Unit IC Mock Exam Suggested Answers

NEBOSH INTERNATIONAL DIPLOMA IN OCCUPATIONAL HEALTH AND SAFETY

UNIT IC - WORKPLACE AND WORK EQUIPMENT SAFETY
SUGGESTED ANSWERS TO MOCK EXAM
These answers, like your own, may contain information from additional reading and personal experience. Examining
bodies encourage this and it will enhance your answers.

SECTION A
Question 1
Possible risks to those entering the sewer:

• Oxygen depletion, causing asphyxiation, nausea and headaches.

• Fire and explosion arising from ignition of methane gas.
• Ill health from fume inhalation.
• Musculoskeletal injuries from restricted work space.
• Heat exhaustion from work in high temperatures.
• Trips and falls due to obstructions, such as cables, pipes and tools.
• Slips due to surface contaminants, such as biological materials or oils.
• Sludge contaminants present being stirred up by worker activity, leading to Weil’s disease (or leptospirosis).
• Needle-stick injuries.
• Entrapment caused by the collapse of the sewer.
• Sudden ingress of water, with risk of drowning.

Question 2
The following should be considered when preparing a scheme for the systematic examination, testing and
maintenance of portable electrical appliances:

• Inventory of the equipment to be tested.

• Source of the equipment, e.g. in-house, workers, contractors or hired.
• Unique identification by serial numbers or barcode.
• Type and frequency of inspection, which will depend on:
–– Type of risk:
–– Higher risk - earthed.
–– Lower risk - double insulated.
–– Voltage (230V or 110V).
–– Environment in which the equipment is used, such as corrosive or dusty.
–– Protective systems provided, such as earthing, double insulation or reduced voltage.
–– Age and usage of the appliance.
–– Experience and competence of the user.

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–– Historical data.
–– Manufacturer’s recommendations.
• Testing criteria:
–– Competence of tester.
–– Calibration and maintenance of test equipment.
–– Records to be kept of test results and repairs.
–– Systems to identify faulty equipment and take it out of use.
• Guidance from the appropriate regulator or professional institute.

Question 3
(a) Typical mechanical hazards when the conveyor is in use:
–– Trapping, which may be between:
–– Interlaced parts of the conveyor bed.
–– Moving baggage items.
–– The lip and trapped baggage.
–– Abrasion – coming into contact with the moving belt.
–– Impact – coming into contact with moving baggage.
–– Entanglement – items of clothing or jewellery being caught in the moving conveyor.
(b) Control measures:
–– Control of the speed of the conveyor.
–– Reduction in gaps in the belt at critical points such as turns.
–– Replacement of worn conveyor parts.
–– Use of emergency stops in the event of blockages or other emergencies.
–– Use of photo-sensitive detectors.
–– Use of a klaxon or strobe warning lights in the case of an inadvertent start-up.
–– Use of workers to assess the conveyors for blockages and to assist passengers when this is seen to be
necessary.
–– Providing signage which:
–– Advises caution when removing baggage from the conveyor.
–– States the action to be taken in the event of a blockage.
–– Warns against placing hands or feet on the conveyor.

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Question 4
(a) A runaway reaction is an uncontrolled exothermic reaction where the heat produced exceeds the heat removed.
The surplus heat raises the temperature of the reaction mass and hence the reaction rate, resulting in a runaway
reaction. At this point the rate of heat production is exponential whereas the rate of heat removal is linear.
(b) The conditions that might give rise to such an event include:
–– An inadequate understanding of the process chemistry and thermochemistry by the operators.
–– Inadequate design for heat removal and inadequate provision of, or failure in, cooling of the reaction.
–– Inadequate control systems and safety systems.
–– Inadequate operational procedures, including training.
–– The presence of a strongly exothermic reaction.
–– The presence of contaminant catalysis.
–– Excessive quantities of reactants present in the reactor.
–– The lack of sensitive temperature detection and control.
–– Inadvertent insulation of the reaction vessel where solid residues have built up on the internal walls.
–– Mixer failure with loss of agitation.
(c) The design and operational features of chemical processes that are necessary to prevent such an event should
be to carry out a hazard and operability study (HAZOP) on the reaction process. The results from the HAZOP
should then be used to incorporate design features such as high integrity temperature detectors linked to the
cooling or reactant addition system with a pressure rise detection system that should be linked to the cooling,
venting or auto shut-down system. The vessel should be protected by correctly sized bursting discs and an
agitator failure alarm should be fitted.
Other measures might include designing the plant to contain the maximum pressure; fitting emergency relief
vents and ensuring vented material goes to a safe place; having a facility in place to “crash cool” the reaction
mixture if it moves outside set limits; and ensuring the process is capable of adding a reaction inhibitor to kill the
reaction and prevent runaway. Finally, operators should be able to dump the reaction into a quenching fluid as a
last resort.

Operational features should be introduced such as ensuring only high calibre operators are employed and
decision-making requirements by operators employed in such processes should be included. Furthermore,
decision-making requirements by operators in response to adverse operating conditions should be minimised.
Maintenance or raw material handling should be controlled to ensure they do not introduce potential catalysts
or contaminants into the reaction and the rate of addition of reactants should be limited to ensure inappropriate
scale-up or fouling is avoided.

Other operational features might include having robust operating and emergency procedures in place; consulting
frequently with workers; training and supervision of operators; maintenance of equipment; and controlling any
modifications to the process using management of change procedures.

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Question 5
(a) In the event of an uncontrolled release, emergency response measures would need to be in place to bring the
situation under control as quickly as possible and to localise the release and contain it. There would be a need to
prevent and minimise the harmful effects of the release on people, property and the environment both inside
and outside the installation with the use of safety systems, alarm systems and the assistance of the emergency
services. Clear and well defined plans should be made available for quick and effective use by the on-site
emergency response teams and the emergency services to optimise the use of resources and, where emergency
equipment and manpower are limited, provision should be made for mutual assistance from neighbouring
industrial activities.
There may also be a legal requirement under national laws to have emergency response measures in place and
in the event of an inquiry following a major accident, the emergency plan will be useful to demonstrate that the
parties concerned had done all that was reasonable for them to do in preparing for such an event.

(b) The general emergency planning measures that should be taken by the competent authorities in association
with the works management of the installation will include the need to establish arrangements for an on-site
emergency plan, which should be drawn up by the management of the installation, together with arrangements
for an off-site emergency plan. These plans are drawn up following consultation with various bodies such as the
fire and police authorities and the hospital and ambulance services and should address the response required
during every phase of the emergency, both the immediate needs and the longer-term recovery. Plans for on-site
and off-site should be consistent with each other and should ‘dovetail’ together. These arrangements should also
cover the need to ensure that regular rehearsals are carried out in order to keep the off-site plan in a state of
readiness. The Code of Practice emphasises that competent authorities should make arrangements to ensure that
safety information is provided to members of the general public.

Question 6
(a) Features of floor design that help to reduce slipping:
–– Minimise any changes in the floor level. If levels must change, use ramps rather than steps when connecting
pedestrian pathways.
–– Ensure the maximum ramp slope does not exceed 1:12.
–– Use slip-resistant floor tiles.
–– Avoid sudden transitions in floor surface texture, if possible. If such transitions occur, ensure good lighting and
visual cues highlight the change.
–– Surfaces of floors and traffic routes which are likely to get wet or be subject to spillages should be of a type
which does not become unduly slippery. A slip-resistant coating should be applied where necessary.
–– Floors near to machinery which could cause injury if anyone were to fall against it (for example, a
woodworking or grinding machine) should be slip-resistant and kept free from slippery substances or loose
materials.
–– At entrances to buildings, fibreglass gratings can be used with grit particles moulded into the upper surface to
provide very good slip resistance.
(b) Methods of reducing the slip potential of the floor in use could be:
• To stop floors becoming contaminated in the first place. By using entrance matting so footwear is
dried before workers walk onto an area where they might slip, such as tiled flooring. Ensure any leaks from
machinery are cleaned up straight away so operators and passers-by do not walk in it. Plant and equipment
should be well maintained to minimise the likelihood of spills or leaks and tasks should be designed to
minimise spillages. Pedestrian and vehicle routes should be planned to avoid areas which may become
contaminated so that workers are kept away from places where they might slip or trip.

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• Using the right cleaning methods. By making sure that the cleaning method being employed in the
workplace is effective for the type of floor and does not introduce more slip or trip risks while cleaning is
being carried out. Smooth floors should be left to dry after cleaning and pedestrians, who may be at risk of
slipping, should be excluded until the floor is dry. Effective cleaning arrangements should be in place to deal
with spillages and they should be promptly removed or cleaned up to prevent workers and others (visitors,
etc.) from slipping. Cleaners should use the appropriate detergent mixed at the correct concentration to
ensure no slippery residue is left behind after floor cleaning.
• Consider the flooring and work environment - housekeeping. Flooring should be regularly checked for
loose, damaged and worn carpets or tiles which may trip workers and others, and replaced as needed. Floors
likely to get wet or have spillages on them should be of a type that drains and does not become unduly
slippery so that workers can move from one area to another without the risk of slips or trips. Lighting should
be sufficient so that slopes or steps are clearly visible. Walkways and work areas should be kept clear of
obstructions and regularly checked by managers and supervisors to ensure slip and trip hazards are eliminated.

SECTION B
Question 7
(a) Automatic fire protection systems that should be in place:
–– Automatic fire detection arrangements, such as fire and smoke detectors, in the supermarket and restaurant
area.
–– Fire suppression systems, such as automatic sprinkler systems or foam flooding systems. These should be
subjected to regular testing.
–– Fire alarm system, with adequate call points located at strategic points in the store. This should be regularly
tested before the store is opened to the public.
–– Smoke control system, comprising roof vents and automatic self-closing doors.
–– Automatic fire service call-out.
(b) Factors to be considered when developing a safe means of escape:
–– Types and numbers of persons to be evacuated.
–– Distance to fire escape routes and the number of routes available.
–– Arrangements for evacuating members of the public, which should include:
–– Use of the public address system.
–– The appointment of fire marshals with training in:
–– Their responsibilities.
–– Ensuring that all areas have been cleared.
–– Ensuring that:
–– Fire exit routes are kept free from obstruction and are clearly signed.
–– The routes from the supermarket and restaurant are sufficiently separated to avoid crowding and
confusion.
–– Location of clearly marked assembly points:
–– In a safe position away from the building.
–– Positioned where they would not obstruct access for the emergency services.

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–– Provision of emergency lighting in the event of failure of the main supply.

–– Arrangements for liaison with the emergency services.
–– Allocation of clear responsibilities to workers for giving assistance to customers, particularly those who
might be disabled.
–– Arrangements for the disabling of lifts and for locking the tills to prevent opportunities for theft.
–– Completion of regular fire drills, at least every six months.

Question 8
Measures that should be considered in order to help reduce risks associated with the movement of vehicles in a
workplace could be:

• Safe Site
Traffic routes should be fit for purpose with a smooth and stable surface, wide enough and with sufficient
headroom for the types of vehicle that will use them. Sharp bends, blind corners and steep gradients should
be eliminated if possible and where this is not possible, convex mirrors should be sited on those blind corners
that cannot be avoided. A one-way system is preferable to minimise the need for vehicles reversing, together
with passing places for vehicles. Speed limits should be introduced and enforced and speed retarders (chicanes
or “sleeping policemen”) put in place to discourage people from driving too fast on site roads. Good levels of
lighting should be provided, particularly for the transition areas between the inside and outside of buildings.
Vehicles and pedestrians should be “separated and segregated” with safe access and egress for pedestrians and
clearly marked crossing places. Employees working in close proximity to traffic routes should be issued with high
visibility clothing and its use should be mandatory.

• Safe Vehicle
Most vehicles used in the workplace should meet the requirements of the Machinery Directive (2006/42/
EC), which has specific requirements relating to the design and construction of all machinery, but in some cases
there are specific supply standards for mobile plant, e.g. some lift trucks. Any power take-offs, chain drives, or
exposed hot exhaust pipes should be guarded so as to prevent harm to drivers or operators. Vehicles that are
operating in areas where there is a danger of rolling over should be fitted with a Roll-Over Protective Structure
(ROPS) and where there is a danger of the operator being struck by falling material (such as in a warehouse or
construction site) then a Falling Object Protective Structure (FOPS) should be installed. Seat restraints should be
fitted and supervisors instructed to ensure they are worn, unless there is a specific reason not to as judged by risk
assessment. Exceptions might be a warehouse lift truck operator picking orders in a warehouse (or similar work),
where the surface is good, vehicles move slowly, and operators need to get in and out of the truck frequently.
Where this is the case, instructions should be clear and enforced.

Drivers should be able to see clearly around their vehicle, so they can see hazards and avoid them, and vehicles
should be clearly visible to pedestrians and other vehicles in the workplace, so employers should consider fitting
additional lights, reflectors and flashing (or rotating) beacons, as well as horns for drivers to warn others that they
are approaching.

Vehicles with poor visibility, either to the side, front or behind, or those with high or wide loads, can severely
limit the drivers’ ability to see other vehicles or pedestrians from the driving position and extra mirrors, reversing
alarms, sensors or CCTV should be fitted in this case.

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Inspections of vehicles and associated equipment should be carried out, including daily driver checks before
using the vehicle and regular preventive (planned) maintenance inspections based on time or mileage. The
manufacturer’s guidelines on regular maintenance should be followed. Any vehicles utilising any form of lifting
equipment (such as lift and reach trucks) must be ‘thoroughly examined’ at appropriate intervals to make sure it
is safe to use. The intervals between thorough examinations should be at least every 12 months, or in accordance
with an examination scheme drawn up by a competent person.

• Safe Driver
Procedures for recruitment, checking references, induction, training, supervision, auditing and assessing
competence should ensure that workers are capable of operating the vehicles and attachments they use at work,
in all of the environments in which they are used. When choosing people to operate a vehicle in the workplace,
the initial requirements should be the same as those needed to drive a vehicle on a public road. In some cases
(such as with forklift truck drivers) regular health screening is advisable and sometimes required by national laws.

The information, instruction and training provided to workers should cover areas such as:

–– The layout of the workplace routes.

–– How and where to report faults or hazards.
–– Procedures for reporting accidents.
–– How to use the vehicle and equipment safely.
–– Information about, for example, particular dangers, speed limits, parking and loading areas, and procedures.
–– What PPE they need for the task they are going to do, and how to use it.
–– Information on the structure and level of supervision that will apply, and the penalties if they fail to follow
instructions and safe working practices.
–– How to follow any emergency procedures.
Workers should be monitored to make sure they are working in accordance with both the training they have
received and any safe systems of work.

For visiting drivers, induction arrangements might include providing information on site rules, including speed
limits and out-of-bounds areas.

Question 9
(a) Types of fault that may be found:
–– Poor earthing and a lack of earth continuity.
–– Damaged sockets and switchgear.
–– Covers missing from junction boxes.
–– Inadequate excess current protection, such as the fitting of fuses with incorrect ratings.
–– Means of isolation being in poor condition and badly sited.
–– Incompetent workmanship in the original installation.
–– Exposed live conductors due to damaged or perished insulation.
–– Short circuits caused by the ingress of fluids.
–– Corrosion of system parts, such as access grilles and transformer casings.
–– Unsuitability of the equipment for use in wet and corrosive conditions.

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(b) Technical information required:

–– Inventory of the equipment, with details of its type and manufacturer.
–– Operating parameters of the system, such as:
–– Voltage.
–– Current.
–– Number of phase.
–– Impedance/resistance.
–– IP classification, including the measure of protection against the ingress of water.
–– Circuit diagrams and manuals for the equipment:
–– Details of any modifications made.
–– Means of isolation and its location.
–– Earthing arrangements.
–– Type and size of cables.
–– Details on the operation of protective devices.
–– Copies of previous inspection reports.

Question 10
Precautions necessary for carrying out the repairs:

• Precautions for the scaffold:

–– Compliance with local regulations.
–– Use of suitable and sound material.
–– Adequate size and strength.
–– Means to restrict access when it is not in use.
–– Properly constructed by a competent person.
–– Should be stable and tied if necessary.
–– Inspection:
–– Prior to first use.
–– At periodic intervals thereafter.
–– After alterations or interruption in use.
–– Exposure to extreme weather conditions or other occurrences likely to affect stability or strength.
–– Working platforms should be guarded with rails and toeboards to protect against falls and falling objects.
• Precautions for ladder access:
–– Ladders should be secured.
–– Ladders should extend for a distance of at least one metre above the landing platform.
–– Three points of contact are required for workers using the ladder.
–– Arrangements for lifting tools and materials to the working area by means of a hoist or gin wheel.

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–– Properly secured roof ladders are required for work on a sloping roof.
–– Protection should be provided around areas where fragile material may be present.
• Edge protection on the roof:
–– Protection against falls from eaves or roof edges using guardrails.
–– If this is not practicable and the potential fall is over 2m, use other means, such as nets or harnesses.
• General workplace precautions:
–– For work carried out near to overhead power lines.
–– Provision of chutes for the removal of debris or rubbish.
–– Issue and use of PPE, including:
–– Hard hats.
–– Boots.
–– Eye protection.
–– Gloves.
–– High-visibility clothing.
–– Provision of adequate welfare facilities.

Question 11
(a) In order for a primary dust explosion to occur, the dust must be combustible, must be capable of becoming
airborne and mixing with air and its particle size and distribution must be capable of propagating flame.
Additionally, the concentration of dust must fall within the explosive limits, an ignition source of sufficient
heat energy must come in contact with the dust and the atmosphere must contain sufficient oxygen to sustain
combustion.
(b) Additional conditions necessary for secondary explosions to occur include the dislodgement of accumulated dust
from horizontal surfaces within the affected building by the initial pressure wave and consequent air turbulence
created by the primary explosion. This usually leads to an airborne suspension of combustible dust throughout
the affected area, which is ignited by the original primary explosion ignition source or by products from the
primary explosion which have caught fire or by another ignition source with sufficient heat energy (Minimum
Ignition Energy (MIG)) within the affected area.
(c) The intention of inerting a process is to prevent the oxygen concentration rising to the point at which the
atmosphere inside the equipment is flammable. This will require that the oxygen content is measured, and is
maintained below the Limiting Oxygen for Combustion (LOC) level.
The four key features of a nitrogen inerting system would be the following:

–– A well-controlled supply of nitrogen at the correct pressure.

–– A monitoring and control system with a number of oxygen level sampling points which must be adequate to
ensure the Maximum Allowable Oxygen Concentration (MAOC) is not exceeded in the system which has to
be protected (known as the Set Point). These sensors must be of a type and calibrated to ensure they detect
the presence of contaminants in the system which could interfere with readings.
–– The system should be sealed and the number of locations where air can enter the plant or process must be
eliminated so far as is possible.
–– There must be a safe means of shutdown if detected oxygen levels are too high (known as the Trip Point),
usually by means of a reliable electronic control system.

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(d) Design features that would minimise the likelihood and effect of a dust explosion, might be the initial design of
the ducting and equipment to withstand the effects of an explosion; the importance of ensuring the ducting
was dust tight; providing local exhaust ventilation at points of transfer; installing explosion relief or suppression
systems together with systems for suppressing fire; using screw conveyors instead of pneumatic systems for
moving materials; providing a magnetic extraction system for removing metal from product fed to the plant;
interlocking equipment to prevent overfilling of vessels and over-pressurisation; using instrument systems with
integral emergency shutdown; using intrinsically safe electrical equipment and bonding all metalwork to earth;
preventing dust build-up in the plant by the use of sloping surfaces; and introducing a mechanised system for the
humidification of the air.

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