitoring the oxygen and flammability levels in the working area
 The use of forced ventilation or breathing apparatus.
 Establishing control by means of permit to work system with the activities being authorized
and undertaken by trained and informed personnel.
7 In relation to dust explosions:
 a) Explain the conditions that must be present for a primary dust explosion to occur (4)
b) Explain the additional conditions necessary for secondary explosions to occur (4)
c) Identify the causes and effects of the General Foods dust explosion Banbury 1981 (4)
d) Identify the design features that would minimize the likelihood and effect of a dust explosion. (8)

SUGGESTED ANSWER
a) Conditions that must be present for a primary dust explosion: -
 The dust must be combustible
 The concentration of dust must fall within the explosive limits
 The ignition source of sufficient heat must come in the contact with the dust
 Sufficient Oxygen should be present in the atmosphere to sustain the combustion.
 The dust must be capable of becoming air born and mixing with air, the particle size must be capable
of propagating flame.

b)Conditions necessary for Secondary Explosions:

 Dislodgement / Force removal of accumulated dust from horizontal surface within the affected
building by the pressure wave and consequent air turbulence.
 Ignition: When lying dust is distributed by the primary explosion and form a second dust cloud , the
dust cloud then can be ignited
 By the combustion of products from primary explosion
 By the heat released through the primary explosion
 Any other source of ignition within the area with sufficient heat energy

c)The causes and effects of the General foods dust explosion Banbury 1981 were:
1. The initial failure of pneumatic conveying system which resulted in the over lifting of a holding bin.
2. Air pressure caused the outlet filter to fail resulting in the emission.
3. The buildup of a cloud of corn starch powder which was ignited by an electrical arc from a broken cable.
4. The explosion caused substantial damage to an external wall and nine men were injured.

d) The design features that would minimize the likelihood and effect of dust explosion are:
The initial design of ducting and equipment to withstand the effects of an explosion, - Ensuring that the ducting was
dust tight, - Providing local exhaust ventilation at point of transfer, - Installing explosion relief or suppression
systems together with systems for suppressing fire, - Using screw conveyors instead of pneumatic systems for
moving materials Providing a magnetic extraction system for removing metal from product fed to the plant, -
Interlocking equipment to prevent overfilling of vessels and over pressurization, - Using instrument systems with
integral emergency shutdown -Using intrinsically safe electrical equipment and bonding all metal work to
earth, - Preventing dust build up in the plant by the use of sloping surfaces and introducing a mechanised
system for humidification of the air.
 Ignition control
Key principles • No smoking policy
• Dust control • No mobile phones
• Ignition source • Provision and use of anti static
control clothing and footwear
• Mitigation of • Earth bonding of equipment
explosion effects • Assessment in compliance with
• DSEAR regs DSEAR regs
• Zoning
• Appropriate zone identification
of areas i.e.. 20, 21 or 22
Reducing risk of dust cloud • Use of spark protected
explosion and mitigating equipment – intrinsically safe
explosion effects to appropriate zone
• Abnormal activities generating
sparks under hot work PTE

Mitigating effects of
Dust control explosion
• Damping down • Equipment able to
• Extraction of dust at withstand explosion
point of transfer (LEV) • Venting and explosion
• Interlock device to panels
prevent overfilling of • Bursting disc on
vessels vessels
• High standard of house • Suppression – inerting
keeping • Compartmentalisation
• Ensuring that systems – minimise effected
are sealed where
possible
 a) Describe the effects of a fire in a workplace on the following structural materials
i)Steel (4)
8 ii)Concrete (4)
iii)Wood (4)
b) Outline the precautions that could be taken to prevent failure of these materials in the event of fire. (8)
SUGGESTED ANSWER
a) The effects of fire in a workplace due to structural material

Steel
1. Steel expands on heating, loses strength as temperature rises and tends to deform and buckle.
2. It regains strength on cooling but its properties may have changed.

Concrete
1. It exhibits limited expansion and has a tendency to spall and crack.
2. It can be exacerbated by expansion of steel reinforcement within the concrete.
3. The structural strength of concrete is lost on cooling and it loses structural integrity.
Wood
1. Thin sections will burn and promote fire.
2. The charred surface of thicker structural members may act as an insulator to protect the inner timber.
3. The burning timber generates smoke and fumes and allows the surface propagation of fire
4. Some varieties of timber are resistant to fire than other large timbers.
5. Wood tend to retain their structural integrity.
b) The precautions that should be taken to prevent failure of the materials in the event of fire.
Steel might be protected by the use of sprayed concrete or inturnescent coating or fibre board of an appropriate
rating & providing an insulating barrier for steel.
1. Concrete the selection of the type of mix to improve fire resistance and increasing the thickness of
concrete between the external face and reinforcement bars that would provide some protection.
2. Failure of wood can be prevented by selecting fire resistant timber . Increasing the thickness used to allow
for a charring outer layer or impregnating it with fire retardant.
3. The other general precautions include the provision of means such as compartmentalization to prevent
heat transfer through long steel members in the event of fire. The automatic means of applying water to
structural members should fire occur and the use of fire resistant surface cladding or flammable sacrificial
cladding.
 Effects Fire on materials

Wood
Steel • Thin sections will burn promoting fire
• Will expand with heat spread
• Loss of strength normally Concrete • The charred surface of thick timber
@600 Celsius • Limited expansion will act as insulation to inner timber
• Deform & Buckle • Cracks and spalls made • Dependant on species
• When cooled will regain worse by expanding • Generates smoke & allows surface
strength but properties may reinforcement steel e.g.. propagation of fire
have changed rebar • Strength after burning depends on
• Acts as conductor • Poor conductor of heat original thickness and proportion loss
transferring heat thus • Will have lost structural to fire
spreading fire strength when cool

Precautions to prevent
failure of materials

Wood
Steel • Selection of thick
• Concrete cladding timbers
• Compartmentalise to reduce Concrete • Selection of timber
conduction • Selection of type and mix to improve e.g.. hardwood burns
• Automatic cooling with sprinkler fire resistance slower than soft wood
system etc. • Increase thickness of concrete from • Treat with fire
exposed surface to steel retardant substance
reinforcement (rebar)

General precautions
• Sprinkle system
• Fire resistance cladding
• Early fire detection
• Control of ignition sources & reduction of fuel type
materials – fire risk assessment and adequate
controls implemented
 Describe the principles and the effects of a boiling liquid expanding vapour explosion (BLEVE). Give examples of
actual incidents to illustrate your answer. (10)
9 SUGGESTED ANSWER:
Principle of BLEVE: A BELEVE (boiling liquid expanding vapor explosion) is initiated by an external heat source
applied to a container of liquid. A drum of petrol on a bone fire is a simple example. The vessels loses
containment, by rapture or pressure release valve opening, which vents the vapour with subsequent ignition.
There is rapid spread of boiling liquid and vapour and a fire ball ensues.
OR
The process by which flammable gases (mainly LPG) that are stored as liquids under pressure are subjected to an
external heat source. This heat has two effects. Firstly, in the liquid phase the heat is absorbed and leads to the
liquid phase boiling and an increase in pressure in the vessel. Secondly, the gas phase absorbs less of the heat and
energy is absorbed by the metal structure leading to thinning of the material and eventual rupture. This loss of
containment causes a sudden drop I pressure inside the vessel leading to large quantities of liquid boiling off. The
expanding vapour is ignited by the external fire or heat source leading to the explosion.
Effects: The effects of a BLEVE include the rapid spread of boiling liquid and vapour resulting in a fireball
producing substantial thermal radiation; flying debris and missiles projected from the vessel and the possibility of
a shockwave.
Example: Relevant examples could have included the BLEVE at San
Carlos de la Rapita in 1978 at a campsite in Spain, the Mexico City incident in 1984 and that involving Tanker
Explosion ( LPG cylinders)in tunnel in Palermo in 1996.
 Area unable to hold internal
over pressure and ruptures. Liquid level falls
Cylinder/container
containing flammable gas heat continues
under pressure e.g.. butane
pressure turns gas into
liquid state
Examples of incidents
San Carlos
• Crashed over loaded road
tanker
Valve opened reduces • Explosion
• 216 Dead
pressure turning liquid into
Mexico city
gaseous state
BLEVE
Area of cylinder just
above liquid level starts to
Cylinder exposed to heat weaken/thin with heat
source e.g.. caught in a fire
liquids absorbs heat.

Sudden release of contents resulting in

Liquids starts to vapour • Blast wave (low)
• Radiation (thermal) high
and is vented off. • Missiles travelling long distances
Substantial thermal heat sever burns e.g.. LPG cylinder
BLEVE has serve burn range of 35m
10 OUTLINE the issues that need to be addressed when planning a fire evacuation procedure for an office building
occupied by a number of different companies. Your answer should include examples where appropriate. (10)

SUGGESTED ANSWER
The issues that need to be addressed when planning a fire evacuation procedure for an office building occupied by
number of companies are:
1. Identification of emergency scenario – such as Fire, Earthquake, Riot etc.

2. Selection for employees to form an emergency control team – Described responsibilities, - Adequate training
to Fire warden , Security and other members

3. Means of Raising Alarm and Alerting Building occupants

4. Liaison with emergency services – such as their access requirements and appropriate locations of assembly
areas.

5. Considering the health situation of occupants and member of visitors in the building , their sensory
disabilities and physical disabilities etc. to be considered

6. Physical Measures – Such as travel distance, number of access, Emergency lights, Exit signs, Evacuation routes
etc.

7. Firefighting Equipment – Alarm, Smoke detector, heat detector, Suitable Fire extinguishing media (DCP, CO2,
sprinkler system, Hose reel etc.)

8. First Aid measures – First aid providers, first aid medicines, first aid equipment, CPR arrangements etc.
 9. Emergency Rescue Equipment – Stretcher, Wheel chair etc.

10. Providing door marshals to prevent entry or re-entry to the store.

11. Security considerations such as minimizing the opportunity for theft would also be an issue.

12. Assembly points - Well defined, Displayed and communicated

13. The procedure, once drawn up, would need to be summarized on prominently displayed fire notices and
tested with regular fire drills.

Raising the alarm

Liaison with emergency services • Consider any disabilities and make
• Numbers of people involved provision for e.g.. visual alarm for
• Specific hazards in building deaf people
• Contacting the emergency service e.g..
Accounting for people interlocked alarm system or manual
call

Publishing and training of

procedure
• Regular drills
• Documented Numbers of people to evacuate
Fire log book & physical ability
• Escape routes
• Distance of travel
required
Issues to address when • Alternatives routes
planning a fire
Emergency light and evacuation
signs
• Exits
• Escape routes
 Prevention of re-entry

Equipment and security

Training of fire wardens
• Equipment may need
• Zoning
shutting down safely
• Areas of
• Security could be an issue
responsibility
after evacuation

Roles and responsibilities Refuges and safe havens

• Managers (muster points)
• Staff
 Element IC: 3 Workplace fire risk assessment
11 Outline the issues that should be included in a fire safety training session for workers. (10)

SUGGESTED ANSWER
The issues that should be included for fire safety training session for workers 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; Fire Types / Classification
 The basic elements of fire prevention such as the storage of flammable materials, good housekeeping
and the need to prevent the accumulation of rubbish;
 The action to be taken on discovering fire such as RACE – raising alarm, alerting concerned/
procedure for calling fire services, and the action to be taken by personnel on hearing fire alarm
(confined fire, evacuate)
 The procedure for calling the fire service; - The action to be taken by personnel on hearing the
alarm
 The location and use of firefighting equipment with practical training for selected employees
 The escape routes and exits from the premises together with the assembly points
 The head counts / roll call that would have to be carried out
 The arrangements for the evacuation of people with disabilities, assisting visitors and members of
the public
 The identity and role of fire wardens and marshals
 The importance of fire evacuation practices and drills and
 Issues directly concerned with personal behavior such as refraining from re-entering the building
after evacuation until instructed to do so.
smoke inhalation cost involved principles of fire triangle methods

RACE Fire fighting Technique

Prohibition of re-entering
12 A factory manufactures upholstery using fabrics and plastics pallets. These raw materials are delivered to a
warehouse. The fabrics and plastic pellets are machined to form furniture coverings and cushions. The plastic
pellets have been sprayed with a flame retardant. The finished product is then stored in a dispatch warehouse prior
to distribution. The movement of goods around the premises is carried out by Liquid Petroleum Gas (LPG) fuelled
forklift trucks. The company is located on the outskirts of a small town and employs 230 people.
Outline the range of factors that must be addressed to ensure a suitable and sufficient fire risk assessment is made
for the premises.(20)

SUGGESTED ANSWER
The forklift trucks fuelled by liquid gas (LPG) have to address the following facts to avoid risk in the premises.

Fuel, Ignition Sources, People Issues, Preventive actions, Mitigating actions, Means of escape and Management
systems.

Fuel
Factors connected with fuels include LPG for forklift trucks, the flammable covers, untreated fillings, structural
issues such as the materials of construction of the premises themselves.
Ignition Sources: 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.
People Issues: Attention to given to the number of persons to be evacuated in the event of a fire including visitors
and contractors with the need of disabled employees being particularly addressed. As for people issues, attention
would have to be given to the number of persons to be evacuated in the event of a fire including visitors and
contractors with the needs of disabled workers being particularly addressed.

Preventive Actions: would include compartmentalisation for higher risk areas such as the plastics and LPG stores
with the latter being segregated, bunded and provided with a fixed sprinkler system; fixed protection systems in
warehouses and an adequate supply of water and/or foam; the use of fire resistant cover materials; minimising the
amount of stock kept on the premises and ensuring a good standard of housekeeping with facilities provided for the
segregation of waste.

Mitigating Actions: The sufficiency and appropriate nature of the firefighting equipment together with its location,
 smoke venting of warehouse. The provision service of access for emergency services.

The Means of Escape: And there would have to be assurance that these were continually maintained and that fire
doors were correctly specified. Attention would have to be given to travel distances including multi-storey
considerations, the provision of normal and emergency signage and emergency lighting together with refuges for
subsequent evacuation and the provision of assembly points in a place of safety.

The Management System : Introduced for the maintenance and testing of fire precautions and mitigation
equipment, the carrying out of fire drills and the training given to workers both in evacuation procedures and the
use of fire fighting equipment.
13 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)

SUGGESTED ANSWER
The factors to be considered for evacuation procedures in the hospital are
1. The various sections & activities of hospital- such as in wards, ICU, theatres, offices, outpatients and visitors.
2. The number of patients and staff to be evacuated.
3. The mobility of the patient including their medical condition and age.
4. Reviewing current and normal evacuation procedures including escape routes, assembly points and fire
bigrade access. Ensuring that the escape routes and assembly points are clear from construction
materials
5. The provision of emergency lighting & appropriate sign ages.
6. Identifying temporary procedures and routes such as the availability of operational lifts for bed ridden
patients.
7. Consideration of a two stage evacuation procedure
8. The provision of training to hospital and construction of staff in the temporary arrangements.
9. Ensuring that escape routes and assembly points are kept clear of construction materials.
10. Considering the possibility of emergency zoning and classification for e.g., full or partial evacuation, area
wise nearest assembly point as per zone
 11. Assessing the effect of construction work on the existing fire detection system, Alarm and firefighting
equipment and the possibilities that might increase the risk of fire.
12. Assessing the need for first aid provision and firefighting and fire protection provisions.
13. Adequate training for the existing hospital employees as well as the construction employees.
Element IC 4: Storage, handling and processing of dangerous substances
14 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)

SUGGESTED ANSWER
The measures needed to assess and control the risks associated with the spray painting activity are
Risk assessment to be carried out for
The activities involved by using paints & solvents with hazardous properties (normally by
reference to safety datasheet).
The circumstances in which the work was carried out.
Possible ignition sources and likelihood that a fire or explosion could occur -
The control measures
The workshop should be constructed of fire resistant materials; An impermeable / solid base to be
constructed
Possibilities to replace the paint with less flammable
An external fire resistant storeroom to be provided for the paints and solvents
A reduced quantities of paint and solvent to be maintained at the workshop
The paint and solvent should be kept in non-spill containers with lids.
Procedures to made and followed for the containment and clean-up of spillages and for the cleaning of
the spray guns
Provision for Local exhaust ventilation
Safe electrical equipment with provisions of flameproof switchboards.
Fire fighting equipment, means of escape route, emergency procedure to be drawn and communicated
to the workforce
Instruction, training on the risks involved in the operation and the precautions to be observed.
15 The physical and chemical properties of liquefied petroleum gas (LPG) dictate a number of precautions which
should be taken in the storage of LPG in cylinders
a) Select four of these properties and explain how one of the precautions is related to each property. (8)
b) Give, with reasons, additional precautions for the safe storage of LPG in cylinders. (12)

SUGGESTED ANSWER
a. The properties can be selected include:
 LPG is a flammable gas at standard temp and pressure;
 It is denser than air; Escape clouds cool and therefore are not buoyant on thermal diffusion
 Liquid releases float on water
 The lower explosive limit (LEL) is reached with small concentrations of LPG
 It is slightly anesthetic and suffocating in high concentrations
b. Precautions for the safe storage of LPG in cylinders include:
 Preferably stored in the open air; Floors should be concreted
 Noncombustible or fire resistant and Ventilated with an explosimeter installed
 Minimise quantity;
 Elimination of ignition sources: no smoking, Provision of signage with 'extremely flammable'
warnings; - Intrinsically safe / flame proof electrical equipment
 Only electrical apparatus for use in Zone 2 area should be allowed in storage area or within
separation distance
 Dry powder extinguishers at storage location
 Control of combustibles; Removal of vegetation around storage area (not sodium chlorate weed
killers / other oxidizing agents)
 Segregated from oxygen cylinders (3m);
 Empty cylinders stored separately from full with valves shut
 Cylinders stored upright; Protective caps kept in place on valves
 Storage compound should be protected from vehicle impact
 Storage situation greater than 3m from cellars, drains or excavations and protected from the
elements;
If more than 400 Kg store must have 2m high mesh fence, 2 exits, with Cylinders at least 1.5m from fence
Properties of LPG
• Flammable at standard temp & pressure
• Denser than air Control of ignition sources Stored away from
• Liquid form floats on water • No smoking excavations, drains,
• LEL is reached in small concentrations • Storage of cylinders away from potential pond, rivers, cellars
• Can cause suffocation in high ignition sources e.g.. fabrication shop
at least 3 m
concentrations • Control of mobile phones
• Storage area regarded as zone 2 so only zone
2 IS rated electrical equipment to be used
• Signage stating highly flammable
• Dry powder fire extinguisher located close to
storage area
Protected from
Storage compound elements were
designed to prevent possible
vehicle impact

Concrete level floor,

surrounding area kept free of
Cylinders stored in vegetation (not with use of
upright position LPG in cylinders oxidising week killer e.g..
sodium chlorate
precautions (storage)

If more than 400Kg stored Empty cylinders stored

must have 2m high mesh separately from full
fence and cylinders at least cylinders, caps fitted to
1.5m away from fence with 2 valves. Well ventilated
exits
Any store room must be
non-combustible or fire
resistant and ventilated Stored away from any oxygen
with and explosimeter cylinders. oxidising
installed substances
16 Unless appropriate precautions are taken, chemical reactions in a batch manufacturing process can give rise to
conditions which can lead to a ‘runaway reaction’
a) 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)

SUGGESTED ANSWER
a) An uncontrolled exothermic reaction where the heat produced by the reaction exceeds the heat removed.
The surplus heat raises the temperature of the reaction mass, which causes the rate of reaction to increase
resulting in RUNAWAY REACTION. Thermal runaway occurs because, as the temperature increases, the
rate at which heat is removed increases linearly but the rate at which heat is produced increases
b) The Condition that may give rise to the ‘Runaway Reaction’ are
1. A strong presence of exothermic reaction is due to inadequate provision of or failure in cooling of the
reaction.
2. The presence of contaminated catalyst.
3. The excessive quantities of reactants present in the reactors.
4. The lack of sensitive temperature deduction and control.
5. The insulation of the reaction vessel where residues have built up or the internal walls of the vessel and
mixture failure with loss of agitation.
6. Increase in pressure and temperature from reaction serve to accelerate the reaction in accord with Le
Chatelier’s principle.

c) The design and operational features to prevent such an event

1. Carrying out a hazard and operability study (HAZOP) on the reaction process would be appropriate in this
scenario; this may then have led to the inclusion of design features such as:
 High integrity temperature detection being linked to the cooling/reactant addition system.
 Pressure rise detection linked to cooling/venting/auto shut-down

 Vessel protected by correctly sized bursting disc.

 Fitting of an agitation failure alarm system
 2. Operational Features such as
 Only high caliber of operator required for such processes was employed
 The decision making requirements by operators in response to adverse operating condition were
minimized
 Ensure that maintenance activities / raw material handling do not introduce potential catalysts
into the reaction; - The rate of addition of reactants was limited and that inappropriate scale-up or
fouling was avoided
Causes If the heat released from
Chemical changes involve • Failure of temp control reaction is not
heat (reaction cooling)
controlled/removed
• Exothermic - Evolutes • Strong exothermic reaction
• Endothermic - Absorbs • Presence of containment reaction will speed up
catalysis (speeds up exponentially
reaction)

Operational features to prevent Temperature Increase

• High calibre of operator
experienced and appropriate speeds up reaction – Le
level of qualification to Chateliers principle
operate process
• Ensure that maintenance RUNAWAY
activities/raw material
handling don’t introduce REACTIONS
potential catalysis into Design features to prevent
reaction • Conduct HAZOP study
• Appropriate temperature control system e.g..
matrix cooler
• High integrity temperature detection linked to
Can result in cooling/reaction addition protection
• auto ignition explosion • Pressure rise detection linked to
• Catastrophic over pressure cooling/venting/auto shut down
resulting in loss of • Vessel protected by correctly sized bursting disc
containment e.g.. vessel linked to safe haven e.g.. secondary vessel to
rupture and toxic release dump reaction to
• Violent boiling • PRV’s, weighted lids to realise pressure
• Secondary competing • Agitation of liquids to promote even temp
reaction distribution
17 An extremely flammable liquid is being transferred from a road tanker to a bulk storage tank.
a) OUTLINE the control measures which would reduce the risk of ignition of the associated vapour due to static
electricity? (10)
Tanker drivers are routinely required to work on top of road tankers during transfer operations.
b) OUTLINE the factors that should be considered when assessing the risk for work on top of the road tanker. (10 )
OR
Identify the safety features needed to protect against ignition by static electricity of the vapour of an extremely
flammable liquid while it is being transferred from a bulk storage tank to a road tanker. (10)

SUGGESTED ANSWER
a. Practical ways of minimising the risk of an electrostatic charge

 The use of tankers and pipework with high conductivity; Earthing the pipework and tanker and
bonding to the same electrical potential. ; Reducing the velocity of the filling or draining operation
by controlling the pump rate .
 Reducing constrictions by the smoother pipe unrestricted by strainers.
 Avoid splash filling or water contamination in pipe; Increasing the relaxation time by using
longer pipe work.
 Add anti-static additives ; Nitrogen blanketing of the road tanker to minimise the risk of
explosion.
 The uses of a vapour return system to improve containment.; The provision of instrumentation to
detect earth leakage .
 Using antistatic clothing and footwear

b. Control measures that could reduce risks with road tanker filling

 Preparation of written procedure and instructions; The identification of specified entry and exit routes .
 High level of communication and cooperation between tanker’s driver and the site operator.
 The use of pumps, hoses and other equipment which are suitable for the purpose, properly installed and
regularly maintained.
 Fitting devices such as a high level alarm to prevent overfilling .
 The erection of barriers or the use of bollards and warning cones to prevent a collision.
  Installing a system to prevent tanker driving away to prevent the tanker driving away if hoses are still
connected.
 Ensuring the tankers are positioned correctly with wheel chokes and hand brake applied.
 Ensuring hoses are coupled without submitting them to abnormal stress and valves operated in accordance
with lay down procedure.
 Switching off electrical equipment which was not required for filling such as mobile phone and bonding
and equalizing the potential between the tanker and fixed installation.
 Using bottom loading tankers in preference to those which are top loaded but if this is not possible
ensuring that the top loaded tankers have a fill pipe which touch the bottom of the tanker and handrails or
fall arrest equipment is provided to prevent falls .
 Finally preparing procedure to be followed in the event of the emergency and ensuring that all workers
are fully aware about.

Worker involved trained and

Controlling pump rate Avoid splash/spray
competent in operation e.g.. • Speed slow – not to filling
aware of hazards and propagate static build up
precautions necessary

Complete containment of Key factors to protect Provision of anti static

flammable liquid, not against ignition from static clothing including
leaks, seals joints etc of a flammable vapour footwear
during transfer of
containment of liquids
Over fill protection system
e.g.. high level indicator,
interlocked shut down Earthing of all conductive surfaces
e.g.. tankers, pipe work, containers
e.g.. IBCs
Keep at zero potential, Earthing
Implementation of a
Use of inert gas blanketing should be interlocked to pump
vapour return system system
above the liquid
 Element IC5 : Work Equipment (general)
18 A serious accident occurred when a threaded steel rod in the braking mechanism of a hoist broke. At investigation
revealed that the cause of the breakage was fatigue.
a) a) Outline the mechanism and characteristic of fatigue failure.(6)
b) Identify THREE factors which can contribute to such a failure AND for EACH factor outline ONE
circumstances in which it may occur.(6)
c) Outline the measures that could have been taken to minimize the likelihood of such a failure. (8)
SUGGESTED ANSWER
a) The mechanism and characteristics of fatigue failure such as
Microscopic progressive cracks (point of high stress, variable loadings, little deformation)

 Crack propagation from points of stress concentration,

 Fluctuating stress environments and
 The characteristic fracture pattern.
The final failure may be ductile or brittle when there is insufficient material to sustain the load
 Failed surface shows conchoidal beachmarks , which Progress as narrow rings at low and extended at full
load
b) Factors which could give rise to fatigue failure in practice such as: (only 3 factor with 1 circumstance)
 High Fluctuating stress – Use outside the design criteria, Relative to fatigue
strength of material,
 Stress concentration – sharp corners, threads, holes, defects / flaws / cracks /
impurities
 Temperature – heat induces stress, change of material properties
 Residual stress – imposed during manufacture and assembly and induced bending
stress, and
 Corrosion – stress concentrations in corrosion pits
c) Measures to minimize the likelihood of fatigue failures such as:
 Design, manufacture and installation
 Minimize stress concentration; specifying materials / components to match the service
condition
 Quality assurance; Correct assembly
 The maintenance , inspection and examination ( with NDT)
 Failure record Reliability data; Non Destructive test
  Examination of critical components
 Replacements at planned intervals
 Maintenance
 Statutory examination requirements
 Provision of training and instruction for those involved in the use and
 The keeping of service history records.

Fatigue failure
• Crack propagation from points of stress concentration
(e.g.. groves, weak weld points), fluctuating stress
final failure may be ductile or brittle
• Factors contributing
• Surface occlusions/damage
• Choice of material
• Residual stress imposed through manufacture
• Corrosion, temperature
• Measures to take to prevent
• Design spec appropriate
• Quality assurance on manufacture
• Assembled according to spec
• Correct use – avoid misuse e.g.. over ,loading
• Maintenance/testing NDT
19 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 conveyor 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).

SUGGESTED ANSWER
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
 Enclosures or distance guards to prevent access to the conveyors
 Edge guards or rails to prevent the coal from falling off the conveyors
 Trip wires or emergency stops that were clearly visible to enable the belts to be stopped in the event of an
emergency
 The provision of adequate space between the conveyors
 Positioning the conveyor belts at a convenient height to facilitate the loading and unloading of the coal
 Carrying out maintenance on the conveyors on a regular basis by competent personnel
 Carrying out a noise assessment and providing 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.
 Guards:

Fixed guard
Nip Guards Carrying out
Edge Guards
maintenance
Distance Guards
Positioning at a
convenient height

Carrying out a
noise
Adequate assessment
space between
the conveyors

Provide
adequate lighting
Monitoring the Inspecting
presence of dust machinery at the
and provide beginning of each
ventilation shift
20 Prevention of pipe work failures is critical in preventing major leaks and incidents. The construction of new
chemical plant is nearly complete and some parts are being prepared for start-up.
a) Outline an inspection strategy that should prevent pipework features within this plant. (10)
b) Outline the items that could be included on a checklist when inspecting pipework after construction. (10)

SUGGESTED ANSWER
a) The inspection strategy that could prevent pipe work failures within the plant are
 A thorough inspection must be done on current basis, more detailed manner than previous one.
 The use of NDT technique such as dye penetrate for the detection of surface faults and
 NDT techniques such as ultrasonic or radiography to detect those that were more serious
 The engagement of qualified personnel to interpret the results and management should resist the
temptation to use unqualified personnel for any type of pipe work inspection.
 Inspection should take place during and after the construction has been completed and should be
ongoing throughout the life of the plant.
 Those carrying out inspections should preferably include a member from design team who will be able to
detect departures from the design intentions and also a member of the startup team who suffer most from
the results of construction defects.
b) Checklist
 Suitable material such as specified grade of steel to be chosen for the construction of the pipe work.
 The required tests have been carried out: the pipes are not secured too tightly and are free to expand.
 The flanges on liquid lines are not located above cables.
 Temporary supports have been removed and permanent supports correctly installed.
 Springs and hangers are not fully compressed or extended; No sub standards joint exits
 No screwed joints have been used and ; all joints have been leak tested
 Temporary branches, nipples and plugs have been removed and replaced with welded plugs
 Pipes do not touch the ground, are not laid underground and do not pass through pits or depressions
containing water.
 Relief valve drain lines are not too close to the ground so that blocking and freezing is avoidable.
 Reinforcement pads are vented ; dead ends , dead legs and water traps have been avoided
 Bellows are not distorted and support rings are not loose.
 Vibrating pipes have been avoided and all pipe work has received hydrostatic testing.
21 a. EXPLAIN the purpose of non-destructive testing (NDT) on items of plant. (2) ic5
b. Other than visual inspection, OUTLINE the principles, advantages and disadvantages of TWO NDT techniques (8)
22 (a) OUTLINE the purpose of non-destructive testing (NDT) on items of plant.
Marks-2 (b) OUTLINE the principles, benefits and limitations of the following
NDT techniques:
(i) Dye penetrant; Marks-4
(ii) Radiography. Marks-4
23 OUTLINE the principles, advantages and disadvantages
of: (a) Dye penetrant;
(b) Magnetic particle inspection;
(c) Radiography;
(d) Ultrasonics
as methods of non-destructive testing on the welded joints of a safety critical vessel. Marks-20
The purpose of non-destructive testing (NDT) is to check for faults (cracks etc) in components before they develop into total
failure without affecting the integrity of the component.
The main NDT techniques required are:
Principle of NDT Techniques Advantages Disadvantages

The use of a dye penetrant
method makes cracks visible as dye
penetrates into it.
It uses the principle of brightly
coloured or fluorescent liquid
applied to the surface of the
component, which
penetrates into any surface cracks
or cavities.
Developer is then applied which
draws out the penetrant, so
indicating cracks etc, that are not
normally detected visually
It is relatively cheap and is a simple
operation
It detects surface faults,
It is quick and easy to use on large
surfaces,
It is cost effective, allows complex
geometries to be inspected and is
a portable technique (e.g. spray
aerosol cans of penetrant can be
used)
it does not detect sub-surface faults
It is only suitable for non-porous
materials,
There must be direct access to the
surface of the component,
Surface finish and roughness can
affect inspection sensitivity,
It indicates the length of the defect but
not the depth and
There are health and safety
considerations such as possible
confined space and flammability.
Additionally, the penetrant used
may have toxic properties
Impact or 'tap' testing involves
detection of the change of pitch
of reverberant sound after striking.
Magnetic particle method involves
coating the surface of the item
involved to be tested with magnetic
particles that may be in powder
form or within a liquid.
With radiography, x-rays or gamma
rays are used to penetrate the item
to leave an image on film.
Any defects are shown up by
the differences in the intensity of
the radiation striking the film.
Ultrasonic technique uses short
pulses of high frequency ultrasounds,
with the reflected waves being
detected and shown on an
oscilloscope or digital display.
It is cheap as no specialist
equipment is required
It is a simple and quick
operation that is very sensitive to
surface cracks and, in certain
circumstances, can detect sub-
surface defects,
The benefits of this technique are
that it detects internal defects and
produces a permanent record of the
test
That it can be used on most
material (ferrous and non-
ferrous),
Detects both surface and sub-surface
defects, requires access to one side of
the joint only and takes little time
with portable equipment that can
be used in most environments.
But it gives no indication of where
the fault is and relies on individual
sensitivity / skill.
its drawback is that the interpretation
of results may be difficult,
particularly on the inside surface of
a pressure vessel.
The space required for
the equipment; It is a
time consuming process;
It is expensive;
It requires skilled operators to use the
equipment and interpret the results;
There is a health and safety
consideration due to the possibility of
radiation exposure;
The results show length but not the
depth of defect; and There is a
limitation of the thickness of the
material
The limitations of the technique are
that it requires a high level of
expertise and coupling the
equipment probe onto rough surfaces
can be difficult.
 Purpose

Check for faults (e.g.. cracks) in Dye testing

• Put dye on
components before they develop
• Dye penetrates making Impact (tap testing)
into total failure without cracks visible • Strike surface
affecting integrity of the • Cheap & simple (pro) • Changes in pitch of
component • Doesn’t detect sub surface reverberant sound
faults (con) • Cheap (pro)
• Not totally reliable (con) • No indication of where
• Can be enhanced by using fault is located (con)
fluorescent penetrate and UV • Relies on individual skill
Other techniques source (con)
• Pneumatic testing • Penetrate may be toxic (con)
• Hydro testing • Need good eyesight

Magnetic particle
• Coat surface with magnetic power or
Ultrasonic Technique liquid
• Short pulses of high frequency • Simple & Quick
ultrasound are used • Very sensitive to surface cracks
• Reflected waves detected and NDT • Interpretation of results can be
shown on digital display or difficult particularly on inside of
oscilloscope vessel
• Surface and sub-surface defects
• Only requires one side of joint
• Quick to perform
• Suitable for most environments Eddy current testing
• High level of expertise required • Surface and near surface crack
Radiography
• Coupling equipment onto rough detection
• X-rays/Gamma rays
surfaces can be difficult • Electromagnetic
penetrate item and leave an
image on film method/instrumentation
• Defects are shown up by • Can be used to verify materials
differences in the intensity of heat treat condition
the radiation striking the film • Can be automated (pro)
• Detects internal defects and a • Can suffer from spurious defect
permanent record is created indications
• Expensive • Doesn’t work on non-conductive
• Bulky equipment materials
• Present radiation hazard and • Relatively expensive and requires
tight controls are required skilled operator
• Skilled radiographers are
needed
24 Outline the characteristic features of and factors that promote the following types of materials failure.
a) Brittle fracture (5)
b) Ductile fracture (5)

SUGGESTED ANSWER
a) Brittle Failure: A brittle fracture generally occurs without warning or prior evidence of distress.
It is a crystalline structure failure with minimal plastic or elastic deformation.
There are generally characteristics ‘chevron’ marks from the point of initiation and the failure is sudden from rapid
stress loading.
The factors promoting a brittle fracture are
 High tensile stresses,; Residual or locked in stresses; Sudden loading which does not give the material time
to deform plastically.
 Case hardening; Low temperatures and the degree of brittleness of the material .

b) Ductile failure: A ductile fracture generally has a smooth fracture surface with plastic deformation of the
material before final fracture. There is evidence of necking and the final fracture is often brittle because there is
insufficient material left to sustain a load
This type of failure generally occurs as the result of a single stress overload though other promoting factors
including
 High temperatures,; Cold work hardening and
 The plasticity of the material

Brittle failure
• brittle fracture, no apparent plastic
deformation takes place before
fracture
Factors which promote brittle fracture
• Low temperature
• Inherently brittle material
(cast iron)
• Impact or snatch loading
(does not give material time
to react
Ductile Failure (stretch)
• Ductile failure in metals occur when the yield
stress of the material has been exceeded by the
material being placed in tension (stretched).
The metal moves from it’s elastic region into
it’s plastic region and loses its shape. There is a
reduction in cross sectional area at failure
point. The failure will appear as a ‘cone / cup’
at 45 degrees to the load along the grain
boundaries
• Factors contributing
COMPONENT • High temperature
FAILURE • Over loading
• Design inappropriate
• Measures to be taken to prevent
• Temp control
• Selection/design of materials
• Maintenance/testing
• Operate within spec limits of
equipment
25 A weld repair to a high pressure steam pipeline requires gamma radiography to be performed to assess the quality of
the repair.
a) Outline the principles of gamma radiography. (3)
b) Outline the advantages and disadvantages of this form of non-destructive testing. (7)

SUGGESTED ANSWER
a) The principles of gamma radiography is it uses the transmission of gamma rays from a sealed ionizing radiation
source through a test object on to a film placed on the opposite side. The film records the intensity of the radiation
received, and since the cracks and flaws are hollow a greater intensity of rays pass onto the film and the defects are
shown as darker regions.

b) The advantages of using gamma radiography in non-destructive testing.

1. It can be used on most materials ferrous and non-ferrous.
2. The internal (sub-surface) defects are indicated.
3. A permanent visual image of the component under the test is provided.
4. Coupling with the surface of the piece under test is not required.

The disadvantages of gamma radiography in non-destructive

1. The health and safety consideration due to the possibility of exposure to radiation.
2. The space required for the equipment.
3. The amount of time taken in setting up the equipment.
4. The delay in obtaining results.
5. The requirement of skilled operators to use the equipment and interpret the result.
6. The limitation on the thickness of the material that can be tested.
7. The process is expensive to run.
 Gamma radiography uses the transmission of gamma
rays from a sealed ionising radiation source (isotope)
through a test object onto a film placed on the
opposite side. The film records the intensity of the
radiation received and since cracks and flaws are
hollow, a greater intensity of rays pass onto the film
showing up defects as darker regions

Advantages
Permanent record produced.
• Can be used to test most
materials
GAMMA RADIOGRAPHY • Internal defects can be identified
• Coupling with the surface of the
test piece is not required
``

Disadvantages
• Poses a radiation exposure hazard to
operators requiring specific SSOW to be
implemented
• Can be time consuming due to
application to HSE each time test is
required
• Equipment can be bulking and difficult to
move
• Specialist operators are required and
staff to interpret results
• Results may take a long time to receive
• Can be an expensive process to run
 Element IC: 6 Work Equipment (workplace machinery)
26 a) IDENTIFY when a fixed guard would be an appropriate means of providing protection against mechanical
hazards(3)
b) Outline the features of a ‘fixed guard’ in relation to machinery safety.(2)
c) Outline the factors to be considered in the design and use of fixed guards that minimize risks to workers. (5)

SUGGESTED ANSWER

a) Fixed guards may be an appropriate method of providing protection against mechanical hazards when
infrequent or no access is required to dangerous parts of a machine during its normal operation. Such as
pedestal fan covers, guards fixed on moving parts of equipment etc.

b) A fixed guard is a guard with no moving parts affixed in such a manner (eg by screw, nuts, welding) that it
can only be open or removed by the use of tools or destruction of the affixing means. It provides
appropriate protection against mechanical hazards when infrequent or no access is required to dangerous
parts of a machine during its normal operation.

c) With respect to the design features, the 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
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 the carrying out of maintenance operations with the guard removed, and -
The provision of information and training for both operators and maintenance staff.
 Design

Material of construction Use

Fixed guard
Defined in BSENISO12100 as a
guard fixed in such a manner
(e.g.. by screws, nuts, welding)
that can only be removed or
opened by the use of tools or
destruction of the affixing
means. It provides protection
against mechanical hazards
when infrequent or no access is
required during normal
operation of the machine. Acts
as a fence between people and
dangerous machinery parts
sufficiently robust to
withstand workplace Monitoring and supervision
rigours and contain any to ensure guards are not
ejected materials removed/tampered with
Should allow sight of SSOW fir carrying out
process if required
maintenance operations
Method of fixing should with guards removed
require special tool to
Guard check procedure to
removed e.g.. torque bolts
ensure guard is kept in
Ensure that any necessary maintained condition
openings provide enough
distance from hazards to Provision of information
prevent harm and training for operators
and maintenance staff
Guards reverberation detailing the hazards
exacerbating noise associated with guard
problems
defeats and other SSOW

Fixed guards factors to

consider in design and
use to ensure people are
adequately protected
27 Outline the practical control measures that can be taken to minimize risk when operating a bench-mounted circular
saw. (10)
SUGGESTED ANSWER
The practical measures that have to be taken to minimize risk in operating a bench mounted circular saw

1. The need for the correct operation and/ or and adjustment of the top guard should be perfect.
2. The effecting guarding of the blade beneath the bench.
3. The use of a push- stick to feed through the material being sawn.
4. Extending the machine table when person employed to remove the material when the machine in motion.
5. The correct positioning of the riving knife, the correct selection, maintenance and adjustment of the blade.
6. A suitable risk assessment on:
7. The training and competence of the operators should be complete.
8. The provision of adequate lighting and local exhaust ventilation system.
9. The use of personal protection equipment such as goggles, hearing protection.
10. The provision of sufficient space around the surfaces around the machine which should be kept free from
obstruction.
11. The provision of an emergency stop device means of isolation.
12. Ensuring the stability of the machine and introducing procedures to ensure the regular maintenance of the
machine and that guards were always in position.
 Sufficient space around
Safe operation and Effective guarding of
equipment kept clear of
adjustment of top guard blade under bench
obstructions

Use of push stick to

Use of appropriate PPE e.g.. feed materials
hearing protection/goggle, being cut
dust mask

Safe operation of Provision of emergency stops

Provision of LEV to
bench mounted and means of isolation
remove dust
circular saw

Adequate lighting and saw Ensure that the riving

suitably fixed to floor knife is correctly
positions through risk
assessment

Ensure that operators are suitable Regular maintenance

trained and experience to use the and safety inspection
saw, also ensure appropriate level e.g.. guard check
of supervision
28 (a) OUTLINE the features of industrial robots that may have particular implications for safety. (6)
(b) OUTLINE how the risk of injury to personnel working with, or in the vicinity of, industrial robots might be
minimised. (14)
OR
a) Outline the features of computer controlled
equipment (e.g. robots, computer Numerical controlled machines, and wireless operated lifting
equipment ) that may have particular implications on safety.
b) Describe how risk of injury to personnel working
with such equipment may be reduced.
OR
IDENTIFY the particular safety problems posed by industrial robots in a work place

SUGGESTED ANSWER
a. Features of Robot / CNC that have particular implications for safety are:
 Sudden, rapid or and forceful movements
 Unpredictable , and Wide sweep of robot arm
 Aberrant behavior such as the robot moving outside its normal range
 Dropping a load or ejecting a material
 Software problem which are difficult to detect
 Danger from the type of work being carried out such as spot welding, painting.
 Particular dangers arising during maintenance and teaching when close access may be needed and
unpredictable behavior may be caused by the release of stored energy
 The possibility of receiving foreign signals – can interfere with planned operations

b. Precautionary measures to reduce the risks: The risks of injury to personnel working with or in the
vicinity of industrial robot might be minimized by introduction of appropriate control measures:
 An initial risk assessment will identify hazard from the task performed (such as ejection,
trapping, hot work) - Identification of persons at risks (operators, maintenance staff,
cleaners)
 And the evaluation of risks in term of likelihood, frequency and severity
 RA would identify the appropriate control measures to eliminate or reduce the risks. This
might include:
 Restricting
 access by enclosing the robotic area with a high fence along with interlock access
 The provision of interlocked access using pressure mats or light curtains.
 Safe system of work such as Lock off or interlock systems for maintenance or any non-
routine work.
 Pressure release systems to relive stored energy by hydraulic oil to reservoir and
pneumatic air to atmosphere.
 The provision of mechanical restraints to prevent physical movement
 Temporary fencing between any robot being maintained and taught and the other working
robots
 Procedures for re-starting after interruption; Using an audible or visual pre-start up
warning signals
 Software checks : taking the robot to the cycle repeatedly to identify the faults
 Remote diagnostic facilities; Remote teaching with the use of pendants to avoid the need
for close access
 Emergency stop system.
 Elimination of stray radio frequency interference.
 Training for relevant personnel
 Introduction of monitoring system including audit and the keeping of records of
maintenance and defects.
 Positive stops Interlocked perimeter fencing
Groups at risk • Limits movement of robot • Positioned to prevent access to dangerous
• Operators • Defined limits to prevent trap parts
• Maintenance • Normally 2 meters high
points
engineers • Avoid creating additional trap • Rigid panels
• Teachers points Brakes • Securely fastened to floor
• Prevent danger of fall under • Infill suitable to protect from other hazards
gravity e.g.. ejected materials
Layout (Envelope) • Gates/access points to be interlocked
• Planning during design • Should be applied automatically
when machine stops • Hinged/sliding interlocks
• Minimise need to approach robot • Trapped key exchange
• Good viewing arrangements outside of • Solenoid lock
enclosure
• Adequate distance between robot &
enclosure
• Prevent trap points
• Adequate access to rescue injured Emergency Stops provided at
person • Control stations
• Access only through interlocked gates or • Teacher control pedestal
similar ROBOT SAFETY • All workstations
• Other positions as necessary

Behavioural - People
• Hazard aware
• Trained in procedures e.g..
entry, emergency
• Adequately supervised

Preventative maintenance and

Electro-sensitive safety systems inspections
Entry Procedures • Used in conjunction with fencing • Software checks to avoid aberrant
• SSOW defined/RA carried out • Photo cell device behaviours
• Analysis of hazards in all possible • Trip with use of light curtains arranged • Stop devices
modes of operation vertically/horizontally/diagonally • Guard checks
• Release of stored energy before • Pressure mats around machinery • Integrity of parts for wear damage
entry/work • Trip wires etc robot comes into contact e.g.. hydraulic rams
• PTW with a person should trip TEACHING
• ISOLATION required • All should require manual restart • Remotely where possible
• Slow mode when live
 NEBOSH DIPLOMA –UNIT IC – REVISION GUIDE

Element IC7 : Work equipment (mobile, lifting & access)

29 a) Outline a range of factors that may cause instability of a mobile crane. (8)
b) Outline control measures that should be taken to reduce the likelihood of a mobile crane overturning during
a lifting operation. (12)
SUGGESTED ANSWER
a) The Factors affecting crane stability can be related to its Load, lateral and longitudinal stability and
general stability: Incorrect initial selection of the crane.

 Load:
 The load may be too heavy ; Exceeding the safe working load; have an off set center of gravity .
 The load may not be adequately secured causing shock loading or become snagged.

 Lateral and longitudinal stability:

 Sloping ground, soft ground or voids or uneven ground; Unstable ground that is incapable of
bearing the weight of the crane and its load;
 Adverse weather conditions (Excessive wind etc); Slewing or hoisting too fast; Not fully
extended outriggers;
 Ignoring rated capacity indicator alarm

 General stability
 Travelling under load on gradients
 Extending the jib under loads; Travelling too fast under load
 Incorrect slinging Incorrect operation of the crane (for example in the non-use of
outriggers);Mechanical failure
 Obstructions being struck by the crane
 Incorrect tyre pressures; incorrect tyre types

b) The measures that should be taken to reduce the likelihood of the crane overturning during a lifting
operation can be divided into Engineering control, Procedural controls, Behavioral control.

 Procedural Control:
 A lifting plan or method statement should be prepared;

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 NEBOSH DIPLOMA –UNIT IC – REVISION GUIDE

 The selection of the crane with respect to its safe working load and reach
 Checking the existence of current test certificates for cranes and all lifting tackles;
 Ensuring the regular thorough inspection and maintenance of the crane and appointing a
competent person to supervise the lift;
 The lifting area should be cordoned off and should be segregated and warning signs should
be displayed.
 Engineering control: should include,
 Ensuring ground conditions are appropriate for positioning the crane
 The out rigger should be fully extended with spreader plate underneath
 Avoiding contact with overhead services and other buildings or structures;
 Using adequate lifting gear
 Speed limiters, over-hoist limit switch and rated capacity indicator and alarm system
 Visibility can be improved by use of mirrors or CCTV;
 Take account of weather conditions and an anemometer should be ensured to identify the
strong wind.
 Behavioral controls such as the competence and training of the driver, slinger , banksman and
supervisor.

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 NEBOSH DIPLOMA –UNIT IC – REVISION GUIDE

30 In order to inspect the insulation condition on pipework 4m above ground level it is proposed. In the absence of
availability of a mobile elevating work platform, to utilize a personnel cage lifted to the required height by a fork-lift
truck (FLT).
Outline the factors to be considered to ensure safety in the performance of this task. (10)

SUGGESTED ANSWER
The factors associated with the design of the equipment:

 The cage must be of adequate design and construction for the intended task
 The cage width should not exceed the width of the truck; The cage must be provided with handrails and
toe-guards.
 Its total weight including that of personnel and equipment to be carried should not be more than 50% of the
rated safe working load of the FLT; Allowable SWL should be clearly marked in the cage.
 Guards should be fitted to afford protection against moving parts on the mast of the truck
Measures while carrying out the tasks:
 The FLT should be positioned on the firm and leveled ground with the mast vertical and the parking
brake applied
 The cage must be securely fixed to the forks and
 The driver should remain at the controls of the truck at all the times and
 FLT should not move when the cage was elevated.
 Barriers should be positioned round the working area to protect against the possibilities of collision and
passers by being struck by falling materials
 Employees in the cage should wear safety harness.

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 NEBOSH DIPLOMA –UNIT IC – REVISION GUIDE
Design of basket
Trained and competent
operator in basket, aware
of hazards associated
with use
Anchorage point in
cage and harness
fitted and connected
to persons in basket
Cage securely fixed to
forks and truck not
moved during activity
 Constructed for task
intended
 Not exceed the width of FLT
 Toe boards/guard rails
installed
 SWL indicated on basket in
either weight or no. of people
possible to carry, not
exceeding 50% of FLT SWL FLT to be parked on firm,
 Guards fitted to protect level ground, brake
against moving parts of FLT applied, driver in truck
e.g.. chain
Factors to ensure
safe use of FLT man Competent FLT driver
basket
Basket maintained and
Barriers positioned around work area
inspected at least every 6
preventing collision from other
months
vehicles and protect others against
falling objects from
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 NEBOSH DIPLOMA –UNIT IC – REVISION GUIDE

Element IC 8 : Electrical safety

31 Outline the precaution that can be taken to minimize the risks associated with a cable strike when excavating near
underground electrical cables. (20
SUGGESTED ANSWER
The precautions taken to avoid risk associated taken to avoid risk associated with a cable strike when
excavating near underground.
 The excavation work has to be carried out with proper plan.
 Planning involves seeking advice from the relevant body such as appropriate electrical supply company or
lighting road authority.
 Assessing the electricity cable plan or understanding the symbols.
 The high and low voltage cable can be shown on separate plans.
 The supply should be made dead and investigating the possibility of diversion.
 Providing the use of mechanized excavation utilizing a permit to work system.
 Before the excavation starts it is necessary to locate the produce of cables by use of cable avoidance tools
(CATS) such as Hum or radio frequency.
 When cable which is recorded in a plan cannot be located, assistance and advice should be sought from
appropriate authority with extreme care.
 The excavation should be carried out with trained and competent person in safe digging practice.
 They should be experienced enough to detect cables which are not indicated in the plans.
 They should be aware although the cable is exposed there may be further cables at a lower level.
 When cables joints are discovered they should be supported not to be moved nor be treated roughly.
 The important precaution during the excavation work includes the need to lookout for permanent marker
posts or other visible indication of buried cables.
 To establish positive location by careful hand digging exposing the cables by digging from the side and using
hand held power tools.
 The use of mechanical excavations helps in avoiding damage to a reasonable way.
 The personnel should be kept well away from the excavation and drivers instructed to stay in the cab if the
cable is struck.
 When the cables are exposed the damage should be reported to cable owners, no work should be
undertaken.
 Support should be provided if more than on meter of cable is exposed and protection such as use of planks
or sand bags should be provided to prevent damage from ongoing work.
 Cables should not be moved aside unless the work is supervised by the cable owners.

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 NEBOSH DIPLOMA –UNIT IC – REVISION GUIDE

32 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)

SUGGESTED ANSWER
The control measures to prevent or limit serious injury or death due to electrical supply within work place are:
Technical control measures include:
 Isolation should be first choice, working dead and locking off all source of power
 All conductors and live parts ( such as cables, bus bars, connections) to be protected by insulation,
 Preventing contact with live part can be achieved by the use of barriers at usual direction of access or
 Full Enclosures to prevent contact from any directions
 Unintentional contact to be prevented by deputing skilled persons under continuous and direct
supervision.
 Usage of RCDs – residual current devices can limit the effect of direct contact with live part , reduce the
risk from electrical shocks
 Use of fuses or circuit breakers to protect against over current
 Restricted access control to switch rooms and switchgear cabinets.
 The provision of mats and use of appropriate tools.
 Correct identification and labeling of electrical systems, 'Live indicator' lights.
Procedural control measures included:
 Safe systems of work and Risk assessment ; Procedural measures such as Implementation of PTW,
LOTO
 Design of systems to include lock off and diversion; Appropriate training, competency and
authorization,
 Operating procedures such as live working only when justified / reasonable
 Periodic testing for earth continuity and impedance loop testing,
 Control of third parties and employees bringing in own electrical equipment;
 Planned preventative maintenance of electrical systems and equipment;
 Warning Signage and Personal protective equipment.

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33 A Worker has received an electric shock from a 240 volt portable drill whilst installing 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 incident.(5)
c) Identify the precautions that might have been taken to prevent the accident. (10)

SUGGESTED ANSWER
a) The Physical effects the worker would have suffered from the incident are
1. Fibrillation of the heart muscles with possible cardiac arrest/affecting its ability to pump blood.
2. Respiratory failure resulting in reduced supply of oxygen to the brain
3. Muscular contraction or spasm causing Involuntary grip that can prolong current flow making it worse .
4. Involuntary grip due to prolong current flow.
5. Burns to tissues and eventually cardiac arrest followed by Death.
6. The possibility of secondary injuries such as falling from ladder if this was being used
b) The emergency action that should be taken immediately after the accident.
1. The first step to not touch the causality directly but
2. Isolating the source of power or using non-conductive instruments to push the victim clear.
3. Wrap the victim in insulating material.
4. Checking for breathing and pulse
5. Administering mouth to mouth resuscitation if needed.
6. Placing the victim in the recovery position and contacting emergency services.
c) The precautions taken to prevent such an incident
Equipment Selection:-
 The use of battery-powered hand held tools; Reducing the Voltage to 110 V by using step down
transformer; Properly earth / Usage double-insulated tools; Conformity with standards.
Technical / Procedural Precautions:-
 The use of residual current devices (RCD) would have isolated the supply on contact with a live conductor.
 Equipment should be inspected and maintained to ensure that components (plugs, sockets, cables
etc) are free of damage, Using correctly rated cables and fuses,
 Pre use Inspection by the operator and testing of portable appliances and electrical systems,
 Housekeeping standards, and the provision of information, instruction and training - particularly in

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relation to systems of work and pre-use checks.

Cardiac arrest Respiratory failure Muscular contraction

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Burn Falling from ladder

34 Outline the precautions that should be taken when construction is to take place under or near overhead power line
that will remain live during the work. (10)

SUGGESTED ANSWER
The precautions that should be taken when construction work is operated near overhead power lines that remain
live during work, should be undertaken according to HSE guidance Note GS6.
The possibilities of re-routing the cables if practicable otherwise the local electricity supply company would need to
be approached for advice on the precautions to be taken. This will include :
Controlling the access:
 Advice on maximum working at heights and horizontal distances permitted near the overhead lines.
 The safe clearance distance should be ascertained from the Distribution Network Operator (DNO) or
local electricity supply company
 Establishment of physical limiting equipment fitted for the maximum height and vertical reach of
the plant.
 Subcontractors and those which could penetrate the safe distances would have to have physical
limiting equipment
fitted with.
 Safe routes where plant could travel and operate would have to be marked, barriers and solid goal
posts erected.
 These arrangements would need to be monitored on a regular basis to ensure they remained intact
and in place, and appropriate warning signs displayed.

Controlling the work

Where field work is taking place it may be impractical to erect barriers and goal posts around the overhead lines -
these are more appropriate for use at gateways.
The following precautions may also be needed to manage the risk:
 Clearance – the safe clearance required beneath the overhead lines should be found by contacting the
Distribution Network Operator (DNO);
 Exclusion – vehicles, plant, machinery, equipment, or materials that could reach beyond the safe
clearance distance should not be taken near the line;

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 Modifications / physical restraints – Vehicles such as cranes, excavators and tele-handlers should be
modified by the addition of suitable physical restraints so that they cannot reach beyond the safe
clearance distances, measures should be put in place to ensure these restraints are effective and
cannot be altered or tampered with;
 Maintenance – operators of high machinery should be instructed not carry out any work on top of the
machinery near overhead power lines;
 Non-conductive equipment, e.g. wooden ladders would have to be used.
 Training – workers and subcontractors should be briefed on hazards associated with the work and
the safe system of
work to be followed. Drivers of visiting vehicles should also be informed.
 Emergency procedure: procedures for dealing with an emergency would be necessary and
information on these
procedures would have to be passed on to workers.
 Supervision – access for plant and materials and the working of plant should be under the direct and
high level supervision of a suitable person appointed to ensure that safety precautions are observed.

Use of barriers,
marking tape and Identification of safe working
bunting distance i.e. 9 m if wooden or steel
Use of goal posts
poles 15m if pylons plus length of
and/or tunnels
Explore possibility of re- jib or boom if cranes/excavators
routing cables or are to be used
making dead
Safe systems of work to be
defined and implemented
Warning signs and
protection for public if Precautions to be taken
necessary when working near an
Supervision and hazard awareness
overhead electrical supply
training for workers e.g.. toolbox talk
on hazard associated with cable and
Consult with utilities what measure need to be taken to
supplier before Page 63 of 68
avoid
taking any protective
measures
 NEBOSH DIPLOMA –UNIT IC – REVISION GUIDE

Height
35 A worker suspended in a full protection harness is at risk of suffering from suspension trauma with the potential for
restrictions on
serious injury or death.
plant
Outline the precautions an employer could take to reduce the risks to the worker in this situation. (10)

SUGGESTED ANSWER
The precaution that an employer should implement in a fall protection harness are:
Initial selections of the harness,
 Particularly its shock absorbency and Manufacturing of harness must complying with
recognized standards
 Implementation of plans to prevent prolonged suspension in the fall protection harness
 If the prolonged suspension occurred then drawing up of procedures for carrying out rescue and providing
treatment as soon as possible
Suitable trainings for all employees who are in need of using fall protection and those involved in rescue;
 determining o the correct use and wearing of fall protections; suitable anchorage; free fall height
 How suspension trauma occurs ;
 The method of reducing risk while suspended
 The procedure that should be followed in a rescue operation
The procedures for rescue should contain
 Contingency based actions - The worker should be trained to pump their legs frequently
 The need for rescue workers to elevate the victim’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 sign and symptom of suspension trauma
 Ensuring the victim 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
 Monitoring the worker after rescue and ensuring evaluation by a healthcare professional.
It is essential that the signs and symptoms of suspension trauma are recognized , it includes:
 Light headedness; Palpitations; Poor concentration; Fatigue, Nausea; Dizziness; Headache
 Sweating, Weakness; Paleness; Breathlessness; Usually low heart rate and blood pressure.

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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. (10)
36 b) Identify the inspection requirements for the scaffold. (10)
SUGGESTED ANSWER
a) Below factors to be considered to confirm that the scaffold is safe to use
 The scaffold must be designed in accordance with recognized standard
 The scaffold should withstand the intended load such as Bricks, Construction materials,
tool and workers
 Must be erected by competent scaffold erectors
 The use of sound scaffold materials and fittings to be ensured
 The scaffold must be erected on firm and leveled ground avoiding all voids & drains.
 The scaffold must be provided with base plates and sole boards
 Scaffold structure to be “Square” and plumb, sprit level can be used for this purpose
 The platform must be fully boarded , secured without any gaps, overhang and wide enough for the
work to be done
 The scaffold must be tied with the building ensuring no vertical or horizontal spacing greaterthan 8.5m
 The platform should be provided with suitable guard rails – such top rails, mid rail, toe guard and brick
guard
 The use of diagonal and longitudinal bracings
 Safe means of access to each work platform ensuring the ladder extended at least one meter above
the platform
 Appropriate method of waste removal such as garbage chute to be ensured
 Suitable means for raising and lowering construction materials through hoist or closed container
 If the scaffold is erected in a position where there is likely to be movement of vehicle and collision is
certain then the protection must be provided to prevent damage from any such collision.
 It should also be provided with an exclusion zone at its base to prevent it from being struck by passing
traffic.
b) The inspection requirements for the scaffold
After any alteration ; after any damage ; after inclement weather condition
 Must be inspected by a competent person after erection.
 Then at intervals not exceeding 7 days.
 Records of inspection should be retained
 The scaffold should be tagged as “inspection completed”.

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Safe means of
Provide raising &
garbage chute lowering
Erected on a
level ground
Tied with
the building

Recognized standard

Provide base
plates, guard
rails, bracings
Withstand the
intended load

Safe means of
access & egress
Competent
erectors
Must be away Sound
from live road material

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 NEBOSH DIPLOMA –UNIT IC – REVISION GUIDE

A Scaffolder is lowering scaffold poles from the third floor of a scaffold assembly to a colleague below using a pulley
wheel and rope. The scaffolding assembly is adjacent to a shop front. The scaffolder on the ground floor is placing
37 the scaffold poles horizontally onto the back of a lorry packed on a busy road. The scaffolders have already received
adequate information, training and suitable supervision.
Outline additional practical measures that could minimise the risk of injury to the scaffolders and others that may
be affected by this activity. (10)

SUGGESTED ANSWER
Practical measures that could minimise the risk of injury to the scaffolders are:
 Investigate the possibility of using an alternative means of lifting such as a crane instead of scaffold.
 The pulley wheel and rope were ; -the required statutory inspections of such tools The SWL of pulley
was not exceeded;
 Correct slinging techniques and rigging on the scaffold poles and use guide ropes where necessary.
 Toe-board and handrails would need to be fitted on the upper platform to protect both the scaffolder on
that floor and public below.
 Suitable safety harness should also be worn by the workman on the upper floor as fall protection
 Attention should be given to nearby hazards such as obstruction and power lines
 Signs and barriers to be erected at ground level to prevent public access to the lowering areas.
 There could be a danger of passing traffic and the placing of cones would help to prevent a collision with
the lorry.
 Finally both workman should be provided with high visibility clothing, gloves and head protection.

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