Tips to help with this exam

• Read the question! pick out the key words

• Try to relate the question to a workplace
situation
• Break questions down e.g.. design, use,
maintenance where appropriate
• Remember HS principles e.g.. RA,
Controls, People
Regs 1 -3
1 Citation
2 Interpretation
3 persons with duties
Reg 16 Persons to be competent to
prevent danger and injury
•An understanding of the concepts of
electricity and the risks involved in work
associated with it
•Knowledge of electrical work and
qualification in electrical principles
•Experience
•Knowledge of systems of work & ability
to recognise risk & hazards
•Physical attributes to recognise
elements of the system e.g.. not colour
blind
Reg 15 Working space, access & lighting
Where there are dangerous live exposed
conductors space should be adequate to
•Allow persons to pull back from the
hazard
•Allow persons to pass each other
Lighting should be adequate preference e
to natural then artificial
Reg 14 Work on or near live conductors
•Competent staff
•Adequate information
•Suitable tools: insulated tools,
protective clothing
•Barriers or screens
•Instruments and test probe to identify
what is live and what is dead
•Accompaniment
•Designated test areas
•PTW
Reg 4 Systems, work activities & protective
equipment
•Systems must be maintained to prevent
danger
•All work activities must be carried out in a
manner not to give rise to danger
•Equipment provided to protect people
working on live equipment must be suitable
and maintained
Reg 5 Strength & capability of electrical
equipment
•Must be able to withstand effects of its
load
•Must be able to withstand effects of
transient or pulse currents
Electricity at work
regs 1989
Reg 13 Precautions for work on equipment
made dead
•Identify the circuit, don’t assume the
labelling is correct
•Disconnection & isolation e.g.. isolation
switches (lock off) removal of fuse/plug
•Notices, signage and barriers
•Prove system dead test the test device
•Earthing
•PTW
Reg 6 Adverse or hazardous
environments
•Must be suitable for the environment
and conditions that are reasonable
foreseeable
•Mechanical dame e.g.. vehicle, people
•Weather, temp, pressure, natural
hazards e.g.. bird droppings
•Wet, dusty, corrosive conditions,
presence of flammable dusts
•Flammable or explosive atmospheres
Reg 7 Insulation protection & placing of
conductors
•Prevent danger from direct contact
through insulation etc
Reg 8 Earthing or other suitable
precautions
•Purpose to prevent harm from indirect
contact e.g.. casings
Reg 9 Integrity of referenced conductors
•Ensure electrical continuity is never
broken
Reg 10 Connections – must have
adequate mechanical strength e.g..
plugs
Reg 11 means of protecting from excess
current e.g.. fuse, RCD
Reg 12 Means of isolation
Groups at risk
Layout (Envelope) Interlocked perimeter fencing
• Operators
• Planning during design • Positioned to prevent access to
• Maintenance dangerous parts
• Minimise need to approach robot
engineers
• Normally 2 meters high
• Good viewing arrangements
• Teachers
outside of enclosure • Rigid panels
• Adequate distance between robot • Securely fastened to floor
& enclosure
• Infill suitable to protect from other
Behavioural - People
• Prevent trap points hazards e.g.. ejected materials
•Hazard aware
• Adequate access to rescue injured • Gates/access points to be interlocked
•Trained in procedures e.g.. entry, person
• Hinged/sliding interlocks
emergency
• Access only through interlocked • Trapped key exchange
•Adequately supervised
gates or similar
• Solenoid lock

Preventative maintenance and

Electro-sensitive safety systems
inspections Robot Safety • Used in conjunction with fencing
•Software checks to avoid aberrant
behaviours • Photo cell device
•Stop devices • Trip with use of light curtains
arranged
•Guard checks
vertically/horizontally/diagonally
•Integrity of parts for wear damage
• Pressure mats around machinery
e.g.. hydraulic rams
• Trip wires etc robot comes into
TEACHING
contact with a person should trip
•Remotely where possible
• All should require manual restart
•Slow mode when live

Entry Procedures Positive stops

• SSOW defined/RA carried out • Limits movement of robot
• Analysis of hazards in all possible Emergency Stops provided at • Defined limits to prevent trap points
modes of operation
• Control stations • Avoid creating additional trap points
• Release of stored energy before
entry/work • Teacher control pedestal Brakes
• All workstations • Prevent danger of fall under gravity
• PTW
• Other positions as necessary • Should be applied automatically when
• ISOLATION required
machine stops
Reference – Supply of machinery
General Controls
regs 1992 schedule 3
• Principles of safety integrations • Safety & Reliability
Consider
• Materials & products used/created • Control devices
•Installation
• Lighting arrangements • Means of starting stopping device
•Use
• Handling & Installation of machine • Normal stopping
•Maintenance
• Emergency stopping
•Decommissioning
• Mode of operation selection
• Failure of power supply
• Software design
• Failure of control circuit

Indicators Protection against mechanical

hazards
• Information devices
Machinery ‘Essential health •Stability/anchorage – e.g.. floor
• Warning devices e.g..
alarms/lights and safety requirements’ fixings

• Warning of residual risks

that should be addressed •Risk of break up during operation
•Falling objects/ejected parts
• Markings
•Surface risk e.g.. sharp/hot/cold
• Instructions
•Variable speeds
•Moving parts
•Choice of protection arrangements

Protection against other hazards

Maintenance
• Electricity e.g.. insulation
• Machinery maintenance
• Other stored energy e.g.. Required Characteristics of guards
• Access to operating and servicing
hydraulic pressure
position • Fixed
• Errors of fitting
• Isolation of energy sources • Movable guards
• Fire/explosion
• Operator intervention • Adjustable guards
• Noise
• Cleaning of internal parts • Special requirements for
• Dust/gases e.g.. extraction protective devices
• Lubrication etc
• Vibration
• Radiation
Key Factors
• Crane
• Lift
• Forensic evidence
Crane
• Type –suitable for lift?
• SWL of crane
• Alarm system
working?
• SWL indicator/radius
indicator
• Exceeded?
• Operational criteria e.g..
adequate strength &
stability
• Design characteristics
• Counter balance
• Out riggers
• Configuration for task
e.g.. level ground,
positioning to load, Range of issues & evidence
distance required to
travel
• Maintenance &
certification records
• Lifting history
Lift
• Load
• Weight
• Gravity – lifting point?
• Slinging method –
appropriate for load?
• Type of lift
• Static
• Slewing
Forensic evidence
• Lift & Travel • Type of failure
• Drag • Buckling
• Site conditions e.g.. wet, windy, • Brittle
foggy, obstructions/excavations
• Ductile
• Lifting plan, witness statements
visual inspections • Integrity of Jib look for
evidence of alterations,
• Training records repair, corrosion, missing
• Crane driver, slingers, rigger, bolts
banksman • Settings & functionality
of controls, switches &
alarms
to examine during
investigation of lift op
failure (crane)
 Key Factors Live Loads
• Dead load • People
• Live load • Furniture
• Dynamic load Dynamic loads
• Equipment
• Solar radiation Dead loads & Live loads change
Dead loads Constantly moving and changing
• Vibration/sudden shocks every day slowly and are called static loads
• Material which buildings is
• Weather constructed from e.g.. columns, Other loads can change suddenly
• Atmospheric contaminants beams, floors such as wind gust, these loads are
dynamic
• Timber decay
• Corrosion
• Subsidence Solar Radiation
• Absorbed when it strikes a
material
Subsidence • Materials expand when warm
• Signs of defects include • Contract when cooling
• Semi random cracks in walls Factors Effecting • Solar radiation causes surfaces to
• Sagging in arches/beams
Structural Safety heat up quickly

• Fractures of pipe joints • Rain falling onto hot surfaces can

causes severe shock and result in
• Builds over mine tunnels or large tension cracking e.g.. roof
holes can cause serious membrane
deformation

Vibration & Sudden Shocks

Corrosion
• Metal combines with oxygen in the
air to form rust
Timber Decay
• Deterioration of timbers can
severely cases lead to building
collapse
• Due to wet rot/dry rot/fungal
attack & insect attack
Atmospheric contaminants
• Combine with moisture to form
acid rains which attack materials
• Sulphur dioxide
• Carbon dioxide
• Oxygen
• Ozone
• Traffic/machinery
Rain/snow/hail
• Can effect foundations of
• Moisture greatest cause of buildings
deterioration
• Buildings can be struck by
• Rising damp causes flaking and vehicles/plant
cracking
• Frozen water causes stresses &
cracks
Wind
• Moisture promotes rust in metals
• Physical damage
• Moisture creates environment for • Dampness by driving rain
fungal growth moisture into buildings
• Build of snow/ice on roofs • Can lift roof covering
increases structural loading
 Effects Fire on
materials

Steel Concrete Wood

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

failure of materials

Steel
Concrete Wood
•Concrete cladding
•Selection of type and mix to • Selection of thick timbers
•Compartmentalise to reduce improve fire resistance
• Selection of timber e.g.. hardwood
conduction
•Increase thickness of concrete burns slower than soft wood
•Automatic cooling with from exposed surface to steel
• Treat with fire retardant substance
sprinkler system etc. 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
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
atmosphere from previous contents
• Robotic inspection
• Access/egress
• Contaminated air from previous
contents
• Build up of heat
• Duration of activity
• Lack of oxygen
• Working at height within CFP
• Ingress of solids/liquids
Confined space
• Impact of other plant
entry • 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
Last paper
• Appropriate PPE e.g.. anti static clothing, BA, gloves
 Controlling pump rate
Complete containment
• Speed slow – not to
of flammable liquid,
propagate static build
not leaks, seals joints
up
etc
Avoid splash/spray
filling

Worker involved Earthing of all

trained and competent Key factors to protect conductive surfaces
in operation e.g.. aware against ignition from e.g.. tankers, pipe
of hazards and static of a flammable work, containers e.g..
precautions necessary vapour during transfer IBCs
of containment of
liquids Keep at zero potential,
Earthing should be
interlocked to pump
Over fill protection system
system e.g.. high level Provision of anti static
indicator, interlocked clothing including
shut down footwear

Use of inert gas

blanketing above the Implementation of a
liquid vapour return system

Last paper
Key points Controlled waste
• Controlled waste • Household
• Duty of care ‘categories • Commercial
of persons’ • Industrial
• Duty of care Exceptions
• Agricultural
• Mines/Quarries
• Radioactive waste

Duty of care Categories of persons

Persons who
• Produces CW
• Imports CW
EPA section 34 • Carries CW
Concepts of duty of • Stores CW
care • Treats CW
• Disposes of CW

Exceptions of house holders

Duty of care
Reasonable steps to prevent;-
•Deposits of CW without waste management license
•Treatment, storage, disposal in manner likely to cause
pollution
•Treatment, storage disposal with out waste handling
license
•Prevent escape
•Transfer to unlicensed holding
 Automatic Fire Detection
Heat Detectors Smoke Detectors
• Fixed temperature type • Ionisation type
– Thermocouple detects when a set –Small radioactive source to ionise a
temperature is reach chamber into which smoke enters
• Rate of rise type during a fire. Detector reacts to
change in current caused by
– Detects abnormal temp rises neutralisation of ions by smoke
(sudden) particles
– Electronic resistors • Optical type
– Usually incorporate fixed temp –Responds to the obstruction of a
element as well focused light ray or the scattering of
Unsuitable for light from an optical ray by smoke
• Rapid heat rise workplace e.g.. Unsuitable for
laundrettes, steel manufactures • Dusty workplace due to false alarms
e.g.. flour mills
• Workplace which generate smoke e.g..
kitchen, welding workshops

Heat (fixed or rate of rise) where there are fumes, steam or other particles may be present that would be
detectable by a smoke detector and cause false alarms.
Smoke (optical or ionization) everywhere else within reason Last paper
 Raising the alarm
Publishing and training of
• Consider any disabilities and Numbers of people to evacuate
procedure
make provision for e.g.. visual & physical ability
• Regular drills alarm for deaf people
•Escape routes
• Documented • Contacting the emergency
service e.g.. interlocked alarm •Distance of travel required
• Fire log book
system or manual call •Alternatives routes

Accounting for people

Emergency light and signs

Liaison with emergency services • Exits

• Numbers of people involved • Escape routes

• Specific hazards in building

Issues to address
when planning a
fire evacuation Refuges and safe havens
(muster points)

Prevention of re-entry

Training of fire wardens

• Zoning
Equipment and security • Areas of responsibility
Roles and responsibilities
• Equipment may need shutting
down safely • Managers
• Security could be an issue • Staff
after evacuation
Key principles
• Dust control
• Ignition source control
• Mitigation of explosion effects
• DSEAR regs Ignition control
• Zoning
• No smoking policy Mitigating effects of explosion
• No mobile phones • Equipment able to withstand
Dust control
• Provision and use of anti explosion
• Damping down
static clothing and footwear • Venting and explosion panels
• Extraction of dust at point of
• Earth bonding of equipment • Bursting disc on vessels
transfer (LEV)
• Assessment in compliance • Suppression – inerting
• Interlock device to prevent
with DSEAR regs
overfilling of vessels • Compartmentalisation –
• Appropriate zone minimise effected
• High standard of house keeping
identification of areas i.e..
• Ensuring that systems are sealed 20, 21 or 22
where possible
• Use of spark protected
equipment – intrinsically
safe to appropriate zone
• Abnormal activities
generating sparks under hot
work PTE

Reducing risk of dust cloud

explosion and mitigating
explosion effects
 Segregate pedestrians
from vehicles with the use
Consider automated
of fixed barriers Separate access & egress
system (robotic to almost
eliminate pedestrians points for vehicles/pedestrians
requiring access

Where possible re-route

pedestrians away from Create safe passing places
vehicle movement area
e.g.. elevated corridors

Design features to Introduce safe crossing

Ensure lighting is reduce risk of points e.g.. zebra crossing
adequate and suitable for vehicle/pedestrian
tasks carried out
collision

Avoid creation of blind

bends if unavoidable
Allow sufficient space for install wall mounts mirror
vehicles to operate (convex) to improve
visibility

Where possible design

routes such to Direction of vehicle
eliminate/reduce the need movement control e.g..
for reversing force one way traffic
 Mechanical hazards
• Vehicle impact
• Plant equipment nearby
• Abrasion from operate
equipment
Weather conditions
• Rain – moisture entering
• Freezing leading to crack
High/Low temperatures through expansion
• Heat
Aspects of a working
environment which • Humidity
increase electrical risk

Corrosive atmospheres
Flammable/explosive leading to corrosion of
atmosphere parts

Intrinsically safe Flame proof

• Restriction of electrical energy in
equipment, insufficient to create
heat/sparks
• Faults may increase energy levels
above safe limit
• Heavy duty of substantial build and enclosed. When
flammable atmosphere enters the equipment can
withstand and enclose an explosion and prevent the
ignition of any flammable atmospheres surrounding
equipment
• May not be suitable for use in areas with combustible
powders of dust. May require special measure to
prevent ingress of water
 Inform of any
significant/unusual
residual risks
Provide info with the
design to assist clients,
contractors, designers
e.g.. notes for drawings,
rational behind design
decisions
Take into account
Workplace (HS&W) regs
when designing workplace
structures
Conduct risk analysis of
major design e.g..
HAZOP/FMEA
Duties apply at all times
e.g.. appointing of CDM
co-ordinator if notifiable
Ensure that client is aware
of their duties
Ensure that they
(designers) are competent
Duties of for the work they do
designers under
CDM2007
Co-operate with others as
is necessary to manage
risks e.g.. contractors
Avoid foreseeable risks
(construction and use)
Co-operate with CDM co-ordinator &
SFAIRP during design by
other
•Eliminating hazards
where poss.
•Reduce remaining risk Provide information for h &
S file
•Give collective risk
reduction measures
priority over individual
measures

Regular maintenance and
safety inspection e.g..
guard check
Safe operation and
adjustment of top guard
Effective guarding of blade
under bench

Adequate lighting and saw

suitably fixed to floor
Use of push stick to feed
materials being cut
Safe operation of bench
mounted circular saw
Provision of emergency
stops and means of Ensure that the riving knife
isolation is correctly positions
through risk assessment

Sufficient space around

equipment kept clear of Ensure that operators are
obstructions suitable trained and
experience to use the saw,
also ensure appropriate
Use of appropriate PPE level of supervision
e.g.. hearing Provision of LEV to
protection/goggle, dust remove dust
mask
 Corrosive Failure
• Chemical/electro-chemical attack
by atmosphere
• Only affects metals
• Materials lose strength can thin
• Occurs when oxygen levels of
carbon dioxide levels are high &
when PH levels are low or high
Hydrogen attack
• Hydrogen seeps into gaps in
molecular frame work
• Causes stresses within framework
• Examples are cathode reaction,
electroplating
Creep
• Under constant load
• Deforms over time (plastic)
• Temperature is important,
materials determine working
temperatures that can be used
Brittle fracture
• Fracture without deformation
• Brittle materials are strong but not
resistant to cracks
• Impact loading causes e.g.. rapid
temp changes, pressure
differences
• High tensile & residual stresses
promote
Excessive Stress
• Ductility – amount of stretch
before a material ruptures
• Usually result of single stress
over load
• Materials can balloon due to
excessive pressure
Pressure systems
causes of failure
Thermal fatigue & Shock
• Shock is sudden change in temp
of water
• Causes rapid
expansion/contraction of system
components
• Leads to fatigue and material
stress ultimately failure of system
e.g.. leaking pipes, fracture of
vessels
Abnormal external loading
• Struck by something e.g.. vehicle
• FLT/Fuel tankers
• Explosion
Over pressure
• Catastrophic results e.g.. vessel
rupture
• Failure of relief valves can cause
• Normally systems tested to 3
times normal operating pressure
Overheating
• Can occur if alarms/controls fail
• Causes rise in pressure
Mechanical fatigue & Shock
• Pressure causes tensile stress in
all directions
• If stresses are greater than
material can cope with it will lead
to ductile or brittle failure
• Fatigue stress is usually
progressive
• Fatigue failure often triggered by
surface interruption e.g.. grinding
marks, weld defects, notches etc
• Pressure focuses at root of defect
Key points
Design
• Design
• Take account of current safe
• Operation practise
• Inspection/Maintenance • Fit for purpose/CE marked
• Material constructed from suitable
for materials in process
• Expected life
• Maintenance/testing accesses
• Operating pressures and
provision of safety devices e.g..
Operation
• Safety valve (PRV)
• Use within performance envelope
• Gauges
• Operators trained and experience
• Level Controls to identify errors and prevent
• Blow down valves faults through error arising

• Pressure gauges • Aware of safe operating limits

• Scheme of examination
• Equipment marked with operating
pressures/temperatures max/min
• Quality control
• Filtering/treating of water (boilers)

Technical & procedural Inspection

• Written scheme of examination –
measures to minimise statutory

likelihood of pressure • Pressure vessels

• Pipe work and valves
system failure • Protective devices
• Pumps and compressors
• Prepared by competent person
• NDT/examination
Properties of LPG
• Flammable at standard temp &
pressure
• Denser than air
• Liquid form floats on water
• LEL is reached in small
concentrations
• Can cause suffocation in high
concentrations
Any store room must be non-
combustible or fire resistant and
ventilated with and explosimeter
installed
If more than 400Kg stored must
have 2m high mesh fence and
cylinders at least 1.5m away from
fence with 2 exits
Storage compound designed to
prevent vehicle impact
Control of ignition sources
• No smoking
• Storage of cylinders away from Concrete level floor, surrounding
area kept free of vegetation (not
potential ignition sources e.g..
fabrication shop with use of oxidising week killer
e.g.. sodium chlorate
• Control of mobile phones
• Storage area regarded as zone 2
so only zone 2 IS rated electrical
equipment to be used
Stored away from excavations,
• Signage stating highly flammable
drains, pond, rivers, cellars at least
• Dry powder fire extinguisher 3m
located close to storage area
Protected from elements were
LPG in cylinders possible
precautions
(storage) Empty cylinders stored separately
from full cylinders, caps fitted to
valves. Well ventilated
Stored away from any oxygen
cylinders. oxidising substances
Cylinders stored in upright position
 Causes of instability Lateral
Key points (side instability)
• Instability • Insecure load
• Training • Drive laterally on slope
• Refresher training Refresher training (angle of slope, elevation of
circumstances appropriate load
• Operator not used truck for • Hitting obstruction e.g..
some time curb
• Been involved in • Uneven ground
accident/near miss • Cornering (fast, sharp)
• Developed unsafe practices • Poor tyre condition/uneven
• Change in working practice pressures
• Best practice every 3 years
or as per company policy Causes on instability
Longitudinally (Front to
back instability)
FLT safety • Overloaded vehicle
Training • Incorrect positioning of load
• Basic training (CITB/RTITB) on forks
• Operating truck • Load slipping forward
(inappropriate tilt of mast
• Maintenance & checks
• Driving with load elevated
• Specific job training
• Changing tilt
• Specific truck type operation
• Driving forwards down
• Use of truck in various conditions slops
• Work to be undertaken & SSOW • Driving backwards up
• Familiarisation training under slopes
supervision • Sudden braking
• Site layout • Striking overhead
• Types of storage/load e.g.. racking obstruction
• Local emergency procedures
 Key points
• Fuses
• Miniature circuit breakers
• Residual current devices
• Reduced low voltage systems
• Precautions to be taken
Precaution to be taken when maintaining
or repairing electrical systems
•Identify equipment to be worked on
•Obtain system drawings & information
•Consider whether work can be done
dead SSOW for dead:
• Isolation/lock off
• PTW
• Proved dead
• Test test equipment
•If work required is live SSOW:
• Screening of conductors near
work
• Testing live conductors through
holes with probes
• Use of suitable test equipment
• Have testing arrangements in
place for testing equipment
• Consideration of accompaniment
• Consideration of insulated tools
• Adequate space
• Adequate lighting
Fuse
• Protects systems not people normally Miniature circuit breaker
• Prevents overloads of electrical system • Close tolerances for design
and overheating of electrical wiring current flow and speed of
operation
• Limits shock under severe fault
condition • Provide visual detection following
operation (e.g.. switch to off
• Limits over currents
position
• Does this by the heating effect of electric
• Need to be reset after fault
current which melts the metal link if
detection
current exceeds the design value
• Are reliable
• Remains broken until replace
• Design to protect system
Methods and devices
designed to improve
electrical safety +
precautions to be taken
when maintaining or
repairing systems
Residual current devices or earth leakage
circuit breakers
•Shock limiting device not system
protection
•Shock is still received but time reduced
Reduced voltage system e.g.. 110V •Monitors balance of current in line and
• Transformer neutral
• Supply centre tap to earth consist of •Operates on earth leakage fault
• Earthed systems •Live and neutral disconnect from local
power supply
• Class 1 equipment
• Double insulated class 2 equipment
• Required procedural measures to be followed
Design Operation Maintenance
• Material to be used for vessels and • SSOW • Arrangements for examination and
pipework inspections
• Operation of equipment
• Suitable to withstand corrosive • PTW system
• Emergency procedures e.g..
nature of substances • Isolation procedures
spill response
• Layout of facility • Cleaning prior to work e.g.. purge
• Training
• Segregation between acid/alkalis • Regular cleaning of bunds
• Tanker drivers
e.g.. compartmentalisation
• Operators • Provision of training to maintenance
• Design and position of inlets staff both maintenance and
• Provision of PPE e.g.. chemically emergency
• Prevent cross connection
resistant suits, gloves, full face visor

• Bunding of tanks
• Separate bunds
• Capacity 110% of largest container
min
• Bunded sealed with appropriate
material (with stand corrosive)
• Safety devices
• High level indicators
• Isolations
• PLC control
• Interlocked system
• Adequate lighting
• Adequate access and egress
• Arrangements for spill containment
• Labelling of system e.g.. flow direction of
pipes
• Emergency arrangements e.g.. drench
water safety shower

Safety provisions required for

receiving and storing acids and
alkalis

Chemical changes involve heat
• Exothermic - Evolutes
• Endothermic - Absorbs
Temperature Increase speeds up
reaction – Le Chateliers principle
If the heat released from reaction is
not controlled/removed reaction will
speed up exponentially

Can result in
• auto ignition explosion
• Catastrophic over pressure
resulting in loss of containment
e.g.. vessel rupture and toxic
release
Operational features to prevent
• Violent boiling
• High calibre of operator
• Secondary competing reaction
experienced and appropriate level
of qualification to operate process
Runaway
• Ensure that maintenance reactions
activities/raw material handling
don’t introduce potential catalysis Causes
into reaction
• Failure of temp control (reaction
Design features to prevent cooling)
• Conduct HAZOP study • Strong exothermic reaction
• Appropriate temperature control system • Presence of containment catalysis
e.g.. matrix cooler (speeds up reaction)
• High integrity temperature detection
linked to cooling/reaction addition
protection
• Pressure rise detection linked to
cooling/venting/auto shut down
• Vessel protected by correctly sized
bursting disc linked to safe haven e.g..
secondary vessel to dump reaction to
• PRV’s, weighted lids to realise pressure
• Agitation of liquids to promote even
temp distribution
 Cylinder/container containing
flammable gas under pressure e.g..
butane pressure turns gas into
liquid state

Valve opened reduces pressure

turning liquid into gaseous state

Examples of incidents
San Carlos
Cylinder exposed to heat source
• Crashed over loaded road tanker e.g.. caught in a fire liquids absorbs
• Explosion heat

• 216 Dead
Mexico city

BLEVE Liquids starts to vapour and is

vented off

Sudden release of contents

resulting in
•Blast wave (low) Liquid level falls heat continues

•Radiation (thermal) high

•Missiles travelling long distances
Substantial thermal heat sever
burns e.g.. LPG cylinder BLEVE has Area of cylinder just above liquid
serve burn range of 35m level starts to weaken/thin with heat
Area unable to hold internal over
pressure and ruptures
 Identify recycling opportunities at
all stages of process

Substitute process materials for

ones that give rise to non
hazardous waste
Explore becoming licensed to save
cost e.g.. EA permit

Improve production efficiency to

produce less waste
Reducing cost and
Explore other disposal means
environmental
(incineration, liquefied waste to impact of hazardous
sewer)
waste (sludge) Treat waste on-site to reduce
quantity (De-watering)

Exchange waste streams to other

companies which could use waste
as raw material e.g.. waste solvents Treat waste to reduce hazardous
to paint producers properties e.g.. ph balancing

Selection of waste contractors that

can process the waste

Last paper
Purpose
Check for faults (e.g.. cracks) in
components before they develop Dye testing
Impact (tap testing)
into total failure without affecting • Put dye on
integrity of the component • Strike surface
• Dye penetrates making cracks visible
• Changes in pitch of reverberant
• Cheap & simple (pro) sound
Other techniques
• Doesn’t detect sub surface faults • Cheap (pro)
• Pneumatic testing (con)
• No indication of where fault is
• Hydro testing • Not totally reliable (con) located (con)
• Can be enhanced by using • Relies on individual skill (con)
fluorescent penetrate and UV source
Ultrasonic Technique
• Penetrate may be toxic (con)
• Short pulses of high frequency
• Need good eyesight
ultrasound are used
Magnetic particle
• Reflected waves detected and shown
on digital display or oscilloscope • Coat surface with magnetic power
or liquid
• Surface and sub-surface defects
• Simple & Quick
• Only requires one side of joint
• Very sensitive to surface cracks
• Quick to perform NDT
• Interpretation of results can be
• Suitable for most environments difficult particularly on inside of
• High level of expertise required vessel

• Coupling equipment onto rough

surfaces can be difficult

Eddy current testing

Radiography
• X-rays/Gamma rays penetrate item and
leave an image on film
• Defects are shown up by differences in the
intensity of the radiation striking the film
• Detects internal defects and a permanent
record is created
• Expensive
• Bulky equipment
• Present radiation hazard and tight controls
are required
• Skilled radiographers are needed
• Surface and near surface crack detection
• Electromagnetic method/instrumentation
• Can be used to verify materials heat treat
condition
• Can be automated (pro)
• Can suffer from spurious defect
indications
• Doesn’t work on non-conductive materials
• Relatively expensive and requires skilled
operator
 Consideration of flammable
atmospheres etc EX rating

Maintenance, cleaning and Availability of natural light

testing considerations

Psychological effects
Compliant with workplace (health,
safety & welfare) regs
Illumination ratio

Level of luminance

H & S Issues to identify Requirements for pedestrians/vehicles

Emergency lighting during a lighting audit
of a factory
Close working tasks
Lighting fort non-daytime
external areas

Equipment lighting to comply

Task specific lighting
with PUWER requirements

Avoidance of stroboscopic effects DSE work station lighting

with regard to rotating machinery

Avoidance of glare
 Access & Egress
Emergency arrangements
• Maintenance workers
• Alarm
• Pedestrians
• Muster points
• Building workers
• Escape routes
• Vehicles

Traffic management
Public safety
• Deliveries
• Falling objects
• Plant
• Screening
• MEWPS etc
• Segregations/barriers
• Security
Safety aspects to consider
• Fencing
before starting external
• Dust damping
Storage of materials maintenance/construction
works on build with public • Noise levels
• Hazardous
• Flammable facing front (footpath) work
• Housekeeping includes roof Building workers safety
• Lay down areas • Safe systems of work
• Provision of PPE
• Fall protection
• Scaffolding
• Edge protection
Welfare facilities Plant and equipment requirements • Signage
• Washing • Suitability • Hazardous materials present e.g.
asbestos
• Toilets • Availability
• Rest/eating etc
Benefits of regular drills
• Compliance with legal Fire Alarm Design/maintenance
requirements FFRO
• Quiet
• Efficient evacuation in future
• Does not extend into all parts
• Highlights deficiencies in alarm,
procedure and evacuation of building

• Allow practise of scenarios such • Poorly maintained sounders

as abnormal normal route use etc
• Faults within infrastructure
• Refresh staff training and leading to partial failure in
awareness of procedure some areas

Deficiencies in procedure
• Difficult to understand
• Poorly communicated
• Not exercised
Factors that could • Poorly planned escape routes
contribute to a delay • Untrained staff
in evacuation +
benefits of regular
drills

Execution of procedure
Human factors
• Delayed response to alarm
• Hearing disabilities
• Staff not reacting quickly
• Belief that false alarm
• Finishing of phone calls
• Belief that above evacuating • Switching off equipment
• Waiting for direct notification • Fire Marshalls not following
e.g.. phone call procedure
• Routine violations • Blocked escape routes
• Staff not trained
• Poor response perhaps many
false alarms have occurred in past
 Introduction of Automated Guided Vehicle to
Warehouse
Risks Reduced
• Manual handling
• Pedestrian/vehicle collision
• Racking Collisions
• Falling objects less likely to
contact person
• WAH access to racking
• Reduction of noise
• FLT collisions
• Incorrect order picking
Risks Increased
• Programming dangers (teachers)
• Interference in signal
• Proximity sensors to prevent
pedestrian contact
• AGV collision
• Guarding of order picking
machinery
• Dropped loads to be dealt with in
automated area
• Maintenance activities for
equipment
• Software failure
 Planning & Organising
• Consider work to be carried out
and devise RA & MS
• Nominate supervisor for task
• All workers briefed on general &
specific risks
• Suitable equipment for task e.g..
PPE, tools, access etc

Preparation of Silo
Working area • Emptied
• Excluding non essential personnel • Locked off to prevent filling
• Erecting barriers Precautions to be movement of parts
• Residue removed before hot
• Sighting of warning signs taken before & works

during repair work • Damped down

• Signage erected of work in
of a 15m high progress etc

grain silo on farm

(with welding
required)

Working at height
Confined space entry
• Use of platforms
• PTW control
• Handrails
• Ventilation
• Toe boards
• Trained staff
• Harnesses if required
• Emergency rescue plan defined
• Protection of fragile sections of and trained
silo top
• Ensure suitable access and
egress
• Oxygen monitoring
 MEWPS
Hazards
• Falls from height of
persons/materials
• Instability of vehicle e.g.. uneven
ground
• Being struck by other vehicles
• Trapping & impact hazards
• Mechanical failure
• Contact with over head power lines
• Exposure of workers to adverse
weather conditions
Requirements for safe use
• Selection of trained competent operators
• Persons may be connected to MEWP
with fall restraint
• Toe boards installed/use of tool wrist
straps
• Barriers installed to protect area MEWP
used in
• Correct positioning e.g.. level firm
ground, not close to over head services,
use of outriggers where installed
• Prevent of use in adverse weather
conditions
• Not exceeding SWL
• Regular inspections & maintenance
• Ensure trap points are guarded
• Ensure used in locked position
• Prohibit transfer of people/materials
whilst in raised position
 Satisfy Essential health and safety
To supply machine requirements and be safe
•Safe and reliable control devices
under SMSR1992 including normal operation and
process emergency controls
•Stable
•Protection against mechanical
hazards e.g.. moving parts guarded
•Protection from other hazards e.g..
vibration, electricity & noise
Satisfy requirements of
•Maintenance activities
EHSR
•Adequate indicators e.g.. alarms
and warning light etc

Responsible person to Preparation of technical file

prepare technical file •Detailed drawings
•Calculations, test reports
•Description of methods used to eliminate
Responsible person to hazards

ensure machine meets •Machinery RA

requirements of other •Instruction draw up in accordance with

provision of information
EC directives

Issue a Declaration of
conformance

Fix the CE mark in a

visible, legible and
obvious manner
Last paper
 Determine appropriate
frequency of inspection for each
item based on factors affecting
level of risk e.g..
•Type of appliance
•Protective systems used
•Use
•Frequency of movements Criteria for each type of
Inventory of all equipment •Earth boning
examination defined including
requiring examination and issues such as
•Age
test to be made and unique •Competence of the tester
means of identification •Environment which appliance
•Calibration and maintenance of
e.g.. number system used in
test equipment
•Experience and competence of
•Format of records to be kept
user
•Results of tests and
•Historical information and
examinations
manufacturers
recommendations •Systems to identify and remove
from use equipment that is
found to be faulty

Factors to consider
when devising
Electricity at work regs and HSE
scheme for PAT published guidance

testing
Sources of Ignition from diesel powered vehicles and possible protection
to minimise risk of explosion in flammable atmosphere
Sources
• Flames/sparks from
exhaust/inlet systems
• Sparks from vehicle electrical
system
• Static build up from over
speeding/loading the engine
• Hot parts e.g.. exhaust
Protection
• Fit spark/flame arrestors preventing
flashback to atmosphere if drawn
into inlet system plus prevent any
sparks from escaping system
• Engine and exhaust system design
to ensure surface temps are below
ignition temp of atmosphere
• Use of water jacket around hot
parts
• Electrical equipment on vehicle
suitable for zones 1 or 2 where
possible
• Speed limiters to prevent speed at
which static could build up
• Use of electrically conductive
materials for parts e.g.. tyres to
reduce static build up.
 Bunding to contain spills

Security features such as locks,

alarms, and signage
Facility to collect & dispose of
spillages e.g.. spill kit

Emergency lighting/appropriate EX
rated electrical equipment e.g.. zone
2 rated lights
Building constructed of fire
Key safety resistant materials

Sprinkler systems/fire extinguishers

features of
building used to
store highly Roof lightweight and/or blast panels
Adequate access and egress e.g.. 2
points of entry/exit including ramp
flammables
to facilitate drum handling

Mean of segregation of materials

e.g.. low walls/dividers, cabinets
High and low level ventilation

Adequate distance from other

Impermeable floor
buildings
 Capacity of water required and
adequacy of existing supply

Design of pump system e.g..

diesel back up if electrical pump
Provision required for testing installed
and maintenance

Means of activating system

Provision of water run off (fragile bulbs or detector
activated

Design factors to
Provision of fire stopping water consider when
curtains to prevent fire spread, Linkage of system to alarms
compartmentalisation providing a
sprinkler system
Spray pattern required
Height of any storage racking
and distance from sprinkler
heads, possible protection from
vehicle movements e.g.. FLT
tines
Area to be covered
Presence of substances which
react violently with water
Possible mechanisms of structural failure of
building during storm
• Adverse weather conditions • Vibration caused by traffic etc
exceeding designed wind loading leading to structural fatigue
capacity of structure • Inadequate design and/or
• Excess weight on roof caused by construction of structure
rain water or snow
• Weakening of steel structure by
corrosion through roof leaks
• Inoperation of rainwater drains
• Alterations to structural members
which have invalidated original
design calculations
• Subsidence or nearby
tunnels/excavation leading to
foundation instability
 Notification of HSE under
CDM 2007 regs
Identification of competent
demolition contractors
Site traffic management if
required
If building partially
collapsed already devise
PPE required for workers method for demolishing to
e.g.. hard hats, ear avoid premature collapse
protections safety boots, of the remainder
protective clothing, eye Protection of nearby
protection etc buildings/business/propert
ies
Welfare facilities provision H & S issues to be
e.g.. toilets, wash and rest considered when planning
facility plus maybe lay demolition of building Protection of public e.g..
down area for barriers, signs, security
contaminated clothing

Control of noise Precautions to prevent

people or objects falling
e.g.. scaffolds, edge
protection
Identification of hazardous
materials, control of dust
Identification of buried
and safe removal of waste
and/or overhead services
from site – use of licensed
Selection of and e.g.. power cables, gas
carrier etc
Inspection, maintenance of pipelines
plant and equipment to be
used
Factors that cause instability of mobile cranes and measures to be taken to reduce likelihood of
overturning during operation
Causes of instability
• Incorrect selection of crane e.g.. SWL to
low for lift
• Incorrect sling of load
• Unstable ground incapable of bearing
weight of crane and load
• Uneven/sloping ground
• Obstructions being struck by crane of
things striking crane e.g.. other plant of
site
• Exceeding SWL of crane of lift tackle
• Inoperation of crane e.g.. incompetent,
inexperienced operator, not using out
riggers
• Poor lift control by AP/banksman.
• Unsuitable lifting plan
• Mechanical failure
• Adverse weather condition e.g.. wind
• Lack of maintenance of crane e.g..
incorrect tyre pressures, rope not
inspected etc.
Measure taken to avoid
• Conduct full assessment of lift required
and surrounding areas including
establishing the load bearing capacity of
the ground that the crane will operate on
• Define and implement sufficient lifting
plan use of competent appointed person
• Selection of appropriate crane for lift
• Ensure that maintenance and testing of
crane is adequate
• Appoint competent person to supervise
lift i.e.. appointed person, competent
banksman
• Engineering controls e.g.. ensure that
outriggers are used and fully extended
where appropriate, ensure that capacity
indicator and alarms are functional
• Ensure that the motion and performance
limit device are in working condition
• Behavioural controls such as
Last paper
competence and training of driver, slinger
and banksman
 Explore possibility of
Consult with utilities
re-routing cables or
supplier before taking
making dead
any protective
Warning signs and measures
protection for public if
necessary Identification of safe
working distance i.e. 9
m if wooden or steel
Supervision and poles 15m if pylons
hazard awareness plus length of jib or
training for workers Precautions to be taken boom if
e.g.. toolbox talk on when working near an cranes/excavators are
hazard associated with overhead electrical to be used
cable and what supply
measure need to be Use of barriers,
taken to avoid marking tape and
bunting
Safe systems of work
to be defined and
implemented Use of goal posts
Height restrictions on and/or tunnels
plant
 Planning and
assessment for
development of
electrical supply by a
competent person
Use of competent
persons for installation
work of electrical
supply
Precautions to ensure safe
provision & use of
Development of safe electricity on construction
systems of work site (feed taken from
overhead lines)
Arrangements for
testing and
maintenance of Arrangements for
portable equipment inspection and
maintenance of the
fixed supply to include
earth bonding checks
Safe positioning of
transformers e.g..
protection from
plant/vehicle impact,
barriers to prevent
workers accessing
area
Routing, marking and
protection for cables
Use of protective
devices e.g.. reduced
low voltage systems
(110), RCD’s and
double insulated
equipment

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
Fatigue failure
• Crack propagation from points of stress Buckling (Compressive force)
concentration (e.g.. groves, weak weld points),
fluctuating stress final failure may be ductile or • Buckling – yield of one side of structural
member under axial compressive loading
brittle
• Factors contributing • Factors contributing
• Excessive/non uniform loading
• Surface occlusions/damage
• Choice of material • Weakening due to removal of cross
members
• Residual stress imposed through manufacture
• Use of out of true members e.g..
• Corrosion, temperature scaffold tube at incorrect angle i.e..
• Measures to take to prevent not 90 under load
• Design spec appropriate • Excessive temperature
• Quality assurance on manufacture • Measures to be taken to prevent
• Assembled according to spec • Design/material selection
• Correct use – avoid misuse e.g.. over ,loading • Avoid overload work within spec
• Maintenance/testing NDT • Temp control
• Maintenance/testing NDT
Component failure

Ductile Failure (stretch)

Creep
• Ductile failure in metals occur when the yield stress of the material
• Gradual yielding of material under stress close to elastic limit
has been exceeded by the material being placed in tension
(undergoes plastic deformation
(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 • Factors contributing
area at failure point. The failure will appear as a ‘cone / cup’ at 45
• Continuous loading
degrees to the load along the grain boundaries
• High temp e.g.. hot pressurised pipes, turbine blades
• Factors contributing
• Overloading
• High temperature
• Design spec etc
• Over loading
• Measures to be taken to prevent
• Design inappropriate
• Temp control
• Measures to be taken to prevent
• Selection/design of materials
• Temp control
• Maintenance/testing
• Selection/design of materials
• Operate within spec limits of equipment
• Maintenance/testing
 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
Sources of specific pollutants likely to be associated with a multi-fuel CHP
power stations using either coal, oil or gas for burning under normal operations
and foreseeable abnormal operations (located on river estuary taking deliveries
by ship, road & pipeline) plant also has water treatment plant

Normal operations Abnormal operations

• Emissions to air
– Carbon monoxide & oxides of
nitrogen from burning of fossil
fuels
– Sulphur dioxide/sulphur
compounds when coal or oil is
burned
• Other pollutants
– Soot & coal dust from
incomplete combustion
– Solid waste from coal & oil ash
– Acid & alkali effluents from
water treatment process
– Emissions from vehicles
delivering fuel to site same for
ships
• Leaks
– Oil storage tanks
– Gas supply pipelines
– Acid/Alkali storage tanks
• Spillage of chemical from road
tank accident
• Oil slicks from ships during
offloading or major disaster
e.g.. sinking
• Fire leading to fire water run off
during fire fighting
 Design of basket
• 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 Basket maintained and
Trained and competent
operator in basket, • Guards fitted to protect against inspected at least
aware of hazards moving parts of FLT e.g.. chain every 6 months
associated with use

Factors to ensure safe FLT to be parked on

Competent FLT driver firm, level ground,
use of FLT man basket
brake applied, driver in
truck

Anchorage point in
cage and harness fitted Cage securely fixed to
and connected to forks and truck not
persons in basket moved during activity
Barriers positioned around work
area preventing collision from
other vehicles and protect others
against falling objects from
basket
A petrol storage tank in a bund containing three similar tanks is overfilled
resulting in a large spillage of petrol into the bund. The petrol vapour
exploded
Design & construction measures to
prevent such an incident
• Adequate segregation between
adjacent tanks
• Separate bunds for each tank
• Interlocked pumping system
with high level alarms min double
redundancy of alarms
• Level detection
• Vapour detection system fitted
in bunds
• Remote shut down system
• Good earth bonding
Measures to mitigate the effects
• Fixed foam installations
capable to spray the surface of
pool in the bunded areas
• Installation of foam monitors
capable of reaching top of tanks
• Radiation walls between
tanks/bunds to prevent other
tanks from being heated
• Adequate supply of fire water
• Installation of remote pumps to
empty affected tanks
• Easy route of access for fire
fighters
• Provision of drainage
interceptors to minimise enviro
affects of fire water run off
• Regular draining and cleaning
to remove rainwater from bunds
• Provision of site based
emergency response team.
 Design
• Material of construction
sufficiently robust to
withstand workplace Use
rigours and contain any • Monitoring and
ejected materials supervision to ensure
• Should allow sight of guards are not
process if required removed/tampered
with
• Method of fixing should
Fixed guard • SSOW fir carrying out
require special tool to
Defined in BSENISO12100 as a removed e.g.. torque maintenance
guard fixed in such a manner bolts operations with
(e.g.. by screws, nuts, welding) guards removed
• Ensure that any
that can only be removed or • Guard check
necessary openings
opened by the use of tools or procedure to ensure
provide enough distance
destruction of the affixing guard is kept in
from hazards to prevent
means. It provides protection maintained condition
harm
against mechanical hazards
when infrequent or no access is • Guards reverberation • Provision of
required during normal exacerbating noise information and
operation of the machine. Acts problems training for operators
as a fence between people and and maintenance staff
dangerous machinery parts detailing the hazards
associated with guard
Fixed guards factors to
defeats and other
consider in design and
SSOW
use to ensure people
are adequately
protected
Fixed electrical systems faults (including corrosive atmospheres) & Information
relating to system that electrician would need before conducting a survey of
system
Type of faults found in fixed electrical
system (including systems in area with
corrosive atmosphere
•Poor earth bonding
•Damaged sockets and switchgear
•Covers missing from junction boxes
•Incompetent workmanship and
inadequate excess current protection
•Exposed conductors due to damaged
insulation from corrosive
•Short circuits caused by ingress of
fluids
•Corrosion of system parts
•Unsuitability for use in wet & corrosive
conditions
Information needed by electrician
before conducting a survey
•Type of equipment and its rating
(operating voltage and current)
•IP classification (including measure of
protect against ingress of water
•Circuit diagrams and/manuals for the
equipment
•Details of any modifications made
•Means of isolations and location
•Earthing arrangements
•Type and size of cables
•Details on the operations of protective
devices
•Copies of previous inspection reports
and repairs made/maintenance carried
out
Robots, implications for safety and how risk to personnel can be reduced when working with
Features of industrial robots that may have
particular implications for safety
•Sudden, rapid or unexpected movements
•Aberrant behaviours e.g.. robot moving
outside normal operating parameters
•Dropped loads or ejected materials people
have to enter area to rectify
•Software problems which are difficult to
detect
•Dangers associated with teaching robot e.g..
may require close work with robot moving
•Dangers from work being carried out e.g..
spot welding, stored energy
•Dangers arising from maintenance activities
e.g.. working in area close, robot may
continue working
•Failure of perimeter sensors leading to robot
collisions with people or other equipment
Reducing risk to personnel working in vicinity or with
robots
•Conduction risk assessment to identify hazards
associated with robots and those at risk, evaluate the
risk and identify controls required to reduce the risk to an
acceptable level (eliminate or reduce)
•Restricting access by fixed fencing
•Provision of interlock access point e.g.. pressure mats
•Installation of light sensors e.g.. curtain or eye to detect
motion and stop robot (automatic guarding)
•Provision of mechanical restrains
•Use of audible start up warning
•Procedures for restarting after interruption
•Emergency stop systems
•Introduction of safe systems of work e.g.. isolation lock
out tag out before maintenance activities commence
•Training relevant people in hazards associated with
robot and precaution necessary
•Introduction of monitoring system including audit and
the keeping of records of maintenance and defects
•Maintenance program
•Routine guard checking procedure
Robots, implications for safety and how risk to personnel can be reduced when
working with

Features of industrial robots that may Reducing risk to personnel working in vicinity or with
have particular implications for safety robots

•Conduction risk assessment to identify hazards

•Sudden, rapid or unexpected
associated with robots and those at risk, evaluate the
movements
risk and identify controls required to reduce the risk to an
•Aberrant behaviours e.g.. robot acceptable level (eliminate or reduce)
moving outside normal operating •Restricting access by fixed fencing
parameters
•Provision of interlock access point e.g.. pressure mats
•Dropped loads or ejected materials
•Installation of light sensors e.g.. curtain or eye to detect
people have to enter area to rectify
motion and stop robot (automatic guarding)
•Software problems which are difficult •Provision of mechanical restrains
to detect
•Use of audible start up warning
•Dangers associated with teaching
•Procedures for restarting after interruption
robot e.g.. may require close work with
•Emergency stop systems
robot moving
•Introduction of safe systems of work e.g.. isolation lock
•Dangers from work being carried out
out tag out before maintenance activities commence
e.g.. spot welding, stored energy
•Training relevant people in hazards associated with
•Dangers arising from maintenance robot and precaution necessary
activities e.g.. working in area close,
•Introduction of monitoring system including audit and
robot may continue working
the keeping of records of maintenance and defects
•Failure of perimeter sensors leading to •Maintenance program
robot collisions with people or other
•Routine guard checking procedure
Scaffolding, factors causing instability and principles of design and
erection to ensure stability
Factors that cause scaffolds to become
unstable/collapse
•Scaffold not erected as per original
design
•In-competent scaffold designers/erectors
•Ground constructed on not being of load
bearing capacity
•Scaffold foundation being undermined
by surface water or site works e.g..
excavation
•Incorrect use of fittings and/or use of
damaged fittings
•Standards were out of plumb or bent
•Unauthorised/malicious alterations by
incompetent people
•Overloading of scaffold e.g.. material
storage
•Impact e.g.. load suspended by crane/hit
by plant vehicle
•Severe weather e.g.. excessive wind
loading
Principles of design and erection to ensure
safe/stable scaffold
•Use of competent persons
•Designed to withstand required loading
•Constructed of sound materials & fittings
•Setting standards on base plates
•Ensure joints are staggered
•Fitting of longitudinal & diagonal bracing
•Ledger braces at every other pair of
standards
•Vertical & horizontal ties no more than 8.5m
apart and replaced by temporary ties if
required to remove
•Scaffold erected in position where
traffic/plant impact likely barriers should be
erected (protection)
•Ground erected on to have suitable load
bearing capacity
•Inspections carried out at regular intervals
i.e.. not exceeding 7 days and after change in
conditions e.g.. adverse weather conditions,
after alterations etc.
•Do not load beyond design capacity
Pressure system
• Is a system comprising one or more
pressure vessels of rigid
construction and any associated
pipe work and protective devices
Siting of equipment to
Separation from flammable
• Pipe work with its protective ensure protection from
atmospheres
devices to which a transportable vehicles
gas container maybe connected
• Pipeline and its protective devices
which is liable to contain a relevant Protection of public from
fluid. i.e.. steam, gas at a pressure emission of noise
greater than 0.5 bar above
atmospheric pressure when at a
temp of 17.5 c or a gas dissolved in
solvent at ambient temp which
System design issues
could be released from the solvent
without the application of heat Pressure system safety • Adherence to standards
requirements to be met
before commissioning • Capacity
• Materials of construction

Provision of information • Layout features

and training for operators • Fitting of pressure
including safety feature, gauges, warning systems
limits and correct
operation of system • Relief valves and drain
lines

Competent person to • Marking of safety related

Establish maintenance and
undertake a pre
inspection procedures and
commissioning check
written scheme of
examination defines
info e.g.. safe working
pressure
• Suitable guarding
• Certificate of conformity
and CE marked
Trackers stability - will apply for most wheeled plant equipment
Factors that cause tractors to
overturn
•Angle of slope operated on too
great
•Direction of travel on gradients
•Uneven or soft ground
•Speed of corner
•Condition and pressure of tyres
•Effects of trailers and other
attachments
•Power take of seizure
•Competence of driver
Minimising risk
•Restriction of use on steep
gradients
•Operator training and awareness
•Correctly maintained tyres and
pressure
•Fitting of wider tyres/additional
wheels
•Fitting of counter balance weights
•Regular maintenance
•Power take of fitted with shearing
pins
Limit effects of over turning
•Fitting and use of seat belt
•Roll over protection e.g.. cage
protections
Computer Numeric control systems (CNC) fitted to lathe
Additional risks
•Increase in operation speed
•Increase in noise
•Possible unexpected movements
•Errors in programming and
software
•Risk from teaching
•Risk from operator unfamiliarity
Minimising risk
•Risk assessment
•Fitting of fixed or interlocked
guards to prevent access during
automatic cycle
•Provision of manual operation for
setting and cleaning operations
e.g.. hold to run system
•Relocation of controls out of
danger zone
•Additional training for operators
and maintenance staff
•Updating of the instruction
manual for use, cleaning and
maintaining the machine
•Conduct regular testing of the
software
 Conduct desk top survey
(feasibility study) involving
residents look at
•Historical records
•Weather patterns
•Links with wind direction Check plant for
obvious faults and
•Identification of potential conduct continuous
other dust sources in area monitoring
(background)
Consult and liaise with
local authorities/EA Investigation into dust
allegation from local
village that dust is from
plant you work in

Conduct analysis of Check supervisor

dust collected from reports over period of
village to establish if it alleged fall out for
matches that produced abnormalities in
from plant process/ check
maintenance logs for
break down e.g.. LEV
systems
 Confined e.g.. in a
tank/vessel or
unconfined e.g.. petrol Presence of flammable
release vapour cloud vapour at
Examples of VCE concentration between
travelling
• Flixborough 74 LEL & UEL

• Grangemouth Ignition source that

exceeds the minimum
• Buncefield ignition energy
required

Principle & Effect of

Vapour cloud explosion
Unconfined vapour
clouds can travel
Effects of VCE considerable distance
before igniting (find
• Vessel or containment ignition source) or may
rupture resulting in be dispersed to a
rapid release of Effects of explosions concentration below
liquefied gas UCVCE LEL depending on
• Projectile materials conditions e.g.. wind
• Overpressure
speeds, atmospheric
• Overpressure • Thermal effects pressure
• Thermal effects • Emission of debris
• People and property
damaged due to
pressure wave and
thermal radiation