NEBOSH DIPLOMA PART 2

EXAM QUESTIONS

CONTENTS

Management of Risk

Legal & Organisational Factors

The Workplace

Work Equipment

Agents

Case Studies
 MANAGEMENT OF RISK

A national campaign aimed at improving standards of health & safety in a particular

industry has been deemed a failure due to a significant increase in the rate of reported
1
accidents over the period of the campaign. Explain why accident rates may have proved a 10
poor measure of the campaign’s effectiveness and identify other measures that might have
been used.
ACCIDENT RATES
 Low accident rate may have been due to under-reporting, so an increase in reported accidents may
actually be a good sign of improved awareness.
 Accidents can be a result of management decisions from long ago.
 Number of accidents, even in poor companies, are generally too infrequent to be statistically significant.
OTHER MEASURES
 Audit
 Inspection, Sampling, Surveys, Tours
 Accident Costs
 Near Misses
 Behavioural measurement (error monitoring)
 Attitude/Perception/Climate Surveys

State the objectives and outline the methodology of Failure Mode and Effects Analysis
2 10
(FMEA), giving an example of a typical safety application.
OBJECTIVES
 To analyse each component of a system in order to identify the causes of a component failure and the
subsequent effects on the system as a whole.
METHODOLOGY
 Break down the system into component parts
 Identify how each component could fail
 Identify all possible causes of component failure
 Identify the effects of the failure on the system as a whole in terms of severity
 Assess the probability of failure
 Identify the means of detection of failure
 Prioritise failures based on severity and probability
 Determine the action required to reduce the risk of failure to an acceptable level
 Document the findings
EXAMPLE
 High risk application such as chemical process safety or nuclear industry, where failure of a simple
component could have disastrous consequences

3 Outline the measures that might be required to ensure effective communication of health
10
& safety information to deaf or hearing-impaired employees in a manufacturing plant.
 Appropriate warning systems for deaf persons which might involve the use of lights, vibrating devices
and buddy systems
 Greater use of written instructions
 Alternatives to the use of the telephone
 Training in sign language skills
 Deaf awareness training for colleagues
 Involvement of specialists to advise
 Visual methods i.e. posters, noticeboards etc.

4 Outline Rasmussen’s model of levels of human operation (skills, rule and knowledge
10
based) and explain how errors may typically occur at each of the three levels.
 SKILLS BASED
Low level “automatic pilot” sequence of actions. Errors occur through:
 Incorrectly selecting a similar routine
 Interruptions or inattention
 Insufficient verification checks to ensure correct routine selected
RULE BASED
Action based on pattern recognition determining routine to be selected. Errors occur through:
 Inaccurate diagnosis due to insufficient training
 Application of usual rules when inappropriate
 Diagnosis based on previous experience
KNOWLEDGE BASED
Action based on high level problem solving. Errors occur through:
 Inadequate understanding of the system
 Insufficient time to diagnose
 Evidence ignored

The frequency of pipework failure in a large LPG storage facility is estimated at once
5 every one hundred years (f=0.01/year). Immediate ignition of the released gas (probability,
p=0.05) will result in a jet flame. Otherwise, prevailing winds will normally carry any
vapour cloud off site across open countryside where it will disperse safely. However, under
certain conditions (p=0.1), the cloud may drift to a nearby industrial estate where ignition 10
(p=0.5) will cause a vapour cloud explosion or flash fire.
Using the data provided, construct an event tree to calculate the expected frequency of fire
or explosion due to pipework failure BOTH on site AND on the industrial estate.
The starting point is to logically construct an event tree which begins with pipework failure (f=0.01/year).
Following the failure of the pipework there are two possibilities. Either the released gas will immediately
ignite (probability, p=0.05) resulting in a jet flame on site. The frequency of this occurrence is 0.01/year x
0.05 i.e. 0.0005/year which gives the answer to the first part of the question.
The other option is that the gas does not immediately ignite but drifts off site. If the probability of immediate
ignition is 0.05, then the probability of non-ignition and drifting off site must be 0.95. Consequently the
frequency of this occurrence is 0.01/year x 0.95 i.e. 0.0095/year.
In most cases the gas disperses safely but there is a one in ten chance (p=0.1) that it will drift to a nearby
industrial estate. The frequency of this happening is therefore 0.0095/year x 0.1 i.e. 0.00095/year.
Finally, having drifted onto the industrial estate, there is an even chance (p=0.5) that a source of ignition will
cause a vapour cloud explosion or flash fire. The frequency of this, therefore, is 0.00095/year x 0.5 i.e.
0.00048/year.

6 Review the relative advantages and disadvantages of operating a “planned preventative

10
maintenance” system
 ADVANTAGES
 Safer operation
 Reduced downtime/lost production,/increased reliability of equipment
 Predicts failure (e.g. low efficiency operating)
 Rapid turnaround (parts needed are known and ordered in advance)
 Maintenance can be undertaken at times of least disruption
 Reduced risk from maintenance operations due to pre-planning
 Possibly reduced storage requirements for spares (ordered as required)
 Assists compliance with legislation
 Aids budgeting

DISADVANTAGES
 “Over-maintenance” may reduce efficiency (“if it ain’t broke…”)
 Possible high cost of replacing parts that remain well within useful life period
 May lead to problems elsewhere in system/process
 Management time required to plan/operate schedules
 Over-familiarity with tasks may lead to complacency
 Requires highly skilled persons to operate system (knowledge of failure modes, etc.)
 Possibly increased storage requirements (if spare parts not normally stocked)

With reference to practical examples, suggest ways of minimising harm due to human
7 10
error at work
 Automate (eliminate human involvement)
 Make errors less critical/design in safety features (e.g. interlocks, pressure relief, alarms etc.)
 Require confirmation of critical decisions (no action until confirmation given
 Monitor/provide feedback (to make human operator aware of effect of action)
 Employee factors (selection, training, supervision)
 Ergonomic/work environment factors (displays, controls, lighting, breaks etc.)
 Procedural factors (SSoW, permits etc.)

Explain the roles of risk avoidance, retention, transfer and reduction within an overall risk
10
management programme.
AVOIDANCE
 The best option when managing risk
 High initial cost, little or no ongoing cost
 Examples: automation

RETENTION
 May be cheaper to retain tolerable/acceptable risks
 Low severity risks
 Can be with or without knowledge

TRANSFER
 Insurance
 Contract out (could also be risk avoidance?)

REDUCE
 Normally more viable than total avoidance
 Hierarchy of control

A medium-sized garment manufacturer has noted an increasing tendency among

experienced personnel to remove needle guards from sewing machines. Outline the 10
possible reasons for this behaviour.
 Human Factors question – Personal, Job, Organisational structure
 Boredom/fatigue
 Guards restrictive to job
 Over confidence/complacency (experienced staff)
 Piece work/unreasonable targets
 Peer pressure
 Perception of risk
 Lack of supervision
 No previous accidents
 Incentives to cut corners

A financial review within your organisation has resulted in a proposal to the Board of
Directors to cut its health and safety budget and to cancel a capital project that was
designed to lead to significant improvements in the working environment. 20
As the organisations Health & Safety Manager, present an argument to the Board for
rejection of this proposal.
MORAL
 Duty to prevent suffering and maintain quality of life
 No-one has right to expect employees to risk life and limb in return for a contract of employment
 Could you explain this decision to a bereaved wife/mother? (Effects on everyone of serious accidents)
LEGAL
 HASAWA 1974 and other Acts and Regs
 Enforcement Notices
 Prosecution
 Civil actions
 Individual liability of Managers and Directors i.e. Section 37 HSWA and Corporate Manslaughter
FINANCIAL
 Reference to HSG96
 Insurance
 Direct/Indirect costs
 Benefits including increased efficiency and productivity from a “cared for” workforce
 Reduced moral
 Bad publicity – Unions, CSR, Accountability etc.

a.) Describe the personal factors that shape and influence an individual’s behaviour at
work.
20
b.) Explain the relevance of the factors described in (a) when selecting an employee for
training as an appointed first-aider.
a.)
 Personality, attitude, aptitude and motivation play a significant part in human behaviour.
 Behaviour is also shaped by ancestry and social/cultural background.
 Experience, Intelligence, Education and Training all have a significant influence.
b.)
 Use factors identified in a.) to illustrate.
 Need to include:
 Someone sufficiently motivated, with responsible attitude and the necessary physical and mental
attributes to complete the training and cope in an emergency.

Explain, with examples, why people may fail to take action to avoid danger at work. 20
PERSONAL
 Danger not recognised
 Lack of experience
 Need for action not recognised (e.g. fatigue)
 Overfamiliarisation with workplace
 Drugs and alcohol
 Stress
ORGANISATIONAL
 Lack of hazard awareness (e.g. lack of training)
 Avoiding action unknown (e.g. lack of training)
 Peer group pressures
 Cultural/Social pressures
 Piecework/bonus schemes
JOB
 Interference caused by PPE
 Production pressures
 Emergency reasons
Note that examples for each of the above would be needed.

Dental Practitioners often work alone or in small teams in the community.

(i) Outline the types of hazard to which the dentist or his/her staff may be exposed.
20
(ii) Explain how the risks from the hazards identified in (i) can be minimised to protect
the dentist and other employees.
HAZARDS
 Hazardous substances (e.g. mercury)
 Biological hazards (e.g. hepatitis, HIV)
 Mechanical hazards (e.g. drills)
 Scalding
 Electrical hazards
 Fire
 Musculoskeletal problems
 Radiation hazards
 X Rays
 Violence
 Stress
 Lone working (exacerbation of other problems)
 Slips/Trips/Falls
CONTROLS
 Risk Assessment (Generic, Manual Handling, COSHH)
 Written Safety Policy? (5 employees?)
 Selection and training of staff
 Assessment of PPE needs
 Adequate ventilation
 Atmospheric and personal monitoring
 Stress management
 Incident reporting and investigation
 Inspection and maintenance of equipment and premises
 Fire precautions
 General housekeeping
 Other measures taken from list of hazards
Identify and explain fundamental failings within management systems which could have
20
contributed to disasters as disparate as Piper Alpha, King’s Cross and Clapham Junction.
Separated into HSG65 headings would provide a structured answer.
What is required in the answer is an explanation of the underlying management failings that contributed to
these disasters such as:
 Lack of proactive assessments and appreciation of the potential for disaster
 The difference between, and failure to monitor, actual work activities and situations compared with those
laid down in the manual
 Failure to take account of human behavioural aspects
 Lack of clear authority, responsibility and accountability
 Absence of, or poor, emergency arrangements
 Failure to make provision to ensure competence of key staff
 Poor communications and distribution of workload

The following table show the lost-time accident incidence rates (per 1000) employees for
two hospitals situated in the same locality. Hospital A, an NHS Trust Hospital, currently
20
employs about 2000 staff and has 600 beds, whereas hospital B, which opened in 1998, is a
private hospital employing about 350 staff with 175 beds.
Year Hospital A Hospital B
1997 36 -
1998 33 -
1999 45 12
2000 50 19
2001 51 16
i.) Suggest reasons for the apparent differences in safety performance between the two hospitals.
ii.) Comment upon the pattern of figures for EACH hospital.
i.)
 Hospital A has A+E department (drunk, drug addicts – uncontrolled)
 Hospital A treats all types of patient. Hospital B can select
 Hospital B better able to plan (patients usually admitted with good background history, fewer emergency
admissions etc.)
 Hospital A has more patient movement (outpatient clinics etc.) therefore more porters and manual
handling required
 Hospital B newer:
 State of the art equipment (reduction in manual handling)
 Equipment more reliable
 Building better designed for purpose/less maintenance
 Designed environment (temperature etc. controlled)
 Staff issues:
 Hospital A requires a greater proportion of maintenance staff (high risks from maintenance)
 Hospital A has lower staff morale (conditions etc.)
 Hospital B better able to select well trained staff
 Safety management system in hospital B better designed (started from scratch)
 Risk assessment in Hospital B from design stage – Hospital A having to adapt steadily
 Cultural issues
ii.)
 Rates worsening by the year in Hospital A – possibly better reporting as Safety Management System
improves
 Hospital B possibly attracted better staff from NHS?
 Morale in NHS reducing generally as time goes by
 Hospital B too new to identify trends – worsening in 2nd year possibly due to development issues
(training, growth of patient numbers etc.)
A small company formulating a range of chemical products operates from a site on which
it employs about 50 staff. Although not falling within the scope of the Control of Major
Accident Hazards Regulation 1999, the site poses a risk to employees, the neighbouring
community and the environment. Following a visit by an inspector from HSE, the company
has been asked to provide details of its procedures for dealing with emergencies.
20
i.) Outline the types of emergency procedure that a site of this nature may need to
have in order to deal with incidents affecting the health and safety of site
personnel.
ii.) Describe the arrangements that should be in place in order to demonstrate an
effective major incident procedure.
i.)
 Local chemical spillage/release procedure
 Fire evacuation
 First aid treatment
 Major incident procedure
 Other (e.g. bomb)
ii.)
 Consider major accident risk (e.g. nature of chemical, rate of release etc.)
 Involvement of emergency services/local authorities, utilities in development and execution of the plan
 Provision of control centre with appropriate information and communication resources (site plans,
drainage plans, inventories, contact numbers etc.)
 Development of a documented plan
 Development of a clear hierarchy (main controller, incident officer etc.)
 Allocation of responsibilities to specific individuals/job roles
 Provision of communication equipment
 Resources for spills, vapour suppression, fire control etc.
 Arrangements to check and maintain emergency equipment
 Clear responsibility for initiation of the procedure
 Call-out arrangements for key personnel
 Arrangements for support services (catering etc.)
 Press management arrangements
 Training of key personnel and site staff briefings
 Periodic practice of arrangements
 Review of arrangements
 Business continuity issues
 LEGAL & ORGANISATIONAL FACTORS

a.) With respect to European Community law, distinguish between Regulations, Directives
1 and Decisions.
10
b.) Outline the possible role of the European Court of Justice in a case between a member
state and a citizen of that member state.
REGULATIONS
 Binding on the member state to which it is directed
 Have a direct effect and may impose obligations that are enforceable in national courts
 Rarely used

DIRECTIVES
 Intention must be implemented by regulations made in the member state
 May have a direct effect if the member state does not implement
 Objectives are binding but the method of implementation is left to national law

DECISIONS
 May be made by Council or Commission
 Are specific and binding on member states
 Main use is to allow a member state to depart from a requirement of a EU treaty

ROLE OF ECJ
 While rulings of the ECJ are binding on national courts, the Court has jurisdiction only in respect of EC
law.
 The European Court of Justice has no jurisdiction in purely internal cases
 It may be asked for a ruling on interpretation of EC law
 Requests for rulings may be made by any court or tribunal but must be made only by the final court of
appeal if requested by an individual
 Ruling of the European Court of Justice is binding on the referring court

A secretary was injured by her chair when the adjustment mechanism, which used gas
2 under pressure, exploded due to a manufacturing fault. With reference to case law where 10
appropriate, provide notes to explain the civil and criminal implications of this accident
CIVIL IMPLICATIONS
The Employers Liability (Defective Equipment) Act 1969 makes employers liable for injury caused by
defective equipment even though the defect was the fault of another party. The appropriate case law to
support this point is Davie v. New Merton Board Mills. The employer, of course, may seek to recover
damages from the manufacturer of the equipment.
The employer would be directly liable (negligence and breach of statutory duty) if he knew, or should
reasonably have known, of the fault. Regulation 4 of PUWER requires the employer to ensure that work
equipment is constructed so as to be suitable for the purpose for which it is used. Wilson & Clyde Coal Co.
v. English established the duty of care to provide safe equipment.
The Consumer Protection Act 1987 places strict liability on a manufacturer, and the manufacturer’s duty of
care to the end user. The relevant case law here is Donoghue v. Stevenson.
CRIMINAL IMPLICATIONS
The manufacturer of the chair has duties under Section 6 of the Health & Safety at Work etc. Act 1974 to
ensure, so far as is reasonably practicable, that the chair was constructed so as to be safe, that such testing
and examination was carried out to ensure this, and that users were made aware of the fault.
There are also possible breaches of legislation by the employer under Section 2 of the Health & Safety at
Work etc. Act 1974, and also in PUWER, already referred to above.

Identify and explain the various statutory provisions aimed at preventing discrimination at
3 work and outline the circumstances relevant to health and safety when it may be lawful to 10
discriminate.
 PREVENTING DISCRIMINATION
 Race Relations Act 1976
 Sex Discrimination Acts 1975 and 1986
 Disability Discrimination Act 1995

LAWFUL DISCRIMINATION
Race Relations Act 1976
 Provision of health & safety information in specific languages
 Head protection requirements for Sikhs wearing turbans
 Recognition of beards on religious grounds

Sex Discrimination Acts 1975 and 1986

 Discrimination of women on health and safety grounds in relation to the Control of Lead at Work
Regulations 1998, the Ionising Radiation Regulations 1999 and the need to suspend pregnant women
from work under certain circumstances.
Disability Discrimination Act 1995
 The requirement for employers to make reasonable adjustments to premises and equipment used by
disabled persons.
A further generic example is discrimination to prevent young persons from high-risk activities under the
Management of Health & Safety at Work Regulations 1999.

4 Explain, with appropriate references to case law, the circumstances in which an employer
10
is said to have “vicarious liability”.
Vicarious Liability – “The liability of the master (employer) for the torts of his servant (employee)
committed in the course of his employment”.
Then need to consider the implications of this definition in terms of:
 “In the course of employment” i.e. establishing the employer/employee relationship and relevant case
law
 “Employee’s professional responsibility” and the extent of the employer’s control over professional
specialists
 “Servant’s frolic” and acts committed outside the course of employment
 Independent contractors engaged by the employer

a.) Explain briefly what is meant by the health and safety culture of an organisation
5 b.) Identify, using practical examples, the barriers to the development of a positive health 10
and safety culture within an organisation
a.) “A system of shared values and beliefs about the importance of health and safety in the workplace” or
“The way we do things around here”. It can be identified, measured and improved. If neglected, it can
deteriorate. Cultures can be positive or negative.
b.)
 Company reorganisations
 Relocations, mergers, redundancies etc.
 Lack of confidence in the organisation’s objectives and methods
 Productivity before safety?
 Uncertainty
 Over future?
 Questionable management decisions
 Inconsistency
 Hidden agendas e.g. point scoring or putting individual goals (career progression?) over
organisation goals
 Lack of management commitment

Outline the means whereby, and the extent to which, employment law offers protection to
6 those who disclose information (“whistle-blowers”) relating to their employers’ health and 10
safety standards.
  Reference to Public Interest Disclosure Act 1998
 PIDA amends Employment Rights Act 1996
 Illegal to dismiss whistle-blowers, or otherwise treat detrimentally
 Disclosure must be in the public interest, not for personal gain
 Employee must reasonably believe that disclosure shows:
 A criminal offence is being (or is likely to be) committed
 Health & Safety is endangered, or…
 There is (or will be) damage to the environment
 There is a deliberate attempt to cover up evidence of the above
 Reasonable for employee to disclose information to Safety Rep (if applicable) before going public
(Employment Rights Act)
 Cases heard by Employment Tribunals
 ET can order reinstatement/compensation of whistle-blower
 No minimum period of employment to obtain protection under PIDA

a.) Identify two types of proceedings dealt with by the European Court of Justice that
could have relevance to the regulation of health, safety and the environment within EU
7 member states.
10
b.) Distinguish between directives made under Article 95 (formerly Article 100) and those
made under Article 137 (formerly Article 118a) of the Treaty of Rome, giving a health
and safety example of each kind.
a.)
 Action against member state for non-implementation of EC law (by Commission, other member state,
etc.)
 Interpretation of EC law (either by referral from national court or on appeal by claimant)

b.)
Article 95
 Removal of barriers to trade/unrestricted movement and sale
 Harmonised product standards
 Unanimous vote/power of veto
 Example (e.g. Machinery Directive)

Article 137
 “Social Dimension” – setting minimum H&S standards
 Harmonisation (and improvement) of workplace H&S standards
 Co-operation procedure/QMV
 Example (e.g. Framework Directive, Work Equipment Directive)

Explain, with appropriate reference to case law, the circumstances in which an employer is
10
said to have “vicarious liability”.
LIABILITY FOR EMPLOYEES
 Master-servant relationship (employer liable for torts of employees)
 Course of employment or Frolic of his own?
 Mersey Docks and Harbour Board v. Coggins and Griffiths Ltd (1947)

LIABILITY FOR CONTRACTORS

 Authorised tort by contractor
 Incompetent contractor selected
 McArdle v. Audmac Roofing Co.

a.) Explain briefly what is meant by the “health & safety culture” of an organisation
b.) Identify, using practical examples, the barriers to the development of a positive health 10
and safety culture within an organisation.
a.)
 A system of shared values and beliefs about the importance of health and safety in the organisation
 “The way we do things around here”
 Can be positive or negative
b.)
 Change
 Reorganisation
 Questionable management decisions
 Focus on productivity
 Redundancies
 Poor communication
 Poor industrial relations – lack of consultation
 Lack of management commitment
 Lack of resource for health & safety

A large organisation has hazardous that impinge upon the health and safety of people both
within and outside the workplace. The organisation has an Environmental Manager, who
reports to the Production Director, and a Health & Safety Manager, who reports to the
Personnel Director. 20
Comment upon this arrangement for dealing with the management of risk in the
organisation, using practical examples to illustrate the types of conflict and disparity that
might occur both in policy development and practical control
 Structure answer into policy development and practical control
 Differing commitment of the two directors could lead to varying levels of importance attached to the two
functions
 Where types of risk affect both disciplines (e.g. noise, chemical, contaminated land etc.), responsibilities
could become confused
 Lack of co-ordination could lead to:
 Improvements in one area having a detrimental effect on the other
 Conflict of advice
 Important areas of risk control neglected by both
 Emergency planning might also be affected, where an ill-defined chain of command could also have
consequences for ensuring control of incidents with both on-site and off-site implications

A small food company imports and blends natural ingredients in order to produce “whole
food” products. Activities involve weighing, mixing and the handling of the ingredients,
many of which are in powder form. This creates a very dusty environment, both in the air
and on the exposed surfaces. Ventilation is provided by open doors and windows and the
company has considered no further provision because it believes that the natural
ingredients are inherently safe.
An employee in the company has been diagnosed as severely asthmatic. He claims that he 20
informed the company on starting employment that he suffered from chest problems but
no masks were provided or further precautions taken. He also claims that his symptoms
have considerably worsened during his three years with the company.
Review the legal actions that might be available to the employee in a claim for
compensation against his employer, clearly showing what he would need to prove for the
actions to succeed.
 Case study has potential for claimant to pursue an action for negligence and breach of statutory duty.
 Tests for each need to be considered:
NEGLIGENCE
 Duty of care owed
 Duty of care breached
 Injury was foreseeable
 Breach resulted in injury

BREACH OF STATUTORY DUTY

Statutory duty:
 Gave rise to civil liability (significance of Section 47 of HASWA and Regulation 22 of MHSWR 1999)
 Was owed to employee by the employer
 Was breached by the employer
 Breach resulted in injury or ill-health
 Was designed to prevent the injury or ill-health
 Was designed to protect the employee

 Breach of statutory COSHH duties is central to the answer (dust exposure)

 Issues to be explored include:
 Does dust constitute a substance hazardous to health? (quantities, capacity to cause ill-health)
 What breaches of COSHH might have occurred (to prevent or control exposure)
 Was the asthma caused or exacerbated by the dust?

a.) Describe the indicators and measures that could be used to assess the health & safety
culture of an organisation.
20
b.) Describe the organisational factors that may influence the success of an attempt to
improve an organisation’s health and safety culture.
a.)
 Attitudes towards health & safety by workers/managers and the acceptance of health & safety
responsibilities
 Extent of communication of health and safety matters
 Integration of health and safety into other management functions (e.g. purchasing)
 Influence of health & safety on management decision-making
 Effectiveness and composition of safety committee
 Status of Safety Advisor
 Relationship with enforcement agencies
 Quality of health & safety policy and its effectiveness
 Reference to health and safety in organisation’s annual report
 Amount of consultation with staff on health & safety matters
 Line managers “managing” health & safety
b.)
 Industrial relations climate
 Confidence of workers in their management’s ability to control risks
 Management commitment to health & safety
 Resources and expertise devoted to health & safety

A customer in a large supermarket is injured when poorly stacked items fall from shelving
and strike her. The items had been stacked by a member of staff who had previously been
warned for ignoring company procedures.
i.) With reference to the Health & Safety at Work etc. Act 1974, and associated 20
legislation, outline the responsibilities of the supermarket and the employee.
ii.) Outline arguments that the customer could use to support a civil action for
compensation and the counter arguments that the supermarket might advance.
i.)
 Health & Safety at Work etc. Act 1974 Sections 2(2)c, 3 and 7.
 Management of Health & Safety at Work Regs 1999 Regs 3, 5, 13 and 14
 Workplace (Health, Safety and Welfare) Regs 1992 Regulation 13
 Possibly RIDDOR 95.
ii.)
 Standard issues involved in a negligence action including vicarious liability, foreseeability and possibly
contributory negligence
 Breach of statutory duty
 Occupiers Liability Act 1957 is also relevant.
 Case Law: Donoghue v. Stevenson, Lister v. Romford Ice, Tesco v. Natrass and Ward v. Tesco could be
cited.

Employers have a duty under the Common Law to take reasonable care to ensure the
safety of their employees. Discuss the nature of this duty in terms of:
i.) Safe plant and equipment
20
ii.) Safe premises; and
iii.) Reasonably competent fellow employees
Supplement your answer where appropriate by reference to significant case law.
Most important case (relevant to each part of the question) is Wilson v. Clyde Coal Co. v. English. This
established the common law position that all employers must provide competent and safe fellow workers, a
safe place of work (including safe access and egress), safe plant and equipment and safe systems of work.
i.) Relevant cases include Bradford v. Robinson Rentals, Close v. Steel Co. of Wales, Davie v. New
Merton Board Mills, Donoghue v. Stephenson and Knowles v. Liverpool City Council.
ii.) Paine v. Coine Valley Electricity Supply Co. Ltd. and Latimer v. AEC Ltd. The Occupiers Liability
Acts 1957 and 1984 are also relevant.
iii.) Hudson v. Ridge Manufacturing Co. Ltd. and Smith v. Crossley Bros.
For each part, you should outline the nature of the duty and supplement your discussion with appropriate
case law.

Explain, with reference to relevant case law, the circumstances in which:

i.) An employer owes a common law duty of care to non-employees who are working
on his premises, describing the nature of that duty.
20
ii.) An employer may be held vicariously liable for the negligent actions of contractors.
iii.) A manufacturer owes a common law duty of care to purchasers of his product,
describing the nature of that duty.
i.) Duty of care owed where:
Workers subject to employers factual and legal control:
 Employer has control over nature/methods of work of non-employees
 The duty owed is similar to the duty for employer/employee for matters within employers control e.g.
safe system of work, competent fellow workers, supervision
 Case law e.g. McArdle v. Andmac Roofing
Workers not subject to the employers control, but involved in the employers activity:
 Duty arises from the employers over property/other workers that may create risk to non-employee
 Duty depends on extent of control
 Duty requires reasonable measures to be provided
ii.) Vicarious liability arises if:
 Employer authorises contractor to commit a tort
 Tort is committed by contractor whilst under employers control
 Issue of control decided on such factors as who gives instructions – who supervises – skill of contractor
 Case law (Mersey Docks)
iii.)
 Manufacturer owes duty to ultimate user
 Duty is one to take reasonable care to ensure product is without defect and not liable to cause injury
 Higher duty exists where no examination is expected before use
 Duty to assess risk in use and provide information to user
 Case law: Donoghue v. Stevenson, Wright v. Dunlop

Review, with relevant examples, the extent to which:

i.) The current UK legislative framework meets the aspirations of the Robens
Committee on Safety and Health at Work, which reported in 1972. 20
ii.) The UK is able to determine the subject, content and form of national legislation on
health & safety.
i.)
Understanding of Robens Philosophy:
 Self-regulation
 Gradual replacement of Acts by HASAWA, Regs, ACOPS, Guidance Notes etc.
 Protection of all employees and non-employees
 Emphasis on human/organisational/management issues (including consultation)
EU Directives and how they fit with the Robens idea of self-regulation:
 Most EU inspired Regs are general in nature (not industry or process specific). They therefore form a
framework not unlike Robens idea.
 Probably more Regs than Robens envisaged.
 Resulted in duplication (risk assessment, training etc.)
 Some Regs seem unnecessary (e.g. DSE)
Regulatory system as envisaged by Robens (policy, enforcement, advice)
ii.)
 UK tends to respond only to EU directives
 In theory UK can enact its own legislation independent of the EU provided it does not contradict a
directive
 Reference to UK legislative procedures expected in answer
 Directives tend to be implemented in the UK by regulations
 Directives binding only in result to be achieved
 UK may interpret and enact in the way it sees fit
 Reasonably practicable seen by commission as lower standard
 Problems of implementing requirements of Directives in ACOP (breach of ACOP not a criminal offence)
 As EU member state, UK can:
 Influence Commissions action programme and draft directives
 Influence form of directives (through Council of Ministers, EU Parliament, Qualified Majority
Voting)
 THE WORKPLACE

Outline the basic principles of operation of (i) heat detectors and (ii) smoke detectors for
1 use in an automatic fire detection and alarm system, explaining the circumstances where 10
each would, and would not be appropriate
HEAT DETECTORS
 Principles of Operation
 “Fixed temperature” detectors use a thermocouple or equivalent to detect a set temperature
 “Rate of temperature rise” detectors use electronic circuitry to detect abnormally fast temperature
rises
 Appropriate Use
 Where detectors might be affected by smoke/steam/vapour in non-fire conditions e.g. kitchens or
hotel bedrooms
 Inappropriate Use
 Where sudden temperature changes might be expected in normal circumstances
SMOKE DETECTORS
 Principles of Operation
 Optical detectors detect obscuration or scattering of focused light rays by smoke particles
 Ionising detectors react to changes in electrical current cause by ionisation of smoke particles
 Appropriate Use
 Where combustion of slow burning materials is to be detected
 Inappropriate Use
 Where detectors might be affected by smoke/steam/vapour in non-fire conditions such as kitchens or
hotel bedrooms
 In positions not rapidly affected by smoke

Outline the health & safety issues to be considered when planning the demolition of a two-
2 10
storey detached house in a residential street.
Note that as this relates to a two-storey house in a residential street, general demolition options such as “use
explosives” are not appropriate.
 Notification of work in accordance with CDM Regulations
 Protection of the public by barriers and consideration of vehicle movements
 Protection of adjoining properties by fencing and shoring up
 A systematic approach using a comprehensive method statement, based on risk assessment, particularly
addressing the issue of premature collapse
 Protection from falls of materials through the use of restricted access and hard hats
 Prevention of falls of people (e.g. edge protection, harnesses etc.)
 Identification and isolation of buried services such as electricity, water and gas
 Manual handling issues and the use of mechanical handling
 Removal of waste, particularly special waste, and the use of licensed carriers
 Safe use of plant and equipment with consideration of maintenance, inspection/examination and training
 Provision of PPE such as hard hats, protective footwear, eye protection, RPE
 Control of general dust through damping down, and the identification and control of asbestos
 Provision of welfare facilities
 Control of excessive noise and providing PPE where necessary

3 Explain, with the aid of diagrams where appropriate, the concept of “integrated pollution
10
control” (IPC)
 In approaching this type of question, we first need to identify the key issues associated with IPC. These
include:
 The concept of IPC arose from the Environmental Protection Act 1990
 IPC was based on a holistic view of environmental discharge which considered the interaction between
air, land and water
 Associated with this was the need for an integrated approach by the different enforcing authorities
 Prescribed processes need authorisation and monitoring
Having established these key points they can be illustrated by diagrams showing inter-media relationships
such as factories discharging contaminants into the air; water affected by leachates from contaminated land;
land used for land-fill sites; acid rain arising from air pollution.

Direct contact with a live, mains voltage electrical supply can result in serious injury or
4 death. Outline a hierarchical range of measures intended to prevent or limit the effect of 10
such contact.
HIERARCHY:
 Isolation
 Work dead
 Lock off isolators
 Prevent contact
 Insulate live parts
 Prevent/Deter contact
 Use barriers and enclosures
 Prevent unintentional contact
 Locate safe by position or use obstacles
 Limit effect of contact
 Residual current devices
 Other measures
 Fuses
 Safe working procedures
 Safety equipment e.g. insulated mats and tools
 PPE

5 Explain the principles and methodology of a Hazard and Operability (HAZOP) study 10
PRINCIPLES
 Structured critical examinations of plant or processes
 Undertaken by an experienced multi-disciplinary team
 Objective is to identify all possible deviations from an intended design and the consequent undesirable
effects concerning safety, operability and the environment
 The possible deviations are generated by rigorous questioning, prompted by a series of guidewords
applied to the intended design
METHODOLOGY
 Assemble an experienced multi-disciplinary team including chemical engineers, chemists and a leader in
the HAZOP technique
 Obtain plant documentation including drawings, flowsheets, plant layouts, operating instructions, logic
diagrams
 Apply the standard guidewords (more, less, reverse etc.) to variable parameters or characteristics of the
plant or process (reactants, temperature, pressure, flow etc.) to identify deviations from the intended
plant design
 Systematically examine every part of the plant or process
 Record any potential hazards and operability problems
 Recommend changes in design, operating procedure or materials

6 Section 34 of the Environmental Protection Act 1990 places a duty of care on persons 10
 concerned with controlled waste:

i.) Explain the meaning of “controlled waste”.

ii.) Identify the categories of persons on whom the duty is placed, and those who are
exempt from such duty.
i.)
CONTROLLED WASTE
 Household waste
 Industrial waste
 Commercial waste
 Exceptions include waste from mines/quarries, agricultural premises, explosives and radioactive waste

ii.)
DUTY OF CARE
Duty owed by any person who:
 Produces…
 Imports…
 Carries…
 Keeps…
 Treats or
 Disposes of waste

No duty owed by householders in respect of own household waste.

A contractor has been employed to demolish a disused paint factory. Give examples of the
7 information that should be provided to the contractor by the owner of the premises in 10
order to comply with the Construction (Design and Management) Regulations 1994
 Location of site services
 Location of buried services
 Hazardous/flammable substances stored on site (e.g. solvents, lead, dyes)
 Hazardous/flammable substances in drains, soil etc.
 Location of other hazards (e.g. asbestos)
 Hazardous machinery/equipment left in building
 Details of structure (weaknesses, fragile roofs, rot, etc.)
 Ground conditions (unstable, underground culverts, etc.)
 Details of no-go areas on site
 Means of access to site/traffic routes
 Proximity of neighbours etc.
 Name of planning supervisor
 Other relevant information (e.g. existing H&S file (if any);previous land use)

In relation to the Ionising Radiation Regulations 1999:

i.) Explain what is meant by the term “classified worker”
10
ii.) Outline the specific arrangements that must be made by employers who are
designated as “classified workers”
a.)
 Likely to receive radiation dose of more than 3/10ths of any relevant dose limit
 Likely effective dose of more than 6 mSv per year
 Must be over 18 years old
 Certified as fit for the work by appointed doctor or Employment Medical Advisor
 Someone who may enter a “controlled area”
b.)
 Dosimeters/film badges to measure exposure
 Assessment of significant doses
 Use of approved dosimetry service
 Provide health surveillance
 Keep records of doses/health checks etc.

Outline the design and procedural issues that are relevant to the safe use of a scaffold hoist
10
tower on a construction site.
DESIGN
 Interlocked gates/overrun devices
 Edge protection/gates or rails at landings
 Marked with SWL
 Installed by competent person
 Suitable stable base

PROCEDURAL
 SWL not exceeded
 Inspection and test 6 monthly or 12 monthly (LOLER)
 Information, Instruction and training for users
 Loads secured on platform before travel

Identify the sources of ignition from an unprotected diesel-engined fork-lift truck and
outline the protection that should be provided on the truck in order to minimise the risk of 10
explosion when it is required to work in a potentially flammable atmosphere.
IGNITION SOURCES
 Hot engine/sparks from engine
 Static sparks
 Exhaust surface temperature/flames/sparks from exhaust
 Sparks from forks – metal contact/collisions
 Arcs/sparks from electrical system
 Flammable atmosphere drawn into inlet

PROTECTION
 Maintenance of truck
 Water jacket on exhaust
 Air cooling measures
 Intrinsically safe electric system
 Start up in another area and drive into flammable area
 Conducting tyres (carbon) – avoid static build-up
 Flame arrestors

An independent tied scaffold to a new ten-storey office block has collapsed into a busy
street.
i.) Outline the factors that may have affected the stability of the scaffold. 20
ii.) Describe the main principles of scaffold design, erection and use to ensure the
stability of such a scaffold.
i.)
 Overloading
 Impact
 Incorrect erection
 Poor materials
 Ground instability
 Extreme weather conditions
 Unauthorised alteration
ii.)
DESIGN
 Correct duty
 Type of structure and loading (BS5973)
 Sound materials
 Ties
 Bracing
ERECTION
 Foundations
 Quality of components
 Competent operatives
 Securely tied into building
 Properly stabilised
USE
 Regular inspection by competent persons
 Control loading
 Prevent unauthorised alterations
 Prevent use during alterations

a.) Outline the dangers against which protection is provided by a fuse in an electrical
circuit and explain how such protection is achieved.
b.) Identify the principal limitations of a fuse as a protective device. 20
c.) With respect to UK mains voltage electricity, describe the methods and devices other
than fuses designed to improve electrical safety.
a.)
 Primary function of a fuse is to limit overcurrent rather than prevent shock
 Provides weak link in circuit by overheating and melting if current exceeds the safe limit
b.)
 Does not protect against electric shock
 Easy to defeat (wrong size fuse or piece of metal)
c.)
 Consider both procedural and physical measures
 Maintenance
 PAT testing
 Circuit breakers
 Residual current devices
 Reduced low voltage
 Earthing (class 1 equipment)
 Double insulation (class 2 equipment)

As part of its water treatment system, a manufacturer is to install an external plant 20

suitable for the reception and storage of sulphuric acid and caustic soda, both of which will
be delivered in bulk containers.
Outline the safety provisions required for the design, operation and maintenance of the
proposed plant.
A useful introduction to the question would include a brief overview of the properties of these corrosive
materials and the need for their separation. Then each of the key areas should be considered in turn,
identifying the principal safety provisions for each.
DESIGN
 Appropriate chemical resistant materials for containment and pipework
 Delivery tanker site access and tank inlet arrangements (connector types, lockable, geographically
separated etc.)
 Designed-in safety features (e.g. pressure relief valves, level indicators, bunding)
 Labelling, signs and warnings for tanks and pipework
 Emergency facilities such as drench showers and eyewash stations
 Located away from buildings
 Located away from, or protected from, traffic routes
OPERATION
 Safe systems of work (e.g. two person operation) developed with the suppliers
 Issue and use of PPE (e.g. chemical resistant gloves, suits, face/eye protection etc.)
 Emergency procedures for spills, including the avoidance of sewer/drain contamination
 Checks on emergency facilities (e.g. neutralising materials, water etc.) before delivery
 Proper stock control systems to avoid over ordering
 Appropriate training and supervision for drivers and operators in safe systems of work and emergency
procedures
MAINTENANCE
 Permit-to-work systems, and procedures for isolation and flush-out of tanks and pipework
 Regular clearance of bunds and appropriate disposal of waste
 Keep vegetation cut down in bunding areas
 Training of maintenance staff in safe systems of work and emergency procedures

The enquiry into a serious fire at a large, two-storey department store concluded that
fatalities had resulted from the rapid spread of fire and from the effects of smoke and
combustion gases.
Describe the measures that could have been taken to: 20
i.) Limit the spread of fire, smoke and combustion gases; and
ii.) Help to ensure that people inside the building were able to escape to a place of
safety.
i.)
 Compartmentalisation
 Fire-stopped voids and ducts
 Concrete encasement of principal construction components
 Incombustible stairways
 Stock management
 Segregation of high risk materials
ii.)
 Routes and capacities
 Travel distance
 Signage
 Emergency lighting
 Electrical interlocking of lifts and escalators with alarm system
 Appointment, training and role of fire marshals

Leakage of flammable gases may present a serious explosion hazard. Explain the 20
circumstances in which each of the following could occur:
i.) A confined vapour cloud explosion
ii.) An unconfined vapour cloud explosion
iii.) A boiling liquid expanding vapour cloud explosion
CONFINED VAPOUR CLOUD EXPLOSION
 Flammable vapour cloud ignited in a container (vessel or building)
 Pressure builds up until containing walls rupture
 Small amount of flammable vapour can lead to an explosion
 Considerable damage but localised effects
UNCONFINED VAPOUR CLOUD EXPLOSION
 Considerable quantity of flammable vapour released as a cloud
 Ignition occurs before the cloud is diluted below the lower flammable limit
 Shockwaves and thermal radiation result from the explosion
BOILING LIQUID EXPANDING VAPOUR CLOUD EXPLOSION
 Pressure vessel containing flammable liquid is heated and ruptures
 Sudden release of vapour containing liquid droplets
 Ignition of vapour cloud causes secondary explosion and fireball
 Thermal radiation from the fireball, fragments from the failed vessel and blast wave from the expanding
vapour

Small electroplating companies often exhibit poor general standards of health and safety,
made worse by the presence of conductive and corrosive fluids and humid corrosive
atmospheres.
i.) Describe the types of fault that may be found in fixed electrical systems under such 20
conditions.
ii.) Outline the information relating to a fixed electrical system that will be required
prior to a survey by a competent electrician.
i.)
 Exposed live conductors/damage/perished insulation
 Covers missing from junction boxes/isolators
 Equipment unsuitable for use in wet or corrosive conditions
 Damaged sockets/switchgear
 Poor earthing/earth continuity
 Corrosion of system parts
 Fluid ingress (short circuits)
 Means of isolation in poor condition
 DIY work by incompetent people
 Cable not protected by conduit/conduit damaged
 Inadequate excess current devices/fuses
 Inadequate working space/access to equipment
ii.)
 Inventory of equipment with details (type, manufacture info./date etc.)
 Operating voltage/current
 IP classification (measure of protection against ingress of water)
 Records of circuit diagrams/manuals/details of modifications etc.
 Circuit identification and what it supplies/controls
 Means of isolation and its location
 Earthing arrangements
 Type and size of cable
 Operation of protection devices
 Previous inspection reports

As the Health, Safety and Environment Manager to a group of manufacturing companies, 20

you have recently discovered drums of a highly flammable solvent being stored on open
land at the rear of one of the group’s factories.
i.) Draft a memorandum to the Production Manager of the company concerned that
explains why storage in this manner is inappropriate.
ii.) Describe, with the aid of sketches, the main features of a storage facility that would
be appropriate for the storage of such drums.
i.)
 Memo format
 Risk of ignition (ignition sources, malicious damage, sunlight etc.)
 Risk of leaks or spillages (land or water contamination)
 Risks from FLTs, handling, stability
 Risks of prosecution/enforcement action for breach of HASAWA (S2, S3), MHSWR, COSHH
 Environmental legislation (water pollution – Water Resources Act/Water Industry Act; if waste –
Environmental Protection Act Duty of Care)
 Civil liability – damage or nuisance
 Clean up costs
 Breach of insurance conditions/environmental accreditation
ii.)
Description of flammable store or compound incorporating:
 Bunding to contain spills/lipped shelves
 Facility for collection/dispersal of rainwater or spillage
 Impermeable base
 Design issues (non-combustible/fire resistant materials, roof design)
 Security (locks, fencing etc.)
 Warning signs (HFL & LPG Regs)
 Protection from sources of ignition/heat/sunlight
 Zone classification
 Adequate ventilation
 Separate from buildings materials
 Emergency provisions (sprinklers, extinguishers etc.)
 Access, egress (including emergency escape)
 Handling issues
 WORK EQUIPMENT

1
Outline the technical and procedural measures needed to minimise the likelihood of
10
structural failures of pressure vessels.
 Split into technical and procedural
 Design specification to ensure fit for purpose and CE marking
 Safety features such as relief valves, sight gauges, level gauges
 Regular checks, tests, inspection and maintenance
 Statutory examination by a competent person
 Non-destructive testing
 Water treatment for boilers
 Filters to remove contamination
 Compliance with design parameters such as temperature and pressure
 Protection from hostile environments such as corrosives or weather
 Training of personnel

Identify:
i.) The factors affecting the likelihood of an agricultural tractor overturning.
2 10
ii.) The measures that may be necessary to minimise the risk, or mitigate the effects, of
a tractor overturn.
FACTORS
 Gradient
 Direction of travel on gradient
 Uneven or soft ground
 Suitability of attachments such as trailers and loads and the effect of attachments on centre of gravity or
lateral stability
 Wheel width
 Tyre type, pressure and general condition
 Speed on cornering
CONTROLS
 Identification of steep gradients and restriction on use
 Fitting of counterbalance weights
 Fitting wider wheels
 Maintenance of tyres
 Roll over protection for cabs
 Seat restraints
 Driver training

3 The number of injuries at the tools of mechanical presses fell significantly after the
introduction of the Power Presses Regulations 1965, the main requirements of which now
for Part IV of the Provision and Use of Work Equipment Regulation 1998.
i.) Summarise the specific legal duties placed on employers in respect of power presses 10
that are additional to general machinery safety requirements.
ii.) Review the factors other than legislation that may have influenced the decline in
power press accidents over the last 35 years.
i.)
 Contained in PUWER and summary should include requirement to inspect guards on power presses
within the first 4 hours of the working period.
ii.)
 Review should concentrate on technical matters, such as replacement of power presses with other types
of equipment, and improvements in guarding and testing.
 Social factors, such as the decline in the manufacturing industry generally, and improvements in the
quality of health & safety management.
4 Identify the particular problems posed by industrial robots in the workplace. 10
Note that it is problems that need to be identified, and not a list of possible safeguards.
 Possibility of sudden, rapid, sweeping movements.
 Consequences of aberrant behaviour
 Software faults which are difficult to detect but may precipitate dangerous activities
 Dangers involved when programming and setting up is carried out
 Electrical interference which may cause non-programmed behaviour
 Inherent dangers with the work for which the robots are used such as welding.
5 a.) Explain the purpose of non-destructive testing (NDT) on items of plant.
b.) Other than visual inspection, outline the principles, benefits and limitations of two 10
NDT techniques.
a.) Fault detection before total failure without affecting integrity.
b.) Select two techniques from the available range:
 Impact
 Dye-penetrant
 Magnetic particle
 Eddy current
 Ultrasonic
 Radiography
 Electrical resistivity
 Thermal imaging
For the techniques selected, (radiography for example), you then need to outline the:
PRINCIPLES
 Diffraction of X-rays or gamma rays by imperfections
BENEFITS
 Detects internal faults and gives permanent record
LIMITATIONS
 Radiation hazards, expensive

A new self-contained air compressor is to be installed in an existing workshop.

6 i.) Outline the “built-in” Protective devices that may be necessary in order to ensure
its safe operation. 10
ii.) Identify the information that must be displayed on the air receiver, and the form in
which it must be displayed in order to comply with EU requirements.
 i.)
 Safety valve – to relieve excess pressure at receiver maximum pressure
 Pressure gauge – to identify receiver pressure
7  Pressure cut-out or unloading device – to cut off compressor when working pressure is reached
 Drain valve – to drain off condensed water vapour
 Fusible plug of metal (overheat protection)
 Electrical protection – fused plug, earthing etc.
ii.)
 CE marking
 Maximum/safe working pressure
 Max/min/Safe working temperature (T in oC)
 Capacity of vessel (V in litres)
 Name or mark of manufacturer
 Type and serial or batch identification
 Last two digits of year in which CE marking was affixed/date of manufacture
 Reference to EN standard
Affixed in visible, easily legible and indelible form – either to vessel itself or on data plate that cannot be
removed.

Susceptible metals are prone to corrode and deteriorate under certain conditions due to an
electro-chemical (or galvanic) process.
i.) Identify the conditions necessary for this form of corrosion. 10
ii.) Outline the technical and procedural controls to limit and identify any corrosive
effects.
i.)
 Potential difference between metals
 Electron path (current flow)
 Electrolyte (conductive atmosphere/medium)

ii.)
 Selection of materials
 Environmental controls
 Cathodic protection
 Sacrificial anodes
 Suitable protection (galvanising/painting)
 Non-destructive testing
 Visual inspections
 Corrosion allowance (e.g. extra material/thicker material)

A plastics injection moulding machine is intended for use within the European Economic
Area. Outline the “essential health and safety requirements” that you would expect to have
20
been addressed in the technical file for the machine in order to demonstrate that the
machine is in fact safe.
In order to answer this question, you need knowledge of the Supply of Machinery (Safety) Regulations
1992 and, in particular, Schedule 3 to the regulations which sets out these requirements under the following
headings:
 Controls
 Protection against mechanical hazards
 Required characteristics of guards and protection devices
 Protection against other hazards
 Maintenance
 Indicators and warnings
The technical file referred to consists of all the relevant material upon which the manufacturer bases his
decision on whether to sign the CE declaration of conformity and must include full details showing that the
machine complies with the essential health & safety requirements.
A manually operated milling machine is to be fitted with a computer numeric control
(CNC) system. Outline the additional risks that this may introduce and the measures 10
required to minimise such risks.
ADDITIONAL RISKS
 Sudden/unexpected movements
 Aberrations
 Software/programming errors
 Unfamiliarity with system
 Increased speeds (aim of computerisation is to improve productivity)
 Increased noise

CONTROLS
 Supply of Machinery (Safety) Regs 1992 (Covers changes of this magnitude – ultimately a new
machine) – Technical file, CE marking
 Risk assessment
 Update instruction manual
 Test software
 Fixed/interlock guards
 Hold to run device
 Controls located outside danger area
 Training

A petrochemical company has experienced a number of false alarms that have activated
sprinklers which form part of the fixed fire protection system in its tank farm. The
company has been advised to install a “voting system” in order to reduce the occurrence of
such “trips” and to incorporate “active redundancy” so that the integrity of the system is
10
maintained.
Explain what is meant in this context by:
i.) a voting system
ii.) active redundancy
i.) A Voting System
 More than one detector of different types
 E.g. smoke, heat detectors combined
 Electronic voting system
 2 or more detectors with different principles of operation
 Reduces influence of spurious trips
 Often used when difficult to obtain single reliable detector

ii.) Active Redundancy

 Duplication to improve reliability
 2 or more of the same component in parallel to improve reliability
 Different electric supplies needed (electrical failure would be common mode failure)

a.) With reference to component reliability, show how the “bath-tub” curve assists in
defining the predictability of component failure.
b.) A safety system depends for its success on a single component. Outline the ways of 20
reducing the likelihood of failure of this component and describe other ways of
increasing system reliability.
a.) Start with sketch of curve, plotting failure rate against operating life. The decreasing rate of early failures
stabilises to a constant chance failure during the useful life of the component before increasing again due
to wearout. Marks are available for a correctly drawn curve but the question asks how the “bath-tub
curve” assists in defining the predictability of component failure. The key point to make, therefore, is
that the failure of an individual component can only be predicted when the failure rate is constant which
is in the plateau region of the curve during its useful life.
b.) It is useful to address each of these in turn relating component failure to the bath-tub curve then
considering hardware and procedural measures to improve system reliability:
COMPONENT FAILURE
 Quality assurance
 Burning-in
 Improved design for better reliability during useful life
 Replace components before wearout
SYSTEM RELIABILITY
 Redundancy (parallel systems as opposed to series)
 Standby systems
 Maintenance
 Operation with design specification
 Detect critical failure modes through Fault Tree Analysis or Failure Mode and Effect Analysis.

a.) Outline the particular problems that may be posed by the use of industrial robots.
b.) Explain how the risk of injury to personnel working with or in the vicinity of industrial 20
robots might be minimised.
a.)
 Dangers from the actual task being performed (e.g. welding)
 Pre-programmed instructions make them unresponsive to the operator
 Have an unexpectedly wide operating range and speed
 Possibility of aberrant behaviour
 The need to enter the robot enclosure for training and maintenance
b.)
 Emergency stop arrangements and restricted access to the danger zone
 Dissipation of stored energy in hydraulic and pneumatic systems
 Isolation procedures
 Movement restriction by mechanical restraint
 Safe systems of work including permits for work
 Arrangements for uncovenanted interruptions and restarting
 Possibility of software and hardware faults and the need for sophisticated audit procedures to identify
 Operator training
 Trips, pressure mats etc.

A serious accident occurred when a threaded steel rod in the braking mechanism of a hoist
failed. An investigation revealed a fatigue failure of the rod.
i.) Describe the mechanisms and characteristics of fatigue failure.
20
ii.) Outline the factors that may contribute to such a failure.
iii.) Describe the measures that could have been taken which might have prevented the
failure.
i.) A specific type of metal failure which usually involves the development of surface cracks around a
stress concentration zone. Need to make reference to creeping nature of the cracks under repeated or
fluctuating loading which is eventually followed by sudden brittle failure.
ii.) Stress concentrations at sharp corners, screw threads, slag inclusions, residual stress points such as
welds, corrosion pitting and heat-induced stress and embrittlement.
iii.)
 Planned preventative maintenance
 Statutory testing and inspections (LOLER, PUWER)
 Non-destructive testing
 Use of equipment within design criteria (not overloaded)
 Trained operatives (importance of not overloading)
 Attention to the suitability of materials used in construction

An investigation of a serious accident has concluded that maintenance operations in a

particular area of a factory should have been subject to a permit to work system. Identify 20
and explain the main factors that should be considered when setting up such a system.
 Defining what the permit system covers (tasks to be performed, legal requirements, personnel
responsibilities)
 Selection, training and competence of personnel (assessment, records, certification)
 What the permit itself prescribes (validity conditions, emergency procedures, the tasks, hand-back
conditions
 How the work should be co-ordinated and monitored
 Permits = HEPPISIP
 Factors questions = Who, Why, Where, When, How, What?

a.) Outline the features of industrial robots that may have particular implications for
safety.
20
b.) Explain how the risk of injury to personnel working with or in the vicinity of industrial
robots might be minimised.
a.)
 Sudden/rapid/forceful movements
 May make unpredictable movements
 Robot arm may have wide sweep
 Aberrant behaviour
 Software faults
 Danger from type of work (spot welding etc.)
 Particular dangers during maintenance
 Stored energy
 Possibility of receiving “foreign” signals
b.)
 Risk assessment – identify hazards from task performed, identify persons at risk, evaluate risk
 Restrict access – ideally fenced off
 Lock off/interlock systems for maintenance
 Pressure release (hydraulics to reservoir, pneumatic to atmosphere)
 Mechanical restraints
 Procedure for re-starting after interruption
 Pre-start warning
 Software checks
 Inching/slow movement during maintenance
 Floor markings
 Remote diagnostic facilities
 Safe system of work/permit to work
 Emergency stops
 Training
 Planned maintenance
 Monitoring, audit, maintenance records, reported defects
A new design of hydraulic press is intended for use within the European Economic Area.
Outline the “essential health & safety requirements” that you would expect to have been
20
addressed in the technical file for the machine in order to demonstrate that the machine is
in fact safe.
GENERAL
 Principles of safety integration (control hierarchy applied, foreseeable abnormal use, ergonomics)
 Materials and products do not endanger users
 Lighting (adequate visibility, no dazzle/stroboscopic effects)
 Handling of the machine (no sharp edges, eye bolt etc.)
CONTROLS
 Safety and reliability of control systems (withstand rigours of normal use/external factors, take account
of errors of logic
 Control devices (visible, identifiable, well positioned etc.)
 Starting (voluntary actuation except where automated)
 Stopping device (must be fitted, must disengage power)
 Mode selection (must override all other control systems)
 Failure of power supply (must not start unexpectedly)
 Software (must be user friendly)
PROTECTION AGAINST MECHANICAL HAZARDS
 Stability
 Risk of break up during operation (inspection requirements)
 Risk due to falling or ejected objects
 Risks due to surfaces, edges or angles
 Risks from combined machinery
 Choice and characteristics of guards and protective devices
PROTECTION AGAINST OTHER HAZARDS
 Electricity and static
 Errors of fitting
 Extremes of temperature
 Fire and explosion
 Noise and vibration
 Emission of dusts and gases
MAINTENANCE
 Remote adjustments, lubrications etc.
 Means of access, isolation etc.
INDICATORS
 Information and warning devices (unambiguous)
 Marking requirements (manufacturers marks, CE, serial no., weight etc.)
 Instructions (installation, use, maintenance)
 AGENTS

1
Outline the means of controlling exposure to biological agents in a pathology laboratory. 10
 General COSHH answer is not sufficient – elimination and substitution are not an option
 Limit number of employees exposed
 Restrict access to authorised persons only
 Minimise the release of biological agents through task design or engineering controls (e.g.
microbiological safety cabinets)
 Display biohazard signs
 Prepare emergency plans
 Decontaminate and disinfect
 Design rooms and surface for ease of cleaning
 Safe collection, storage and disposal of waste
 Safe handling and transport of samples
 Appropriate PPE e.g. gloves, coats, overalls and eye protection
 Vaccination programme and health surveillance
 Hygiene measures such as washing facilities and prohibition of eating, smoking and drinking in the
laboratory
 Appropriate containment level, a minimum of containment level 2
 Competent and trained personnel
 COSHH assessments

An organisation that provides sports facilities for employees and their families is about to
2 install ultra-violet sunbeds and lamps. Identify the risks associated with the use of such 10
tanning equipment and the precautions that should be taken.
RISKS
 Skin cancer or melanoma
 Burns
 Eye damage such as cataracts or conjunctivitis
 Weakened immune system
PRECAUTIONS
 Screening of tanning equipment
 Provide and ensure the use of goggles
 Train staff in the use of equipment, safety controls and the importance of exposure times
 Safety features such as timers and emergency alarms
 Maintenance of equipment
 Correct types of UV tube fitted
 Advise users on the need to limit or avoid exposure if high risk
 Electrical precautions such as PAT testing, maintenance, cable management
 Information to and supervision of users

Outline:
3 i.) The physical, mental and social effects of stress at work 10
ii.) The legal obligations on employers in relation to occupational stress at work
 i.)
PHYSICAL
 Headaches
 Heart and circulatory problems
MENTAL
 Depression
 Aggression
SOCIAL
 Alcohol and drug use
 Absenteeism
ii.)
STATUTORY
 HSWA74 Section 2
 Management Regs Regulation 3 (risk assessment)
COMMON LAW
 Employers common law duty of care (Wilsons & Clyde Coal Co. v. English)
 Examples of relevant case law specific to stress (Walker v. Northumberland CC)

a.) By means of a labelled sketch of an audiogram, show a typical pattern of hearing in an

4 individual suffering from noise-induced hearing loss.
10
b.) Outline the benefits and limitations of audiometry as part of a hearing conservation
programme.
a.)
 Labelled sketch of an audiogram should include correctly labelled axes for hearing loss in dB and
frequency (octave band). The audiogram should show the distinctive 4-6 kHz dip.
b.)
BENEFITS
 Evidence of effectiveness of the hearing conservation programme
 Pre-employment identification of pre-existing problems
 Identification of early signs of noise induced hearing loss
 Basis to defend claims of noise induced hearing loss
LIMITATIONS
 Not preventative
 Information may precipitate claims
 Possible inaccuracies in data
 Doesn’t identify source of noise induced hearing loss

5 In a recent survey of European Union workplaces, more than half of the employees
surveyed reported a perceived progressive increase in stress. In this context outline:
i.) Five major causes of stress at work 10
ii.) Five strategic management issues to be addressed in order to reduce or eliminate
the causes of stress at work.
 i.)
 Unreasonable pace of work
 Lack of control over work
 Inadequate managerial support
 Demanding work schedules
 Feelings of isolation
 Bullying and harassment
 Physical work environment (lighting, temperature, noise, space)
ii.)
 Positive organisational culture (objectives, communication, staff involvement)
 Careful management of change (flexibility, openness, fairness)
 Clear role definition (clear responsibilities, role in organisation)
 Job design and staff selection (job should match skills and abilities, need for training)
 Work schedules (flexible, agreed, reasonable)
 Work relationships (interpersonal skill training, grievance procedures)

6 Outline appropriate procedures to minimise the risk of violence to local authority

10
employees required to make official visits to people’s homes.
 Risk assessment (e.g. reason for visit, locality etc.)
 Keeping records of previous incidents etc./checking clients records
 Recording appointments (address, time, etc.)
 Arrange appointments with persons to be visited in advance if practicable
 Not inviting acts of violence (e.g. no identifiable clothing, unmarked vehicles, no valuables)
 Contacting staff overdue
 Staff to contact office at agreed times
 Provide mobile phones/personal alarms
 Two members of staff where appropriate/no lone visits
 Instruct staff in procedures
 Train staff in dealing with potentially threatening situations

a.) Outline the potential ill-health effects from the use of hand-held vibrating tools
7 10
b.) Explain how the severity of disability in affected individuals may be assessed.
a.) ILL-HEALTH EFFECTS
 VWF/HAVS – Numbness, tingling, blanching of digits, reduced blood flow and dexterity, possible
gangrene
 Raynaulds disease

b.)
 Cold provocation diagnostic tests
 Vibro-tactile threshold measurements

Outline the measures that may be used to prevent or control the growth of legionella
10
bacteria in cooling towers and hot and cold water systems.
 Control temperature of water (20-45oC is ideal for legionella growth)
 Avoid water traps/dead legs
 Avoid stagnant water
 Water treatment (disinfectant/biocides)
 Regular cleaning and maintenance
 Replace wet cooling systems with dry air
 Ultraviolet treatment
 Chlorination
 Regular monitoring/sample tests

A noise assessment carried out by a soft drinks manufacturing plant has revealed that 20
personnel working in the vicinity of an automatic bottle filler are exposed to noise levels in
excess of acceptable limits. It has been decided to investigate engineering methods of
reducing noise exposures. In this context, advise the works manager on the purpose and
essential design and construction characteristics of:
i.) an acoustic enclosure
ii.) an acoustic haven
 Use sketches to illustrate
i.)
PURPOSE
 Enclose equipment and contain noise
DESIGN
 Octave band analysis to characterise the nature of the noise source
 Noise reduction index of the panelling of the enclosure
 Access for operation and maintenance
 Double glazed observation windows
 Adequate internal space
 Adequate lighting/ventilation
CONSTRUCTION
 Protection of the internal absorbent lining
 Sealing between panel and floor, and around penetrating ducts and pipes
 Flexible connectors for pipes and ducts to prevent vibration
 Robust locks to doors and hatches
 Acoustic louvres to vent the enclosure
ii.)
PURPOSE
 Provide haven for workers to protect from workplace noise
DESIGN
 Octave band analysis to characterise nature of noise source
 Noise reduction index of the panelling of the enclosure
 Double glazed observation windows
 Adequate internal space
 Adequate lighting/ventilation
 Adequate seating
 Include as many controls as possible to reduce time spent out of haven
CONSTRUCTION
 Sealing between panel and floor, and around penetrating ducts and pipes
 Robust locks to doors
 Robust construction

Occupational Exposure Standards (OESs) and Maximum Exposure Limits (MELs) are
two types of Occupational Exposure Limit (OEL) used in the UK.
i.) Explain the key differences between OESs and MELs both in terms of the criteria
used to determine which type of OEL is appropriate to a given substance and with 20
respect to legal compliance.
ii.) Discuss the limitations of accepting the control of hazardous substances solely on
the basis of minimal compliance with an OES.
i.)
 OES is a health-based standard, non-injurious at the set concentration
 MEL is a standard at which a risk may still exist but where a “safe” limit is either difficult to determine
or not reasonably practicable to achieve.
 Consequently compliance with the OES is achieved at that standard, whereas exposure to a substance
assigned an MEL must be reduced as far below the standard as is reasonably practicable.
ii.)
 OES takes into account inhalation only
 Individual susceptibility (sensitisation)
 Validity of standards (derived from TLVs without re-evaluation, limited toxicological or epidemiological
evidence in support)
 Variations in control
 Accuracy of determined exposure levels
 Possible synergistic effects of different substances
 Anticipation of revision of standard to a lower level

Outline the techniques that can be used to investigate whether a substance for use at work
may be carcinogenic, clearly identifying the advantages and disadvantages of each 20
technique.
 Chemical analogy
 Advantages – quick, economical, indicative
 Disadvantages – not conclusive, restricted application

 Human Epidemiology
 Advantages – definitive method for identifying carcinogens
 Disadvantages – not an option for new substances, expensive and time-consuming, requires large
populations, poor historical records, problems with sensitivity and specificity
 Animal testing
 Advantages – Best experimental method, data collected faster than by epidemiology
 Disadvantages – Expensive and time consuming, difficulties in extrapolating animal data to humans
since large doses may be used, response may vary with different animal species, ethical
considerations and adverse public opinion
 Short-term Testing
 Advantages – rapid, economical, flexible, test batteries allow range of different tests
 Disadvantages – Problems with validity and/or reliability leading to false negatives or positives

Heat stress can be a serious problem for workers employed in certain processes such as
glass making and laundry work.
i.) Describe how the thermal environment of such workers should be assessed, clearly
identifying the factors that may lead to heat stress and the instruments that might 20
be used in such an assessment.
ii.) Review the measures that might need to be considered in minimising the risk of
heat stress.
i.)
FACTORS
 Air temperature
 Water vapour content/relative humidity
 Air movement
 Radiant heat
 Work load
 Clothing thickness

INSTRUMENTS
 Liquid in glass thermometer
 Hygrometer
 Anemometer
 Kata thermometer
 Globe thermometer

Then need to describe how this information relates to the assessment of the thermal environment by using
various heat indices:
 Wet bulb globe temperature
 Corrected effective temperature
 Heat stress index
 Predicted 4-hour sweat rate

ii.)
 Circulation of air using fans
 Ventilation or air conditioning
 Redesign the workplace or process to reduce physical effort, distance persons from heat sources, shield
or insulate
 Organise work to carry out hot work during cooler periods or by job rotation/increased breaks
 Take account of personal factors by selection, health monitoring, acclimatisation, ensuring suitable water
and salt intake, and the provision of PPE.

Describe the key features of an organisational strategy to ensure that, where appropriate,
20
effective eye protection is selected, issued and used by personnel.
ORGANISATIONAL ISSUES
 Appointment of a competent person
 Management policy and commitment
 Allocation of adequate resources and facilities
 Monitoring and review of the strategy

SELECTION CRITERIA
 Nature of the hazard
 Assessment of risk
 Equipment specification
 Factors affecting acceptability e.g. comfort and range of choice
 Effectiveness (fit and compatibility with other PPE)

ENSURING PROPER USE

 Information, instruction and training for all exposed groups
 Enforcement and disciplinary issues
 Signage
 Maintenance and replacement of equipment

The main part of a factory manufacturing steel tubes consists of a workshop staffed by a 20
foreman, 15 machine operators and 6 labourers. After manufacture, the tubes are placed in
racks to await dispatch.
i.) Outline how you would carry out a survey to assess the health risks arising from
exposure to noise in the workshop.
ii.) Suggest a control strategy that could be used to reduce the worker’s noise
 exposures to acceptable levels.
i.)
SURVEY
 Plan of workshop
 Background data gathering (talk to employees, past surveys, maintenance records, audiometry, problems)
 Identify persons at risk
 Define activities
APPROACH TO SURVEY
 Type of sound level meter
 How equipment is used (sound meter to pinpoint sources, dosimeter, calibration, limitations)
 Assessing normal work patterns/work rate
ANALYSIS/INTERPRETATION OF RESULTS
 Concept of noise dose
 L,epd – peak levels – sample Leq
 Comparison with action levels (NAWR89)
 Assess current controls/PPE
 Use of octave band analysis
 Assessment report and recommendations
 Consideration of points relevant to scenario
ii.)
 Identify people at greatest risk
 Identify main noise sources
 Identify nature and pathways of noise
 Investigate scope for noise attenuation/exposure reduction
 Eliminate/isolate, damping, insulate, absorption
 Process change/technical modifications
 Machine maintenance
 Job rotation/reduce exposure time/noise havens
 Implement simple measures immediately
 Consider need for PPE/protection zones
 Information, instruction and training
 Periodic monitoring
 Audiometry

Discuss the key issues to be addressed in a guidance document on HIV infection for
20
employees within the social services department of a local authority.
 Form of guidance (practical, non-alarmist)
 Nature of HIV/latency
 Transmission (sharps, sexual contact) and misconceptions
 Associated health effects (pneumonia, skin cancer, AIDS etc.)
RISK ASSESSMENT
 Source of HIV infection and identify those at risk (clients/social and care workers/spillages/injured
persons/first aiders)
 Tasks involved
 Assessment of current controls

CONTROLS
 Use of protective clothing
 Treatment and disposal of clinical waste/sharps
 Ways to avoid contact with body fluids
 Levels of training

PROCEDURES AFTER POSSIBLE CONTACT WITH BODY FLUIDS/INFECTED MATERIALS

 Reporting
 HIV tests
 Confidentiality
 Counselling
 CASE STUDIES

JUNE 2002 EXAM. (See exam paper for Case Study)

Describe the inherent stresses that might normally be expected in a crane jib of the type
20
involved in the accident.
 Bending motion on jib
 Predominantly downward forces due to load and sideways due to slewing action of crane
 Putting tension on top or on one side, and compression on bottom or other side
 Bending motion at point near centre of jib due to securing at lower end and load at top
 Weakest point likely to be at jointing point of sections, particularly at hinged gate
 Stress on hinge and lateral stresses due to slew will place additional stress on side opposite hinge
with tendency for jib to fold back on itself (into travelling position) at this point
 High bolting up stresses at connection points of gate may induce stress cracking from excess torque
 Stresses due to cyclic loading/fatigue
 Use sketches etc. to demonstrate general understanding
Discuss the various factors that may have caused an increase in the normal stresses on the
40
jib in this case and suggest an overall mechanism of failure.
 Lateral forces due to slewing from left to right
 Direction of break suggests main reason for failure
 Slope of ground
 Wind speed
 Wind direction
 Incorrect placement of gate
 Loose fitting pins
 Greater bending stresses
 May result in high torque on bolts, hence increased stresses on gate section
 Low yield strength of steel pins results in low elastic limit and will deform (e.g. bend easily)
 Work hardening/ageing
 Welding/heat embrittlement
 Induced heat stresses and changed properties
 May cause stress cracking
 Possible shock loading (e.g. due to gust of wind or de-snagging of sling)
 Radius of jib
 Operating at max radius will increase compressive/tensile forces in jib
 Faulty gauge
 Less tolerance (de-rating due to lower safety factor)
 Impact damage/faulty repair on gate – may have affected strength and load capacity

 Overall failure due to combination of inherent and additional forces resulting in brittle or ductile failure
of jib due to excessive lateral forces induced by a bending motion.
Outline the possible statutory breaches by the parties involved to which the Health &
40
Safety Executive may refer on completion of its investigation.
AB Construction as principal contractor:
 HSW Act s.2 (duty to own employees)
 HSW Act s.3 (duty to others, inc. train passengers)
 MHSWR Reg. 3 (inadequate risk assessments)
WE Liftham as operator of crane:
 HSW Act s.2 (duty to own employees)
 HSW Act s.3 (duty to others)
 MHSWR Reg. 3 (positioning, proximity of railway etc.)
 LOLER Reg. 4 (crane strength and stability)
 LOLER Reg. 6 (positioning and installation – relative to railway line etc.
 LOLER Reg. 7 (Marking of SWL following de-rating)
 LOLER Reg. 8 (Lifting plan by competent person – Position, adverse weather etc.)
 LOLER Reg. 9 (Examination & inspection - pre-use inspection by competent person and particularly
following repairs)
 PUWER Reg. 4 (Suitability)
 PUWER Reg. 5 (Maintenance re radius gauge)
 PUWER reg. 23 (Marking of SWL)
 PUWER Reg. 24 (warnings – radius gauge)
Engineering Company
 HSW Act s.3/s.6 (incorrect materials used in repair)
Armstrong Ltd as designer/manufacturer
 HSW Act s.6 (weakness in design)
Other legislation (in context)
 CDM
 Construction (Health, Safety & Welfare) Regs e.g. Reg. 27 – plant and equipment
 Other possibilities