Nebosh National Diploma Unit C Revision Pack

NEBOSH NATIONAL DIPLOMA UNIT C REVISION PACK
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NEBOSH National Diploma Unit C Revision Pack Revision Questions
NEBOSH NATIONAL DIPLOMA UNIT C REVISION PACK

SUBJECT REVISION QUESTIONS INTRODUCTION SHORT QUESTIONS LONG QUESTIONS ANSWER NOTES INTRODUCTION SHORT QUESTIONS LONG QUESTIONS 11 13 24 1 3 7 PAGE
Copyright RRC Training
INTRODUCTION
Since there are, as yet, few Unit C National Diploma examination questions, those presented here have been selected and adapted from past NEBOSH National Diploma Part 1 and 2 examination papers to exercise the various techniques that are expected in the examinations and also to give a representative coverage of the topics covered by the syllabus. The broad approach to tackling any examination question is as follows:
Read the question carefully and thoroughly. Note the first word of the question or sub-question (discuss, describe, explain, outline, list, etc.) which indicates what type of answer the examiner wants. Note the allocation of marks at the right hand side of the question or subquestion. This will give you an idea of how much information is required and, therefore, how long you need to spend on each part. Note carefully any ways in which the question suggests subheadings for the information required such as "....use, storage, transport..." or "design, construction, maintenance...". These are not simply extra descriptive terms but should be used to subdivide and structure your answer to ensure that each topic is covered.
You can apply these general techniques on the questions that follow. It is suggested that you practice answering the question first of all, then compare your work with the guidelines given in the answer notes.
Short Questions
In the examination allow 10 minutes for each question. 1. Outline the basic principles of operation of: (i) heat detectors and (ii) smoke detectors for use in an automatic fire detection and alarm system, explaining the circumstances where each would, and would not be appropriate. (10) 2. Outline the health and safety issues to be considered when planning the demolition of a two-storey detached house in a residential street. (10) 3. Explain, with the aid of diagrams where appropriate, the concept of 'integrated pollution prevention and control' (IPPC). (10) 4. Direct contact with a live, mains voltage electrical supply can result in serious injury or death. Outline a hierarchical range of measures intended to prevent or limit the effect of such contact. (10) 5. Outline the technical and procedural measures needed to minimise the likelihood of structural failures of pressure vessels. (10) 6. Identify: (i) the factors affecting the likelihood of an agricultural tractor overturning. (6)
(ii) the measures that may be necessary to minimise the risk, or mitigate the effects, of a tractor overturn. (4) 7. The number of injuries at the tools of mechanical power presses fell significantly after the introduction of the Power Presses Regulations 1965, the main requirements of which now form Part IV of the Provision and Use of Work Equipment Regulations 1998. (i) Summarise the specific legal duties placed on employers in respect of power presses that are additional to general machinery safety requirements. (4) (ii) Review the factors other than legislation that may have influenced the decline in power press accidents over the last 40 years. (6) 8. Identify the particular problems posed by industrial robots in a workplace. (10) 9. (a) (b) Explain the purpose of non-destructive testing (NDT) on items of plant. (2) Other than visual inspection, outline the principles, benefits and limitations of TWO NDT techniques. (8)
10. Describe, with practical examples and sketches where appropriate, the characteristic features of, and the factors that promote, the following types of failure in metals (i) Buckling (ii) Creep (5) (5)
11. A process plant stores and uses large quantities of a substance that has the potential for giving rise to an explosive atmosphere. Given that the substance cannot be substituted, outline the hierarchy of control measures required by the Dangerous Substances and Explosive Atmospheres Regulations 2002 to minimise the probability of an explosion, providing examples of the specific preventive measures that may be necessary. (10) 12. Regulation 9 of the Lifting Operations and Lifting Equipment Regulations 1998 specifies fixed intervals between thorough examinations of lifting equipment but also includes an option for thorough examination to be carried out in accordance with an "examination scheme". Outline the factors that a competent person would need to take into account when deciding whether less frequent examinations might be justified, identifying the documents that would be needed for such an exercise. (10) 13. With reference to the Fire Precautions (Workplace) Regulations 1997: (i) Identify the workplaces to which the Regulations do NOT apply. (3) (ii) List the factors that should be considered when carrying out an assessment of fire risk (7)
14. Outline the possible factors that could have led to the collapse of racking within a cold store in which forklift trucks operate. (10) 15. Outline the factors that should be considered in ensuring the suitability of work equipment in order to comply with Regulation 4 of the Provision and Use of Work Equipment Regulations 1998. (10) 16. Outline the main duties of sub-contractors under the Construction Design and Management Regulations 1994. (10) 17. Outline the precautions to be taken in the storage of flammable substances. (10)
18. (a) List the hazards associated with the use of mobile elevated work platforms. (4) (b) Outline the precautions to be taken in order to prevent accidents when using mobile elevated work platforms. (6)
19. (a) Identify when a fixed guard would be an appropriate means of providing protection against mechanical hazards.
(2)
(b) Outline the factors to be considered in the design and use of fixed guards in order to ensure that persons are adequately protected. (8) 20. (a) Identify the hazards associated with automatic guided vehicles (AGVs) used to transport palletised goods in automated warehouses. (5) (b) Outline the measures that should be taken to reduce the risk of accidents from the use of AGVs. (5) 21. Identify the particular features of a working environment that should be taken into account when portable electrical equipment is used at work. (10)
Long Questions
In the examination allocate 40 minutes to each question. It is well worth planning your answer before you begin. 1. 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. (8)
(ii) Describe the main principles of scaffold design, erection and use to ensure the stability of such a scaffold. (12) 2. (a) Outline the dangers against which protection is provided by a fuse in an electrical circuit and explain how such protection is achieved.(5) (b) Identify the principal limitations of a fuse as a protective device. (5) (c) With respect to UK mains voltage electricity, describe the methods and devices other than fuses designed to improve electrical safety. (10) 3. 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: (i) and (ii) Help to ensure that people inside the building were able to escape to a place of safety (10) 4. Leakage of flammable gases may present a serious explosion hazard. Explain the circumstances in which each of the following could occur: (i) A confined vapour cloud explosion. (7) (7) (6) (ii) An unconfined vapour cloud explosion. (iii) A boiling liquid expanding vapour cloud explosion. Limit the spread of fire, smoke and combustion gases (10)
5. 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 been addressed in the technical file for the machine in order to demonstrate that the machine is in fact safe. (20) 6. (a) Outline the particular problems that may be posed by the use of industrial robots. (6) (b) Explain how the risk of injury to personnel working with or in the vicinity of industrial robots might be minimised. (14)
7. 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. (ii) Outline the factors that may contribute to such a failure. (6) (6)
(iii) Describe the measures that could have been taken which might have prevented the failure. (8) 8. (a) By reference to the Pressure Systems Safety Regulations 2000, explain what is meant by a "pressure system". (6) (b) A compressed air system is to be installed in a motor vehicle repair workshop. Describe the safety requirements that should be met before the system is commissioned. (14) 9. (a) Explain the principles of an interlocked machine guard. (b) Identify ways in which the following types of electrical, camactivated position switches (limit switches) may fail to operate as intended: (i) (ii) Negatively operated (or "normally open"). Positively operated (or "normally closed"). (3) (3) (4)
(c) By means of a labelled sketch, show the method of operation of an interlocked guarding system incorporating two position switches (limit switches) operating in opposite modes together with a simple selfmonitoring arrangement utilising the "spare" contacts within each switch. (10) 10. The Construction (Health, Safety and Welfare) Regulations 1996 require certain places of construction work to be inspected by a competent person. (i) Identify when statutory inspections of supported excavations must be carried out. (3) (ii) State the information that should be recorded in an excavation inspection report. (5)
(iii) Describe the particular features of an excavation that could result in it being considered unsafe. (12) 11. In relation to welding operations carried out in a confined space: (i) Identify the possible hazards to health and safety. (8) (ii) Outline the precautions that should be taken to reduce such hazards. (12) 12. A company is planning to move to new multi-story offices due to business expansion. Outline the issues that will need to be considered when assessing the level of compliance with the Workplace (Health, Safety and Welfare Regulations) 1992 at the new premises. (20)
13. Maintenance of lifts can expose both maintenance staff and users of the building to risk. (i) Explain the main dangers of such work. (12) (ii) Outline the precautions that should be taken to minimise the risks during lift maintenance. (8) 14. (a) Outline the main requirements of a safe means of escape from a building in the event of fire. (10) (b) Outline the fire safety issues on which employees should receive training. (10) 15. An industrial process produces residue in the form of a granular, hazardous waste that is transported from the site in skips. Describe the procedures that should be adopted for the handling and storage of the waste on site, and its transport to the disposal facility. (20)
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NEBOSH National Diploma Unit C Revision Pack Answer Notes
INTRODUCTION
These notes do not represent model answers but are intended to highlight, using actual questions, the key issues to consider when structuring answers to NEBOSH Diploma examination questions. These can be summarised as follows:
Analyse the question carefully to ensure that you fully understand what you are being asked to do. Note the first word of the question or subquestion (discuss, describe, explain, outline, list, etc.) which will give some indication of what type of answer the examiner wants. The allocation of marks at the right hand side of the question or subquestion will give you an idea of how much information is required and, consequently, how long you should spend on each part. For the short questions you have about 10 minutes in which to accumulate 10 marks. The longer questions are worth 20 marks and you have up to 40 minutes to spend on each one. However, you should be very careful about time management ensuring that you complete all questions and that you leave at least 5 minutes at the end to check through your completed paper. Often the phrasing of the question will suggest key topics that need to be addressed within the answer and consequently how the answer should be structured. One simple reason for not scoring many marks for a question is that the answer is too narrow and does not cover all the issues that marks are available for. In the answer notes that follow there are a number of examples showing how to ensure that your answer is broad enough to cover all the essential points. For the long questions you should spend at least 5 minutes planning your answer in order to ensure that all relevant points are identified. It is not necessary to cross out the answer plan, provided it is labelled as such, since it may contain creditworthy points that have not been developed in the full answer due to time pressure.
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Short Questions
1. Based on information included in element C3. This question is clearly structured, requiring that for two different types of fire detection equipment, you outline the basic principles of operation, and also explain the circumstances where each would and would not be appropriate. Consequently the shape of the answer is as follows: 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 nonfire conditions such as 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 caused 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 nonfire conditions such as kitchens or hotel bedrooms in positions not rapidly affected by smoke. 2. Based on element C9. This is a straightforward demolition question but it is important to note the particular circumstances of the scenario which relates to a two-storey detached house in a residential street. Consequently, general demolition options such as, 'use explosives', are not appropriate.
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The question asks you for an outline of the health and safety issues. This can be presented chronologically as follows:
Such as hard hats, protective footwear, eye protection, respiratory protective equipment. Notification of the work in accordance with CDM Regulations. Protection of the public by barriers and consideration of vehicle movements. Protection of adjoining properties with fencing and shoring up. A systematic approach using a comprehensive method statement, 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. 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 hazardous waste, and the use of licensed carriers. Safe use of plant and equipment with consideration of maintenance, inspection/examination and training. Provision of personal protective equipment control of general dust through damping down, and the identification and control of asbestos. Provision of welfare facilities.
3. Based on element C10. This question has been adapted by RRC from a similar previous Diploma Part 2 question on IPC, which was the regime in force prior to IPPC. This question asks for an explanation of the concept of 'integrated pollution prevention and control' (IPPC), but in addition to this your explanation is also required to include the use of diagrams. In approaching this type of question we first need to identify the key issues associated with IPPC. These include:
The IPPC regime is applied in the UK under the Pollution Prevention and Control Regulations 2000. These regulations were made under the Pollution Prevention and Control Act 1999.
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The concept is for industry to prevent or, where this is not possible, reduce pollution by means of an integrated approach. Only applies to certain industries. "Integrated" means that it takes a holistic view taking account of the whole environmental performance of an installation. This covers:

Emissions to air, water and land. Generation of waste. Use of raw materials. Energy efficiency. Noise. Prevention of accidents. Risk management, etc.
IPPC involves authorisations (i.e. application and issue of permits by enforcing authority) which are based on the use of Best Available Techniques (BAT). Application for a permit also involves the preparation of a "site condition report" which is used for site remediation and decommissioning (i.e. so that when an installation is closed, the land can be returned to state it was in at the time the permit was originally granted). BAT (which is steadily replacing the former regime of BATNEEC and BPEO) - basically means:

BEST most effective protection for the environment as a whole. AVAILABLE economically and technically viable. TECHNIQUE the technology and the way it is installed, maintained, etc.
Permits are subject to review and compliance is monitored (monitoring results reported to authorities). 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.
4.
Based on element C8. This question simply requires you to consider the measures available to protect from electric shock. However, note that the question requires you to outline the measures as a hierarchy. The following is an indication of how the answer should be structured:
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Isolation Work dead, lock off isolators. Prevent Contact Insulate live parts. Prevent/Deter contact Use barriers and enclosures. Prevent Unintentional Contact Location safe by position or use obstacles. Limit Effect of Contact Residual current devices. Other Measures Fuses. Safe working procedures. Safety equipment such as insulated mats, tools. Personal protective equipment.
5.
Based on element C5. This question asks for an outline of both the technical and the procedural measures needed to minimise the likelihood of structural failures of pressure vessels. It is important, therefore, to ensure that both are considered in your answer, which should include the following issues:
Design specification to ensure fit for purpose and CE marking. Safety features such as relief valves, sight gauges, level gauges. Regular checks, tests, inspections and maintenance. Statutory examinations 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.
6. Based on element C7. This is a straightforward and clearly structured question concerning the risks of an agricultural tractor overturning. The two parts require you to identify, the factors affecting the likelihood, and also the measures that may be necessary to minimise the risk or mitigate
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the effects. Consequently your answer is best structured in two clear parts as follows: 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 pressures 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. 7. Based on element C6. This is an interesting question concerning power presses that looks at both legal and other factors affecting their safety. The first part of the question requires specific knowledge of the legal duties placed on employers in respect of power presses that are additional to general machinery safety requirements. These are contained in PUWER and your summary should include the requirement to inspect the guards on power presses within the first 4 hours of the working period. The second part of the question requires some thought on the factors that might have influenced the decline in power press accidents over the last 35 years. Note that the question specifically excludes legislative factors and therefore your review should concentrate on technical factors, such as the replacement of power presses with other types of equipment, and improvements to guarding and testing; and social factors, such as the decline in the manufacturing industry generally, and improvements in the quality of health and safety management. 8. Based on element C6. This is a straightforward question requiring you to identify the particular problems posed by industrial robots in a workplace. Note that it is problems that need to be identified and not a list of
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possible safeguards. Your answer, therefore, should refer to the acknowledged issues such as:

9.
The possibility of sudden, rapid, unpredictable, sweeping movements. The consequences of aberrant behaviour. Software faults which are difficult to detect but may precipitate dangerous activities. The 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.
Based on element C5. This question is clearly structured, and in two distinct parts. The first part, for 2 marks, asks for an explanation of the purpose of non-destructive testing (NDT) on items of plant. A simple explanation such as "fault detection before total failure without affecting integrity" would suffice. The second part is clearly sub-structured, asking for an outline of the principles, benefits and limitations of TWO NDT techniques. Consequently you need to select two techniques from the available range, which includes 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 a permanent record. Limitations Radiation hazards, expensive.
10. Based on element C5. Buckling is where one side of the component yields when subject to axial compression loading. Once yielding begins and the plastic deformation region is entered, it continues to failure without any increase in load. Examples include a scaffold pole and also an overloaded crane jib (topside is under tension, bottom under compression). The following factors are important in promoting buckling:
Excessive non-uniform loading. Structural weakening by removal of cross-members.
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Use of bent members.
Creep is a gradual yielding/extension when a component is stressed to its elastic limit. The component deforms plastically. The following factors are important in promoting creep:
Continuous loading with unequal relaxation of stresses. High temperature can accelerate creep failure.
11. Based on elements C2, C4 and C8. Regulation 6(4) is the relevant regulation here. Key to this question is recognising it is wanting details of measures to stop an explosion happening in the first place rather than mitigating the effects of an explosion. The hierarchy is thus:
Minimise quantity of substance. Avoid/minimise possibility of release (enclosure, plant maintenance). Control releases at source (detection, automatic shut-off). Prevent formation of explosive atmosphere (ventilation, inerting). Measures for collection, containment, removal to safe place. Control of ignition sources zoning, permits, anti-static, no-smoking, Explosion proof equipment/installations. Protection of vessels from adverse weather, collisions with vehicles. Segregation of incompatibles.
12. Based on element C5. Reg 9 of LOLER requires that lifting equipment be thoroughly examined at least every:
6 months (for lifting persons OR for lifting accessories exposed to conditions causing deterioration). 12 months (for all other lifting equipment).
You may however draw up your own examination scheme as an alternative. In that case the factors to take into account include:
Machine age. History (frequency, loads, environment, maintenance, accidents, faults, repairs, modifications all supported by documentation). Performance history when compared to similar equipment. Design spec that the machine has been made to. Manufacturer recommendations and whether they have been followed!
13. Based on element C3. Take note of the word 'not'. (i) These regulations were amended in 1999 (S.I. 1999/1877) and 2003 (S.I. 2003 /2457). They do not apply to workplaces of sole self Copyright RRC Training 19
employed; those located in private dwellings; any workplace which forms part of a mine, other than buildings on the surface at a mine; means of transport including any vehicle, vessel, aircraft or hovercraft; locomotive or rolling stock, trailer or semi-trailer used as a means of transport; any ship within the meaning of the Merchant Shipping Act 1995 other than a ship which is under construction or under repair by persons other than the master and crew; offshore installations; workplaces that come under the Construction (Health, Safety and Welfare) Regulations 1996: and outdoor places of agriculture and forestry that are sited away from the main buildings; tents or movable structures. Many of these places have their own fire regulations. (ii) The main factors for an assessment should cover means of preventing a fire from starting, methods of detection, methods of raising the alarm, fire-fighting measures and the means of escape, in addition there is the training of staff. As with any risk assessment attention has to be paid to those who might be injured, the disabled, children, senior citizens. 14. Based on elements C1, C5 and C7. There are three groups of reasons for the collapse, the construction of the racking, the possible collisions of the forklift trucks and the failure of systems. The racking if made of metal may have suffered from brittle fatigue due to the intense cold, they could have been set up with insufficient width between racks so that the FLTs had difficulty to manoeuvre, the racking may not have been bolted down to the floor, it could have been of poor design and not stable when heavy loads may have been stacked on the top shelves. The FLTs may have been travelling too fast or, when reversing, collided with the racking, there could have been ice on the floor so that they skidded, potholes in the floor could have caused the load to shift and crash into the structure, the drivers may have made errors of judgment when negotiating their way around. The system failures could have included that the risk assessments were not suitable and sufficient, there could have been a lack of inspection and maintenance, the drivers selected may not have been suitably and sufficiently trained, there may have been a lack of supervision, monitoring or reporting procedures, also excessive work demands. 15. Based on element C5. Another 'outline' question. This question covers the basic requirements for the Regulations, and include the selection of equipment that is suitable for the job in hand, suitable for the environment and situation in which the work is to be carried out. The equipment must be properly constructed and assembled, properly maintained and in date for tests. The operator must be competent to use the equipment in the environment and for the task in hand. In addition the equipment should conform to the EU standards (CE) marked. Each point should be briefly explained, perhaps with an example.
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16. Based on element C9. Do not just list the duties, put them in with some brief explanation. To co-operate with the principal contractor. So far as is reasonably practicable to provide the principal contractor with a risk assessment and the aspects of the Management of Health and Safety at Work Regulations 1999 which effect any person by the work being carried out. To comply with the directions of the principle contractor as under Regulation 5. To comply with the Health and Safety plan and rules. To provide the principal contractor with information as to death, injury, etc. as under the Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 1995. To control the activities of his employees so that no employee shall work unless he has been provided with information as in paragraph 4, as to the name of the principal contractor, the planning supervisor and the contents of the health and safety plan, as relevant, etc. 17. Based on element C4. Again 'outline,' so a list will not be acceptable. The details should include the storage of both large and small quantities and show how each may prevent fire. Large quantities to be stored outside, either in tanks or in a well ventilated store. Ideally each type of substance should be stored separately. Signs to state Flammable substances on outside. Stores to be locked to prevent arson. Empty containers to be kept separately from full ones. Lids to be in place to prevent fumes escaping. Fire equipment, alarms and flame detectors. With small quantities, a maximum of 50L of all substances to be held in the workshop, then stored in fire proof cupboards. Each cupboard to have sign to show the contents. Decanting to be done in a well ventilated space, with the use of drip trays to catch spills. Substances to soak up spillage on hand and this information as to how this is to be disposed of to a safe place. 18. Based on elements C7 and C9. (a) Your list should include, falls from a height of either men or materials, instability of the vehicle, striking or being struck by other vehicles, trapping and impact hazards, mechanical failure, obstructions, overhead power lines and adverse weather conditions. (b) Outlined examples of precautions include, selection and training of operators, the scissors mechanism to be guarded to prevent trapping, stabilisers fully extended to ensure stability of the vehicle, erection on firm ground, correct positioning to prevent operators having to over reach, toe boards to stop things being kicked off and guard rails to prevent operators falling off, avoidance of raising under power lines and other obstacles. Persons should not climb up or down unless the platform is in the lowered position. These factors will require safe systems of work, risk assessment and assurance that the safe working load is never exceeded. Before using the vehicle it should be inspected and properly maintained. To prevent persons and vehicles crashing into it there should be barriers and there may be a need for traffic directors to control the flow of other vehicles in a road way.
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19. Based on element C6. (a) A fixed guard is the best type of guard but as it is permanently in place there are limitations to its use. It should never be removed by an operator, only by a maintainer when he wishes to adjust, inspect or lubricate the parts guarded. The generally accepted places include protection over transmission machinery, shafts, belt drives, gear boxes, clutches, etc. (b) This part asks for an outline so some details are required. The factors to be considered include:

The method of fixture and the frequency with which it will have to be removed for maintenance. The noise due to the material due to vibration, a solid guard is more noisy than one made of wire mesh. Rigidity, a guard is to protect the operator so it must be strong enough to withstand being bumped into. Heat is contained in a solid case and this could be a cause of fire. The ergonomics of the operator, the guard should not create other hazards due to the operator having to work around it. The material used, as above, must be strong enough, there is a BS for the specification of wire mash. The guard needs to be maintained, all the bolts must be secure and not allowed to vibrate loose.
20. Based on element C7. (a) Automatic guided vehicles are part of the syllabus, they are often used in modern warehouses and production lines. As AGVs are unmanned they are computer controlled, so the programming can go wrong. They avoid collision by the use of sensors so these could fail. Other sensors should cause them to stop if they encounter an obstruction. Loads can fall off due to bad or unstable loading of the vehicle, parts of the load could overhang and strike objects or persons when passing. A wide load could cause a trapping hazard. The ground could have faults, holes, steep gradients which could shake the load off. (b) The hazards identified in part (a) will give a lead into the precautions, in addition there are points such as the good maintenance of the vehicle, if any defects occur in the computer programme then the vehicle should stop and the main computer should recognise this and take action to make the system safe. Segregation of the vehicle routes will prevent pedestrians walking into them, the sensors need to be regularly tested. 21. Based on element C8. The key words here are 'the particular features of the working environment', so the answer must not be just on portable
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electrical equipment. Cables may have to be dragged through wet and muddy areas, so damp could seep into the connectors. Vehicles may run over the cables and either break them or become entangled in them. Abrasion, cuts due to running over sharp edges can cause faults. As the question did not specify the type of environment then sites other than a construction site should be considered, the equipment may be used in an atmosphere that is dusty or has vapours from flammable substances and the equipment could be a source of ignition. Also the cables may be used in corrosive atmospheres. The equipment should not be used where there is a restriction of space, light or confined access, these are in accordance with the Electricity at Work Regulations 1989.
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Long Questions
1. Based on element C9. This question is designed to test your understanding of basic scaffold issues and, in particular, the factors relating to scaffold stability. The first part of the question for 8 marks requires you to outline the factors that may have affected the stability of the independent tied scaffold referred to. These should include overloading, impact, incorrect erection, poor materials, ground instability, extreme weather conditions, and unauthorised alteration. The second part of the question, for 12 marks, asks for a description of the main principles of scaffold design, erection and use to ensure stability. It is useful to construct your answer around these three issues to ensure that key points are not missed as follows: 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. 2. Based on element C8. This is a clearly structured question about electrical safety, with the mark allocation for each part indicating the level of detail required. Parts (a) and (b), for 5 marks each, require you to outline the purpose, means of operation and limitations of a fuse. The key point to make is that the primary function of the fuse is to limit overcurrent rather than prevent shock, providing a weak link in a circuit by overheating and melting if the current exceeds the safe limit.
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Part (c) asks for a description of the methods and devices other than fuses, designed to improve electrical safety. Consequently we need to consider both procedural measures such as maintenance and portable appliance testing, and also technical measures, such as circuit breakers, residual current devices, reduced low voltage, earthing (class 1 equipment) and double insulation (class 2 equipment) in order to address both issues. 3. Based on elements C2 & C3. This question is concerned with the principles and prevention of fire spread, and the provision and maintenance of means of escape. It is clearly divided into two parts with equal mark allocation for each. The first part is designed to test your knowledge of passive fire precautions and your answer should include:
Compartmentalisation. Fire-stopped voids and ducts. Concrete encasement of principal construction components. Incombustible stairways. Stock management. Segregation of high risk materials.
The second part is concerned with escape arrangement and your description should consider:
Routes and capacities. Travel distance. Signage. Emergency lighting. Electrical interlocking of lifts and escalators with alarm system. The appointment, training and role of fire marshals.
4. Based on element C2. This question simply requires an explanation of the circumstances in which each of the principal types of vapour cloud explosion could occur and consequently your answer should be structured as follows: (i) 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.
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(ii) 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. Shock waves and thermal radiation result from the explosion. (iii) 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. 5. Based on element C5. 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 and safety requirements. 6. Based on element C6. This is a clearly structured, straightforward question concerned with the hazards and precautions associated with the use of industrial robots. In outlining the problems posed by the use of industrial robots you should include issues such as:
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 or maintenance.
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Your explanation of how the risk of injury to personnel working with or in the vicinity of industrial robots might be minimised should cover:

7.
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 to work. Arrangements for uncovenanted interruptions and restarting. Possibility of software and hardware faults and the need for sophisticated audit procedures to identify. Operator training.
Based on element C5. This question is concerned with the integrity of materials and components and is divided into three distinct sections, with the mark allocation indicating the level of detail required for each. Section (i) asks for a description of the mechanisms and characteristics of fatigue failure which is a specific type of metal failure which usually involves the development of surface cracks around a stress concentration zone. In your answer you also need to make reference to the creeping nature of the cracks under repeated or fluctuating loading which is eventually followed by sudden brittle failure. For section (ii) answers should outline factors such as stress concentrations at sharp corners, screw threads, slag inclusions, residual stress points such as welds, corrosion pitting and heat-induced stress and embrittlement The final part of the question asks for a description of the measures that could have been taken which might have prevented the failure which include:

8.
Planned preventative maintenance procedures. Statutory inspections and testing. Non-destructive testing methods. Use of equipment within its design criteria. Attention to the suitability of materials used in construction.
Based on element C5. A system is one or more pressure vessels of rigid construction with any associated pipework and protective devices OR pipework with its protective devices to which a transportable gas container may be connected OR a pipeline and its protective devices which contains or is liable to contain a "relevant fluid". A relevant fluid
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here includes steam, gas at a pressure exceeding 0.5 bar above atmospheric pressure (at the temperature of the liquid or at 17.5C). For part b, the safety requirements include:

9.
Siting (vehicle collision, public access, segregation from flammables, noise considerations, etc). Design (standards (CE), capacity, construction materials, etc.) Installation (pressure gauges, relief valves, drain lines, marking and signage (SWP), guarding. Information/instruction to operators. Maintenance (procedures, scheme of examination, pre-commissioning checks).
Based on element C6. For part a), interlocking is when the machine cannot be started or placed in a dangerous state with the guard open OR, conversely, the guard cannot be opened when the machine is in a dangerous condition OR the opening of the guard shuts down the machine from a dangerous condition. (For part b) a negatively operated switch can be defeated by taping up the plunger; the spring may also fail and the contacts may weld together through arcing or from damage/debris inside the mechanism. Positively operated switches can fail due to misalignment (cam and cam-follower), wear/damage to plunger, over-travel of guard, etc. (Part c) requires a sketch showing the two switches in a circuit with a monitoring circuit with guard open and guard closed like the following diagram from the RRC notes:
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Positively operated (normally closed) position switch
Guard open
Guard closed
Lights off
Monitoring circuit
Negatively operated (normally open) position switch
Lights on
10. Based on element C9. Parts (i) and (ii) refer to the Schedules of the Regulations, there are similar duties for both excavation and scaffolding. (i) These duties come under Regulation 29(1) and are listed in Schedule 7 which states: Before anyone carries out work at the start of every shift; and after any event likely to have affected the strength or stability of the excavation or any part thereof, and after any accidental fall of rock or earth or other material. This could include if any flooding takes place or any alteration to the excavation or shoring. (ii) This information comes under Regulation 30 and is listed in Schedule 8. Name and address of the person on whose behalf the inspection is being carried out. Location of the place of work. Description of the place of work or part of that place inspected (including any plant and equipment and materials, if any). Date and time of inspection. Details of any matter identified that could give rise to a risk to the health and safety of any person. Details of the action taken as a result of any matter identified. Details of any further action considered necessary. Name and position of the person making the report. (iii) This is the more general part of the question where you are expected to consider how an excavation could become unsafe, the answers need not be for the same excavation. The sort of situations that
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could be described are: flooding, soil collapse, shoring collapsing, vehicles working too near the edge and falling in, people falling in, spoil or tools left on the edge and falling in, main services being disturbed and not disconnected so causing hazards, near by buildings having their foundations disturbed by the excavation, the work may include blasting or drilling and so cause excessive dust, it could be that work has to be carried out at night and so lighting is required, this entails electrical hazards. 11. Based on element C1. This question does not stipulate a particular type of welding, gas or electric. (i) The risks to health include those due to the welding operation as well as working in a confined space. These hazards include breathing difficulties due to the lack of oxygen; oxygen enrichment, fumes from the chemicals of the welding rods; explosion from a leaking gas cylinder; electric shock; arc eye from the electrodes, cramp; from the spelter, hearing damage; heat exhaustion; burns; claustrophobia; unsafe access and egress. (ii) Once the hazards have been identified the precautions should be obvious. There is always a need for rescue, fire and first-aid facilities. Gas cylinders should never be taken into a confined space, all the parts of the welding kit should be tested before use, including gas regulators, hoses and cylinders tested for leaks. There should be a competent supervisor on site during all working hours. Intrinsically safe lighting will be required. Permits to work will be necessary as under the Confined Spaces Regulations 1997. All persons must be competent and have had adequate training, information and instruction. 12. Based on C1. This is a very open question and so you need to consider the ergonomic factors as well as the welfare ones. The question does not give details as to the type of office work that are to be carried out or the number of men and women staff so these can be given figures to suit your experience. The Workplace (Health, Safety and Welfare ) Regulations 1992 have 21 different topics, of which Regulations 20-25 are the main facilities, so there is plenty of scope. You do need to outline what you would be looking for in order to comply with a particular Regulation. The more often forgotten Regulations include maintenance of the space and the equipment, devices and systems; Ventilation: windows and their cleaning; temperature; space; removal of waste materials; condition of floors, stairs, doors, lifts and escalators. 13. Based on elements C5 and C7. i) The hazards of lift maintenance should include both the maintainers and the public including disabled, blind, old and curious people. The answer can then be divided into these two categories. The maintainers are working on an unfenced piece of machinery which has weight, electrics, wire ropes and lifting gear. They often have to
30
ride on the top of the lift in order to get at the mechanisms, they could be crushed when the lift rides to the top of the shaft and comes close to the winding mechanism, of course they have to work with the doors open and in shaft with out the lift present. The public may not notice that as the doors are open that there is no lift, and so could fall down the shaft, the cupboards containing all the electrics may be open, the doors may be opening and shutting at different floors during testing. If the lift is present it is not safe to board while under test, at times the lift has to be drop tested, this can cause injury to anyone inside. (ii) The precautions are obvious, remember that a notice is not considered to be sufficient in a court of law, so firm barriers at all strategic places must be in place. 14. Based on element C3. (a) The question asks for the main requirements for a safe means of escape so details should be left out, alternative escape routes; keeping routes free of obstructions; short routes away from the fire; signs; emergency lighting; fire resistant walls, floors, ceilings and doors; exit doors opening to a safe place; alarms and tannoy messages are the things that should be outlined. The issues for fire safety training should start with fire prevention, smoking policy, use of electrical equipment, use and storage of flammable materials, etc. The action to be taken in the event of discovering a fire, raising the alarm, use of fire equipment, if trained. Then there is the training in the action on hearing the alarm, the orderly evacuation and dealing with customers and disabled persons, etc.
(b)
15. Based on elements C4 and C10. Procedures for handling and storage of waste include:
Hazard identification and risk assessment. Systems of work for control of exposure transport to skip and containment whilst in the skip. Prevention of overfilling of skip. Access for vehicle to collect skip. Security/marking of area. Adverse weather protection. Control of potential contaminated rain water run-off. Emergency procedures. Licensed carrier.
Transportation would include:
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Planned route to disposal site. Vehicle suitability. Load security. Consignment notes and pre-notifications. Marking of vehicle (waste may be dangerous for transport) and carrying of emergency information and equipment. Driver training/information. Involvement of Dangerous Goods Safety Advisor.
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NEBOSH National Diploma Unit C Revision Pack Revision Questions

NEBOSH NATIONAL DIPLOMA UNIT C REVISION PACK

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Excessive non-uniform loading. Structural weakening by removal of cross-members.

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Use of bent members.

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