C July 2010

Front 1

Tanker drivers are routinely required to access the top of road tankers during normal operations.
Outline the factors that should be considered when assessing the risk of falls whilst undertaking the work on top of the road tanker.

Back 1

The initial factor that should be taken into consideration is the need for access to be gained to the top of the tanker. If this is found to be unavoidable, then the height of the tanker, the frequency of access required, the task to be performed, for example valve or pipe connection or valve operation, and the normal duration of the work to be carried out would again be important factors in assessing the risk of falls. Additional matters to be considered include the means of access provided on the tanker, the condition of the tanker roof and the walkway and hand rails, the consequences of falling which might indicate the need for the use of harnesses when on top of the tanker or the provision of fall mitigation equipment such as air bags; and the availability of an alternative existing workplace such as an overhead gantry. Other factors include the possible exposure of the driver to inclement weather, experience, competence, fitness and ability to work at heights and the personal protective equipment that should be provided such as footwear and gloves. Consider the risk of falls and measures to prevent fire and explosion

Front 2

Outline practical control measures that should be taken to help ensure electrical safety in relation to the provision and use of electricity on a construction site.

Back 2

The planning and assessment of requirements for electricity on site would be an important primary control measure to be taken. This would point up the need to use suitably robust and protected cabling for a site environment, together with appropriate equipment which as far as portable equipment is concerned, would require its connection to the system through residual current devices (RCDs) or be operated by means of a reduced low voltage system via step down transformers or be battery operated. The portable equipment should also be subjected to regular testing and maintenance (PAT). One of the problems that can arise on site is the number of contractors that might be involved and it will be necessary to coordinate and control the type and quality of equipment they bring with them. The fixed supply should be regularly tested and reassessed by a competent person and the routes of existing and temporary supplies whether overhead or underground should be conspicuously marked and precautions such as ‘goal posts’ used to avoid contact with moving equipment. Should it be found necessary for work to be carried out on the site electrical system, this should be carried out by a competent person and a safe system of work introduced, such as a permit to work particularly if live working is to be involved. referred to relevant legislation and published guidance such as for example HSG141 Electrical Safety on Construction Sites, and gave the demonstrated that they had not only read them but also understood what they required. precautions to be taken in the use of portable equipment such as the use of 110 volt systems and residual current devices + power supply to the site and the need for it to be checked and maintained

Front 3

With reference to European machinery standards, explain the meaning of the following categories of standard: Type A, Type B1, Type B2 and Type C AND give a practical example in EACH case.

Back 3

Type A standards are concerned with basic safety concepts and design criteria and apply to all machinery. Examples quoted could have included general safety requirements contained in EN ISO 12100 and the principles for risk assessment ISO 14121 (EN 1050).
B standards relate to particular safety aspects in support of the general principles of the A standard. B1 standards for example refer to safety distances, such as in the design of fencing or the approach speed that is required for calculating the safety distance for safety light curtains or multiple light beam safety devices. B2 standards, deal with the performance requirements of special protective devices and contain notes on the design and testing of components or devices such as stop buttons, safety door switches, safety mats and safety light curtains.
Type C standards describe specific risks and the measures for reducing these risks at specific machines or machine types. A relevant example would have been BS EN 693 concerned with hydraulic presses. if a C standard exists for a particular machine type, it takes priority over a B or A type standard. If, however, no C type standard exists for a machine being designed or manufactured, risk reduction in accordance with A and B standards should be made.

Front 4

A new, self-contained air compressor is to be installed in a workshop.
(a) IdentifyTHREE protective devices that may be necessary to control the risk of over-pressurisation AND for EACH device outline its purpose.

Back 4

pressure gauge to identify the receiver pressure; a safety valve which would relieve excess pressure when the maximum safe working pressure of the receiver is attained; a pressure cut-out or unloading device which cuts off the compressor when the working pressure is reached; and a fusible metal plug which prevents over-heating and in turn over pressurisation if external heat sources are applied by melting and thus again relieves the pressure.

Front 5

A new, self-contained air compressor is to be installed in a workshop. (b) Identify the information that must be displayed on the air receiver in order to comply with EU requirements for pressure vessels.

Back 5

CE marking with the last two digits of the year in which it was affixed; the maximum and minimum safe working pressure and temperature (in ºC); the capacity of the vessel in litres; the name or mark of the manufacturer; the type and serial or batch identification; and a reference to the relevant EN standard. The information must be displayed in easily legible and indelible form either on the vessel itself or on a data plate that cannot be removed.

Front 6

The condition of pipework 4m above ground requires inspection. It is proposed, in the absence of the availability of a mobile elevating work platform, to utilise a personnel cage lifted to the required height by a fork-lift truck.
Outline the factors to be considered when assessing the risks associated with this method of access.

Back 6

consideration would have to be given both to the condition and suitability of the equipment to be used and then to the way in which the operation was to be carried out.
(Equipment) - the cage would need to be of adequate design and construction and provided with guard rails and toe boards, and its total weight including that of the person or persons and equipment it is to carry should not be more than 50% of the rated safe working load of the fork lift truck and this weight would have to be clearly marked on the cage. Means should be provided to fix the cage securely to the forks and guarding would have to be provided to afford protection against moving parts on the mast of the truck. Finally both the cage and truck should have been thoroughly examined and tested in accordance with the requirements of LOLER.
(The operation) - the forklift truck should be positioned on firm, level ground with the mast vertical and forks in mid-position, mechanically locked so that the controls cannot be inadvertently operated. The driver should remain at the controls at all times, should not move the truck when the cage is elevated and the possibility of providing a means of communication between the driver and the person in the cage should be considered. Barriers would have to be positioned round the working area to protect against the possibility of collision and to prevent passers by being struck by falling material. Additionally, the advisability of the use of fall arrest equipment by those in the cage would have to be considered as would also the installation to be inspected which might pose hazards, for example from lagging containing asbestos or from heat if the pipe work is used to conduct steam

Front 7

An independent tied scaffold to a new ten-storey office block has collapsed into a busy street. (a) Outline the factors that may have affected the stability of the scaffold.

Back 7

the original erection of the scaffold not following the intended design or the design itself being inadequate; the unsatisfactory bearing capacity of the ground on which the scaffold was sited; the scaffold foundation being undermined either by surface water or by site works such as excavation; the use of incorrect or damaged fittings such as non-load bearing couplers or those affected by corrosion; standards which were out of plumb or bent; a lack of ties; unauthorised alteration of the scaffold; overloading either with materials or because waste chutes became blocked; impact by a load suspended from a crane or by a road vehicle and severe weather conditions including high winds or snow.

Front 8

(b) Outline the main principles of scaffold design, erection and use to ensure the stability of such a scaffold.

Back 8

to ensure that it is designed to carry all loads, is suitable for its use in accordance with BS EN 12811-1 and is constructed of sound materials and fittings. In practical terms this would involve setting standards on base plates on suitable sole plates taking care to ensure joints are staggered; fitting longitudinal and diagonal bracing and ledger braces at every other pair of standards and fitting vertical and horizontal ties which should be replaced by temporary ties in the event that any have to be removed. If the scaffold is erected in a position where there is likely to be movement of vehicles, protection should be provided to prevent damage from any collision that might occur. The scaffold should be erected only by competent persons and after erection should be used only at the designed and correct level of duty and not overloaded. Inspection by a competent person is necessary at intervals not exceeding seven days and additionally after alterations, damage or after a period of inclement weather.

Front 9

As part of its water treatment system, a manufacturer is to install a plant suitable for the reception and storage of sulphuric acid and caustic soda, both of which will be delivered in bulk tankers. Both of these substances are highly corrosive and can react together violently. Outline the safety provisions required for: (a) the design;

Back 9

the need for the storage tanks and pipe work to be constructed of suitable chemical resistant material with organic materials such as wood being avoided in or near to the acid installation; the delivery inlets for each substance to have different connector types to prevent connection being made to the wrong tank; the positioning of the storage tanks in separate bunds with the bunds being capable of holding the entire contents of the tanks plus 10% with protection being provided against weather conditions such as trace heating on caustic soda lines; the pipe work to be colour coded to British Standards; the fitting of level indicators and high level alarms to prevent overfilling interlocked with a cut-out pump on high level; the provision of good vehicle access including a hard standing for tankers with facilities for spill containment and drench showers, the provision of a good standard of lighting and measures to avoid tankers driving off when still connected to the delivery system.

Front 10

As part of its water treatment system, a manufacturer is to install a plant suitable for the reception and storage of sulphuric acid and caustic soda, both of which will be delivered in bulk tankers. Both of these substances are highly corrosive and can react together violently. Outline the safety provisions required for: (b) the operation;

Back 10

introduction of a safe system of work agreed with the material suppliers requiring a two man operation; emergency procedures to deal with spillages and to protect against sewer or drain contamination; the provision and maintenance of a contingency supply of neutralising and absorbent materials and water; providing training for the personnel involved including tanker drivers in the risks associated with the operation and the control measures to be followed and the provision of personal protective equipment such as chemical suits, chemical resistant gloves and full face protection.

Front 11

As part of its water treatment system, a manufacturer is to install a plant suitable for the reception and storage of sulphuric acid and caustic soda, both of which will be delivered in bulk tankers. Both of these substances are highly corrosive and can react together violently.
Outline the safety provisions required for: (c) the maintenance of the proposed storage facility.

Back 11

arrangements for the examination and testing of safety critical plant; the use of permit to work systems; the completion of the flushing out of tanks and pipe work and their isolation before the start of maintenance work; regular cleaning of the bunds with proper disposal of the contents and the provision of training to maintenance staff in emergency procedures.

Front 12

A warehouse that stores stationery products generated six false fire alarms over a three month period while in the process of expanding its premises. On each occasion, the local Fire and Rescue Authority attended the premises. After the last occasion, the Fire and Rescue Authority inspected the warehouse and discovered that the employees had failed to evacuate on all but the first occasion. They also discovered that no testing or maintenance had been carried out on the fire alarm system for five years. (a) Outline the range of enforcement action options the Fire and Rescue Authority may take as a result of their inspection findings.

Back 12

if the Fire Authority considers that the premises are or have the potential to become a high risk premises, they might issue an alteration notice requiring the employer to send them proposals of any changes they propose to make together with a copy of the completed risk assessment.
If, however, the Fire Authority is dissatisfied with the risk assessment, or the action the employer has taken, or indeed with his compliance as a whole with the requirements of the Regulatory Reform (Fire Safety) Order (RRFSO), they might issue an enforcement notice requiring improvements to be made which would allow a minimum period of twenty eight days before compliance was required.
Should the Fire Authority consider that the premises does or will involve a serious risk, they may issue a prohibition notice prohibiting or restricting the use of the premises until specific matters have been remedied. The notice may include directions as to what steps need to be taken and may be enforced immediately or take effect at the end of a specified period.
Finally the Fire Authority may decide to prosecute for any of the summary or indictable offences detailed in Part 4 of the RRFSO.

Front 13

A warehouse that stores stationery products generated six false fire alarms over a three month period while in the process of expanding its premises. On each occasion, the local Fire and Rescue Authority attended the premises. After the last occasion, the Fire and Rescue Authority inspected the warehouse and discovered that the employees had failed to evacuate on all but the first occasion. They also discovered that no testing or maintenance had been carried out on the fire alarm system for five years. (b) Identify the possible causes of the false alarms.

Back 13

possible cause of the false alarms such as faults due to corrosion; wiring defects; the wrong choice of detector heads or the wrong positioning of detectors or call points; a failure to isolate a zone in the vicinity of hot work; dust from maintenance or product spillage activating an optical detector and ultimately clandestine smoking or horseplay. The possible technical causes of the false alarms such as wiring defects and the choice of detector heads were not generally recognised though most candidates provided sufficient information to gain reasonable marks for this part of the question.

Front 14

A warehouse that stores stationery products generated six false fire alarms over a three month period while in the process of expanding its premises. On each occasion, the local Fire and Rescue Authority attended the premises. After the last occasion, the Fire and Rescue Authority inspected the warehouse and discovered that the employees had failed to evacuate on all but the first occasion. They also discovered that no testing or maintenance had been carried out on the fire alarm system for five years. (c) Identify the actions the warehouse company should take to ensure their employees respond appropriately to fire alarms.

Back 14

an important primary action to be taken would be to minimise the number of false alarms and the consequent ‘alarm fatigue’. Following this, the employer would need to provide the employees with a comprehensive programme of training, backed up by the use of reminders such as pocket card campaigns and posters. This could be coupled with the use of a fire warden evacuation system; a programme of fire drills where senior management are seen to play a leading part; the use of an incentive scheme to reward the department with the best time for evacuation and finally disciplinary action in the case of persistent offenders. importance of senior management involvement in fire drills.

Front 15

(a) Outline what is meant by the term ‘fixed guard’ and ‘automatic guard’ in relation to machinery safety AND identify the circumstances where each type of guard might be appropriate AND give a typical example in EACH case.

Back 15

a fixed guard is a guard which is not connected in any way to the controls, motion or hazardous condition of a machine and is fixed to the machine in such a manner for example with screws, nuts or by welding that it can only be opened or removed by the use of special tools or by the destruction of the means of fixing. It is 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. A typical example of its use would be as a guard for a belt and pulley drive. An automatic guard is a guard connected to the machine mechanism which, when the machine is operated, pushes the operator away from the danger area. It is generally used on slow moving, long stroke machines such as certain types of press.

Front 16

(b) To ensure that machine operators are adequately protected, describe the factors to be considered in the design and use of: (i) fixed guards; (ii) automatic guards.

Back 16

Design features of fixed guard = material of construction- sufficiently robust to withstand the rigours of the workplace + be able to contain any ejected material, but still allow sight of the process when required; method of fixing, usually requiring the use of a special tool for the guard’s removal; need to ensure that any necessary openings in guards are such that they do not allow access to the dangerous parts; need to address the possibility of the guard reverberating and exacerbating a noise problem. Factors to be considered in the use of fixed guards = 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 features of automatic guards = compatibility of the guard with the machine function and the convenience of its use; speed of movement of the machine since this type of guard would be inappropriate on fast moving machines; height and reach of the operator; force of movement of the guard together with the possibility that the operator might be crushed between the guard and an adjacent fixed object or structure. Factors to be considered in the use of automatic guards= possibility that the guard might fail to danger; the ease or difficulty with which the guard could be defeated and the training that would have to be given to operating and maintenance staff.

Front 17

Employees in a vehicle maintenance workshop undertake spray-painting of vehicles using a solvent based paint that has a low flash point.
Assuming that a risk assessment has been carried out, outline the practical measures to control the risk of fire and explosion associated with the paint spraying activity.

Back 17

Control measures = workshop constructed of fire resistant material, consider replacing paint in use with one that was less flammable. Provide external fire resistant storeroom for paints and solvents; reduce quantities present in the workshop to minimum; keep paints & solvent in non-spill containers provided with lids. A separate external fire resistant and ventilated storeroom for the bulk of the paint and solvents should be provided at a safe distance from the workshop.
Put procedures in place for containment and clean up of spillages; for cleaning of the spray guns. Local exhaust ventilation would have to be provided in the workshop
Ensure all electrical equipment are to the standard appropriate for the conditions that might prevail, i.e. flameproof or intrinsically safe, earthed to avoid the possibility of electrostatic ignition and where possible the employees should wear anti-static footwear and clothing. Provide fire fighting equipment i.e. fire extinguisher; provided adequate fire escape routes and emergency. Provide staff with instruction and training on the risks and precaution to be observed. Procedures for the containment and clean up of spillages and for the cleaning of the spray guns with a fire resistant container provided for waste rags put in place.