National Diploma in Occupational Health and Safety Unit C: Workplace and

Work Equipment

Section B

7. (a) Under the Pressure Systems and Safety Regulations 2000 a pressure
system means a system comprising one or more pressure vessels of rigid
construction and associated pipe work and protective devises.

The pressure systems means the pipe work with its protective devices to
which a transportable gas container is connected.

The pressure system must contain a relevant fluid where relevant fluid can be
taken to mean steam, any fluid or mixture that is at a pressure greater than
0.5 bar or a gas dissolved under pressure in a solvent contained in a porous
substance at ambient temperature could be released from the solvent without
the application of heat, i.e. acetylene.

(b) Common causes of failure maybe as a consequence of over heating

caused by a low water level in a steam boiler. The main causes of this could
be a lack of testing and maintenance and inadequate standards of control.

Over pressurising caused by pressures in excess of the vessel capacity

leading to failure of the vessel. The main causes of over pressurising could
be failure of pressure relief devices, ie: the pressure relief valve is stuck in the
closed position and does not relieve any excess pressure, operator error due
to overloading, overfilling of the system and inadequate design and or lack of
information on the safe working pressure.

Corrosion may lead to loss of metal thickness and strength in the pressure
system which may subsequently lead to distortion and failure of the pressure
system/vessel. Sudden failure of the system results in an explosion with
devastating consequences.

(c) Technical measures to minimise the likelihood of failure of pressure

systems include the provision of safety devices such as a water gauge to
indicate the water level within a steam boiler, safety valves to prevent over
pressure within the pressure system, a pressure gauge to indicate the
working pressure and maximum working pressure allowed, high and low
water alarm within a steam boiler to indicate the water levels, blow down
valve to ensure the removal of settled water solids, the ejection of sludge and
emptying a steam boiler prior to inspection. In compressed air systems
doubling plates are used to increase strength of the steel cylinders at points
where strength is lost or strength is weakest, e.g. at inspection hatches or
legs.

Procedural measures would include the user of the system or owner ensuring
that a written scheme of examination is drawn up in relation to the pressure
system and examinations are made in accordance with the written scheme.
All users of the equipment should be competent to do so and have the
necessary instruction, information, training and supervision where necessary
to ensure that safe systems of work including recognising a developing
dangerous situation with over pressure etc. is recognised and dealt with
accordingly by the operator.
8. (a) LPG is heavier than air and therefore settles to low level drainage systems
and underground cavities. LPG storage systems should therefore be well
ventilated and free from underground drainage and cavity systems which
would allow accumulation of an explosive gas mixture.

LPG is a flammable gas. Storage precautions would include adequate

ventilation and the removal of any potential ignition sources.

LPG as a liquid is approximately half the density of that of water. If LPG is

spilt on water it will float on the surface before vaporising. Fire fighting
precautions in relation to LPG storage should include foam extinguishing
agents.

LPG is a colourless odourless gas and is therefore odorised prior to

distribution and storage in cylinders.

(b) LPG should be stored within a secure perimeter and fenced off to allow
adequate ventilation yet provide suitable security.

The compound should be appropriately signed that the compound contains

flammable materials and no ignition sources should be allowed to be present,
e.g. No smoking signs, no naked flames.

The LPG cylinders should be stored away from other habitable areas and or
other hazardous materials. Adequate separation distances should be
maintained in order to allow adequate ventilation and mitigate the
consequences of fire whilst allowing access and egress.

Where adequate separation cannot be provided due to space restrictions then

a fire wall, i.e. a wall preventing the spread of fire should be in place between
the LPG storage stack and any habitable buildings.

The number of cylinders which are contained within the compound and stored
together should be limited to reduce the quantities of LPG in any particular
location at any time. This would reduce the effects of or consequences of a
fire on site.

At appropriate locations adjacent to the storage compound emergency fire

fighting equipment consisting of sand buckets and portable fire extinguishers
should be present and clearly marked.

The compound should be assessed and zoned in accordance with the

Dangerous Substances and Explosive Atmospheres Regulations 2002 and all
ignition sources removed from the appropriate areas. Where zone 1 and
zone 2 areas have been identified then the appropriate electrical equipment
which is Ex rated should be provided in that area.

Good housekeeping should be practiced in order to avoid the accumulation of

rubbish etc. which could represent fuel in the event of a fire. In order to
protect the cylinder valves the cylinder should be stored up right with
protective covers and caps in place.
9. (a) The stability of a counterbalance of a forklift truck relies upon the engine
or battery to counterbalance the mass of the load. The front wheels of the
truck are the fulcrum or pivot point. The further forward the load is from the
front wheels the greater the leverage will be.

The safe working load of a forklift truck is calculated as a function of the lift
height and the load centred distance, i.e. the distance from the fulcrum.

Longitudinal instability or tipping forward may cause loss of control in vehicles

which are rear wheel steered. The main causes could be excessive loads
working outside of the safe working load of the vehicle or loads placed too far
forward on the forks or are too large for the vehicle forks to accommodate.
Instability may also be caused by travelling forwards when descending a
slope moving the centre of gravity of the vehicle and load beyond the fulcrum.
Travelling with a raised load would increase the height of the centre of gravity
and therefore destabilise the vehicle this would increase a tipping forward
affect during breaking and harsh acceleration or breaking whilst carrying a
heavy load may also destabilise the vehicle. Lateral instability or tipping
sideways may be caused by uneven loads or loads which are positioned
unevenly with the centre of gravity to one side thereby destabilising the
vehicle. As a load is raised so the centre of gravity of the vehicle is raised
and travelling at speed especially whilst turning with a raised load will cause
the vehicle to become unstable and tip over sideways. When negotiating
slopes or travelling on un-even grounds or hitting pot holes the sudden
movement may cause the vehicle to become unstable and tip over sideways.
Mechanical faults or tyre faults with the vehicle may cause the vehicle to lift to
one side which may cause enough movement at the centre of gravity to
cause the vehicle to overturn sideways. Finally carrying live loads, ie. Where
the centre of gravity can shift may cause enough force on the vehicle to pull
the vehicle over sideways.

(b) The training of forklift truck operators may be divided into three stages
basic skills training, specific job training, and familiarisation training.

Basic training should cover fully the skills and knowledge required for the safe
operation of the lift truck and any handling attachments which the trainee will
be required to operate, including the risks arising from lift truck operation. An
operator with basic training on one type of lift truck or handling attachment
cannot safely operate other types, for which they have not been trained,
without additional conversion training. The training should consist of practical
training on a fork lift truck and classroom sessions on the theory of truck
stability.

Specific job training would normally include the specific requirements of the
employer’s activities. Such training would include detailed operation of the
truck in conditions which are likely to be found on the employer’s premises,
e.g. stacking, racking, working in cold stores etc. The detail of site rules such
as one way systems, specific handling techniques for loads to be lifted, safe
systems of work such as key control procedures and refuelling and
recharging of the vehicle as appropriate.

Familiarisation training should take place in the work place under strict
supervision and give the trainee the opportunity to practice and develop
experience in their new skills. On completion of the training the trainee
 should receive a certificate and written authorisation to operate the forklift
truck.

(c) Refresher training for forklift truck drivers would be appropriate if there
was evidence of the deterioration of driving standards, e.g. evidence of
collisions in the work place. If the type and nature of the vehicle and or
operation change refresher training for operators would be appropriate.
Following a change in job role or return to work following a period of absence
then appropriate refresher training may be required.

10. (a) A fuse in an electric circuit will protect the circuit from over current. The
flow of electrical current generates heat, the higher the current the more heat
is generated. The fuse is a weak link designed to melt thereby breaking a
circuit at abnormal currents. Without a fuse the equipment might be damaged
and the wiring would eventually become hot enough to melt it’s insulation and
start a fire. A fuse will not protect people from direct electric shock as it’s
operation is relatively slow.

(b)

Double Insulation:

This method of protection uses two discreet layers of insulation instead of

one. Each layer alone is capable of ensuring that the conductor it protects
cannot give rise to danger. Double insulation is particularly suitable for
portable equipment, however, danger is eliminated only so long as the
insulation remains in tact. For this reason regular maintenance and
inspection is essential.

Earthing and Automatic Disconnection:

Since the UK public supply is referenced to earth it is possible to detect earth

faults of equipment and disconnect faulty equipment automatically. Automatic
disconnection is by the provision of devices such as fuses and circuit
breakers. Fault currents caused by a short circuit to earth are likely to allow
much higher currents to flow than the equipment or cables were designed to
carry. The presence of an earth/protective conductor which allows a low
impedance path to earth should be of an adequate rating to safely carry any
expected fault current for the time it takes any protective device to operate. In
ensuring the effectiveness of automatic disconnection devices the integrity of
the earth conductor is of great importance since without it protection is
removed.

Safe Voltages:

The use of reduced voltages is particularly suitable for use with portable
equipment. The low voltages maybe provided by a step down or voltage
reducing transformer. Typically the use of 110 volt cte (centre tapped to
earth) equipment is used in the construction industry. The secondary winding
of the transformer is centre tapped to earth, i.e. the line conductor is at 55
volts whilst the return conductor is at -55 volts. Consequently the maximum
shock from an earth vault is 55 volts unless in a very rare situation where an
individual is in contact with the line and the return conductors at the same
time. Other low voltages of less than 25 volts maybe preferable in certain
 situations where an environment might make the risks associated with
electricity worse.

Equipotential Bonding:

This method involves the earth bonding of all exposed metallic conductors
which may become live under fault conditions. Should one conductor be
raised to a high potential then all are raised to the same, this significantly
reduces the risk of being in contact with different conductors at different
potentials, i.e. no potential difference means no current flow.

Miniature Circuit Breakers:

MCB’s are either thermal or electromagnetic mechanical devices which

perform the same function as a fuse.

Residual Current Device:

These devices know as RCD’s or current operated earth leakage circuit

breakers will protect operators from electric shock. The RCD will detect earth
leakage current by monitoring the line and return conductors. Any deviation
from the expected potential in these conductors will lead to a relay
disconnecting the power supply. Typically the trip current will have a rating of
30 milliamps operating within 30 milliseconds thereby ensuring protection
against electric shock.

(c) The electrical system should be isolated from an electrical supply, i.e.
disconnection and separation of the electrical equipment from every source of
electrical energy in such a way that the disconnection and separation is
secure. A written safe system of work should be in place and should include
the following:

Following isolation a method of proving that the circuit is dead.

The test equipment should be proved to be working and then the isolated
equipment should be tested to ensure that it is dead followed by reproving of
the test equipment. As an additional precaution an earth lead that is capable
of carrying a fault current should be attached at the point of isolation
described above. The area should be adequately cordoned off and suitable
cautionary notices posted to ensure that persons are aware of the work being
carried out on the equipment. Other precautions would include physical
barriers temporary insulation, e.g. rubber matting and permit to work to
ensure that safety critical functions are completed prior to the maintenance
work. The system of work should be adequately communicated to all relevant
persons. Only in exceptional circumstances should work be carried out on
electrical equipment whilst it is live.

11 (i) The design of the storage vessels should ensure that the materials used in
construction are capable of withstanding the corrosive nature of the
substances.

Adequate separation should be maintained between the storage vessels to

ensure that mixing does not occur in the event of spillage.
 Each storage facility should be adequately bunded, i.e. a low level
containment wall to ensure that spillage is contained.

Each storage facility should be adequately protected from physical damage

by collision with vehicles whether loading or unloading adequate barriers
should be in place.

Each connection method to each storage facility should be unique to that

particular substance, i.e. a sulphuric acid carrying tanker could not connect to
the caustic soda storage vessels due to substance specific couplings as well
as colour coding.

Each of the storage vessels should be designed with adequate fill level
indicators and warnings to prevent over filling and subsequent spillage of the
materials.

(ii) Each storage facility should be clearly identified with adequate signage and
colour coding. All connections and pipework should be similarly colour coded
and substance specific to ensure that inadvertent filling could not take place.

Adequate precautions and actions should be in place in order to deal with

small scale spillage and the triggering of indicator alarm levels.

All operators including vehicle drivers should be adequately trained and

informed of the dangers associated with the substances, i.e. corrosive nature
and violent reactivity.

Suitable PPE e.g. respiratory protection and corrosive resistant clothing and
footwear and splash protection should be worn by operators.

(iii) Arrangements should be in place to prevent the loading or unloading of the

storage vessels during inspection procedures in relation to the maintenance
of the facilities.

Such arrangements should include permit to work controls and isolation of the
systems. Adequate arrangements should be made for safe access and
egress for the purpose of carrying out inspections of safety critical plant.