NEBOSH PSM Exam Practice session - No.

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Attempt 3
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Question 1Correct
Which of the following is a leading indicator?
Defective equipment
Manufacturing defects
Your answer is correct
Audit results
Design failure
Overall explanation
Leading indicators Proactive measurements of conditions that monitor
process safety before something goes wrong and to see if things are
operating as intended. Audit results gives out the findings that could be
rectified even before an incident occurs.
Question 2Correct
Inspecting a workplace where contract workers are carrying out work is
reactively monitoring
Your answer is correct
performance monitoring
actively monitoring
condition monitoring
Overall explanation
Periodic review of contractor safety performance

It is important to maintain a close working relationship with contractors, and

to be comfortable and satisfied with their safety performance. This will
require regular reviews of the activities of contractors, which may include:
carrying out site inspections to check compliance with the method
statements and risk assessments; carrying out safety tours to monitor
general standards, including housekeeping; attending regular meetings with
contractors to discuss any issues and review accident data.

Question 3Correct
You are conducting a hazardous area classification for a petroleum fuel
storage site; in particular you are concerned with the area around the fuel
pump and pipelines connected to each storage tank.

Assuming all components are in good condition, what zone is the area
around the fuel pump likely to be under normal operation?

Your answer is correct

Zone 1
Zone 21
Zone 2
Zone 22
Overall explanation
From the text book

"Zone 1 is defined as a place in which an explosive atmosphere is likely to

occur in normal operation occasionally"

Question 4Correct
A permit-to-work is required in preparation for an activity with
Low risk
no risk
Your answer is correct
High risk
any risk
Overall explanation
A permit-to-work is used commonly for high-risk activities, such as: hot
work; y work on complex plant that requires isolation (chemical, electrical,
mechanical or gas); confined space entry; work on high-voltage electrical
systems; excavations near buried services
Question 5Correct
To manage an organisation's reputation during emergencies, there should be
a nominated trained person to specifically liaise with
plant workers
site visitors.
Your answer is correct
media reporters.
corporate managers.
Overall explanation
Refer to the text book under " Emergency Preparedness" ,

Senior managers can also play an important role in the emergency plan as
there may be a need to manage contact with families (next of kin) for injured
parties, and manage media and regulator communications.
Question 6Correct
Which of the following is likely to be most helpful in developing a positive
health and safety culture?
High level communication chains with diluted messages at lower
levels
Senior management creating workforce fear of disciplinary
proceedings
Management focus on productivity not unreasonable safety
regulation
Your answer is correct
Promotion of process safety leadership and board level visibility of
site visits
Overall explanation
In the text book, please refer the topic " Board level visibility and promotion
of process safety leadership" under " Process safety leadership"

Board level visibility and promotion of process safety leadership

The Principles of Process Safety Leadership also place emphasis on

board level visibility to promote process safety. Directors and senior
managers play a key role in promotion of process safety - they provide
leadership, set direction and assign priorities, establish the health and safety
‘tone’ of the organisation and ensure that the organisation’s legal
responsibilities are met.

Question 7Correct
Pressure, temperature, flow, level, pH and density are common
procedures associated with sate operating envelopes.
Your answer is correct
parameters associated with safe operating envelopes.
problems associated with sate operating envelopes.
processes associated with safe operating envelopes.
Overall explanation
From the text book " The common process parameters are temperature,
pressure and volume but, depending on the process, may also include
properties such as pH, conductivity, level, flow (rates) composition,
mixing (agitation), etc" . Chapter " Operating procedures", sub topic "
what is safe operating envelope"
Question 8Correct
Which of the following is most likely to help you develop a safe system of
work?
Statistical analysis
Data analysis
Your answer is correct
Task analysis
Casual analysis
Overall explanation
Refer to the topic in the text book " Role, purpose and features of a permit-
to-work system". The permit is only part of the safe system of work and is
used in combination with method statements and task analysis or risk
assessments. The permit issuer requires a detailed knowledge of the plant
where the work is to be carried out, and the workers use the method
statements and task analysis to communicate the hazards and controls
needed to the issuer.
Question 9Correct
Maintenance work is planned on Plant A. The work is likely to have a
significant impact on the operation of a second plant, Plant B.

What is the most effective way of controlling risk between the two plants in
this situation?

Your answer is correct

Display a duplicate permit-to-work in plants A and B
Display a warning sign between plants A and B
Display a single permit-to-work in Plant A only
Display 2 single permit-to-work in Plant B only
Overall explanation
Refer to the topic in the text book "Interfaces with adjacent plant "

It is essential that the permit issuer considers the potential impact of the
works on adjacent plant or equipment, or the possibility that other
plant could affect the safe operation of the permit. Equally, if the
installation has duty and stand-by plant, then controls must be in place to
ensure that these are not worked on simultaneously. This is often
achieved by ensuring all permits are issued from a central issuing
authority or location, and displayed clearly so that any clashes can
be identified - at a simple level, it would be dangerous to issue a permit to
carry out hot work in the vicinity of work to remove and replace equipment
containing flammable materials.

Question 10Correct
One of the hazards of using nitrogen as an inerting gas
increased flammability.
increased oxygen concentrations
Your answer is correct
decreased oxygen concentrations.
decreased flammability.
Overall explanation
From the text book under the topic "Characteristics and industrial uses
of inert gases and associated hazards" , it is mentioned as "Because they
displace oxygen in the air, the inert gases are particularly
hazardous in areas where people may be exposed to them. They act
as asphyxiants by reducing, or completely removing, the oxygen from the air
people in the close vicinity are breathing. This very quickly leads to
disorientation, dizziness, and ultimately death as the level of oxygen
reduces.
Question 11Correct
A bulk fuel tank is normally filled automatically from a pipeline through a
filling valve. The tank is fitted with a level gauge that enables operators to
remotely monitor the level from a control room. The tank is also fitted with a
high-level alarm and an independent high-level switch that, if activated,
closes the filling valve. The filling valve can also be closed using an
emergency switch located in the control room. On one occasion all of these
devices failed and the tank overflowed.

While all of these devices help prevent overfilling, which is the most safety
critical item required to effectively prevent the tank overfilling?

The filling valve

Level gauge
High level alarm
Your answer is correct
Independent high-level switch
Overall explanation
Refer to text book , the topic bulk storage operations and sub topic "
Overfilling"

Overfilling Continuous monitoring should be used when filling

storage tanks to protect against overfilling. The volume of the
receiving vessel and its content level should be known before filling
commences.

An Independent high-level switch serves the purpose.

Question 12Correct
The most effective standard operating procedures for process plant are
those developed with the involvement of
plant engineers and clerical workers.
Your answer is correct
plant engineers and process operators.
supervisors and plant designers.
supervisors and clerical workers
Overall explanation
Refer to the text book on the topic " Who is involved in developing the
procedures?".

Who is involved in developing the procedures?

Traditionally, many safety incursions in process operations have been

blamed on failings by operators, very often because the SOP has not been
followed, is not accurate or does not exist. To overcome such problems,
current high reliability organisation (HRO) theory and practice points to the
involvement of experts in the design and writing of the SOPs. The experts
include those actually doing the work, so in reality the initial writing and
development of any SOP requires input from the designer/engineer and
also the operator(s);

Question 13Correct
One of the main typical features of a jet fire is
a diffuse flame with low momentum.
Your answer is correct
a highly directional flame.
a rapid spread in every direction.
a flame with an enormous surface area
Overall explanation
EXAMPLE given under Jet fire in the text book, An everyday example of this
is a propane blowtorch that might be used for brazing or soldering; the
flame is a highly directional jet.
Question 14Correct
Alerting and Informing when problems occur during process operation is the
main function of
an indicator.
a dial.
a gauge.
Your answer is correct
an alarm.
Overall explanation
Systems for alerting and warning workers (From text book)

Most organisations will require a means of alerting on-site workers to the

presence of an incident. At the basic level this could be a fire alarm, but for
some installations the alarm may need to include: separate alarms for fire
and chemical release; staged evacuation of the facility, with some areas
evacuating while others remain operational; first aid and medical
emergency alerts; off-site alarms to alert local businesses and residents
Question 15Correct
Safe operating envelopes involve adhering to
variable operating limits.
lower operating limits only.
upper operating limits only.
Your answer is correct
upper and lower operating limits.
Overall explanation
The expression " safe operating envelope" refers to the limits of the
operating conditions under which the process can take place safely.
Typically, process limits are established by setting upper and lower levels
for a range of parameters. Providing the process reaction takes place
within these limits, it will operate safely, all else being equal.
Question 16Correct
Process safely involves a commitment to continuous
improvisation.
Your answer is correct
Improvement
implementation
Impartiality
Overall explanation
Refer " Process safety leadership" and the subtopic " Commitment to
continuous improvement"

Commitment to continuous improvement

Leaders should not only actively and effectively monitor the safety
performance; they should also seek to continually improve, eg by
benchmarking against other organisations. Ultimately, process safety, like
the personal safety we explored at the start of this element, is a never-
ending story. Organisations develop, plants change and the desire for further
safety improvements is therefore a continual process, rather than being
disheartening, this is enlightening as it acknowledges that the best
organisations strive continually for the injury-free workplace or the incident-
free plant and acknowledge that it is achievable with the right level of
commitment

Question 17Correct
For which operating environment is ATEX-approved equipment essential?
Corrosive atmospheres in offshore oil and gas installations
Pressurised atmospheres requiring associated relief valves
Toxic atmospheres within confined space work activities
Your answer is correct
Potentially flammable atmospheres from dust or vapour
Overall explanation
From the text book
3. Selection of equipment for the operating environment

Some operating environments are such that use of the incorrect equipment
can cause serious safety implications. For example, in a potentially
flammable atmosphere where vapours or dusts can result in fire or
explosion, the selection of the correct ATEX approved equipment is
essential.

Question 18Correct
Several workers were killed by fire and explosion after a worker cut into the
wrong pipe. The pipes contained flammable hydrocarbons and had not been
isolated. The release was ignited by the sparks generated during the cutting
operation.

You are the process safety representative investigating the accident. What is
the most significant cause of this incident?

Plant and process design

Your answer is correct
Failure to control work
Failure to control ignition sources
Lack of deluge system
Overall explanation
Such works shall be controlled by Permit to work with proper isolation and
authorization. Cutting wrong pipes could have been prevented by controlling
the work by means of Permit to work (PTW). PTW system clearly identifies
the work to be carried out with proper isolation. This case is clearly due to
failure to control work.
Question 19Correct
A consequence of a thermal runaway reaction is catastrophic plant failure
through
overrunning.
overloading.
overriding
Your answer is correct
over-pressure.
Overall explanation
Refer the text book under the topic " Reaction hazards: and the sub topic "
Possible consequences of occurrence" which says " The serious
consequences include over-pressurization of the vessel as a result
of the reaction, which then ruptures the vessel and releases the
contents into the surrounding area (Seveso). Depending on the energy of the
explosion and the nature of the contents, the effect may be widespread"
Question 20Correct
Rapid temperature change can cause cracking of materials. This type of
failure mode is known as
creep
brittle fracture.
Your answer is correct
thermal shock.
stress corrosion cracking
Overall explanation
Thermal shock ( From the text book)

Thermal shock results from exposing materials to rapid and extreme

temperature changes. This causes the different parts of the material to
expand by differing amounts, which in turn gives rise to uneven expansion.
As a result, cracking occurs when the stress applied by the expansion
exceeds the strength of the material. The crack will continue until the object
or material fails.

Question 21Correct
A chemical plant, located four kilometres from a city centre, accidentally
released a very large quantity of a toxic gas. The release of the toxic gas
occurred when a process operator mistakenly added water to a storage tank
containing a toxic liquid. The two reacted violently causing the contents to
boil.

The reaction that occurred within the storage tank was one that

absorbed energy with a corresponding temperature drop.

absorbed energy with a corresponding temperature increase.
Your answer is correct
released energy with a corresponding temperature increase
released energy with a corresponding temperature decrease
Overall explanation
Refer to the text book on the topic " Exothermic reaction "

The majority of chemical reactions give off energy when they take place.
This is usually as heat (but may be light). Hence, the expression
‘exothermic’, to give off heat. Combustion (eg any fuel burning in air) is a
common example of an exothermic reaction. Once it gets going, it generates
a good deal of heat.

Question 22Correct
There has been a near miss incident where an experienced operator failed to
respond to a high-level alarm on a fuel tank, resulting in a loss of
containment from the tank. The incident could have had major catastrophic
consequences had the fuel found an ignition source. It is important that
lessons are learnt from all incidents, including near misses.
Which of the following is the best way to learn lessons from this incident and
prevent such an incident happening again?

Suggest the organisation re-train the operator for a new role where
they will not be put in charge of alarm management
Accept that on this occasion a mistake was made. Offer the operator
refresher training that reminds them of the need to manage alarms
effectively
Discuss the incident with the operator as a personal matter. Ensure
that they understand the significance of the incident and that they
must respond appropriately to alarms in the future
Your answer is correct
Investigate the incident thoroughly, identify the root causes and
ensure this is communicated to as wide an audience as possible
Overall explanation
From the text book , topic "The significance of learning lessons from
incidences of actual or potential consequence "

Major incidents cannot easily be ignored - they create an awful lot of

damage. As an organisation (or even as an individual), it is tempting to play
down the significance of a near miss that could have led to a major incident
(but was caught in time and averted.

When incidents happen to other similar plants or organisations (rather than

to you), there is a tendency to be complacent and think it could never
happen to you (simply based on the idea that it has not so far and therefore
you must be doing it all right). But, you might just have been lucky. If you
fail to investigate and learn lessons (of how to do things
differently), the danger is that the very same issue will repeat and
next week, next month or next year, you will not be so lucky.

Question 23Correct
Which of the following is an example of a condition needed for a dust
explosion to occur?
Very high humidity
Your answer is correct
Dust is confined in a hopper or silo
Dust particle size is very large
Dust concentration below lower explosive limit
Overall explanation
Humidity and size do not matter at Dust explosion. Below the explosive
limits, the dust cannot explode. So only option is "Dust is confined in a
hopper or silo"
Why dust explosions occur

Dust explosions happen when a combustible dust with the correct particle
size forms a cloud of the right concentration in air. This dust is known as
‘explosible’. Combustible dusts include some commonly found materials,
such as flour, sugar, milk powder, coal and grain. Dust explosions can
occur in processes where there are dusts handled, such as grain
silos, extraction systems, spray driers and material transfer
systems.

Question 24Correct
Which of the following best describes workplace consultation?
Appraisal of performance between employer and worker
Resolving of workplace disputes between employer and worker
Your answer is correct
Two-way exchange of information between employer and worker
Employers regularly keeping workers informed about safety issues
Overall explanation
In the text book, refer Work force engagement

Consultation

The two-way exchange of information between parties, in this case

between employer and worker. This is far more effective than the
one-way exchange that we see when people are simply ‘informed’.

Question 25Correct
A thorough visual inspection of the plant to determine that all work has been
completed is most relevant within
Your answer is correct
pre-start-up safety review
post-start-up safely review
pre-shutdown safety review
post shutdown safety review.
Overall explanation
Refer to the text book, topic " Safe start-up and shut-down" and sub topic
" Pre-start-up safety review"

Pre-start-up safety review

There are various stages prior to the start-up of a process: ensuring

the plant is ready to operate. This can be a highly involved process
in itself as it requires the checking and testing of all the physical
and operational elements of the process before the plant is charged
and the process initiated; typically, this involves a pre-start-up
phase in which detailed checks are carried out to ensure that
pipework, valve and other structural elements are correctly fitted
and to the appropriate standard (design conformity); ensuring
mechanical, electrical and instrument installations are correct;

Question 26Correct
Saturated steam is also known as
supercritical water.
dry steam.
superheated steam.
Your answer is correct
wet steam.
Overall explanation
From the text book " One of the problems with saturated steam is that it is
still wet, as not all of the water is necessarily converted to
steam (between 3 and 5% of water may be entrained in the steam)"
Question 27Correct
Maintenance of bunds primarily contributes to
operational excellence.
Your answer is correct
emergency preparedness.
change management.
Inventory management
Overall explanation
Refer to the topic " Bulk storage Operations" .

In order to limit the consequences of loss of containment ( Which

means emergency preparedness), tanks either individually or
collectively, when they have the same contents, are surrounded by a bund
wall

Question 28Correct
The main reason why a shift handover should be given as much time as
necessary is to allow for
Your answer is correct
an incoming operator to ask questions about the status of the
process and an outgoing operator to clarify and explain.
an incoming operator to familiarize themselves with control panel
instrument readings and operating trends.
an outgoing operator to remove personal locks from isolation
control boxes associated with maintenance preparation.
an outgoing operator to remove permits from a permit board and
sign off completed permit-to-work documentation.
Overall explanation
Refer to the topic " Shift Handover requirements" which says " given as
much time as necessary to allow for questioning, explanation and
clarification"
Shift handover requirements

Shift handover should be: considered a high priority: it may be necessary, for
instance, to bring the incoming shift in a bit earlier to ensure that there is
time for the discussions; carried out face-to-face between those involved:
this is usually between the shift leaders; carried out using accurate written
and verbal communication: the handovers are usually supported by
documentation to record the discussions (eg handover log); based on
analysis of the information needs of the incoming staff: there are some
activities that would be essential to communicate to the incoming teams, eg
if the sprinkler system was not working or if critical spares were due to
site; given as much time as necessary to allow for questioning,
explanation and clarification.

Question 29Correct
Liquid is being transferred from a road tanker into a storage vessel. The
failure to open a vent valve on the tanker during the transfer could result in
a tanker
over-pressure
explosion.
overflow.
Your answer is correct
Implosion
Overall explanation
When vent valve is not opened while transferring, a vacuum is created inside
the tank, which causes implosion
Question 30Correct
A process was shut down automatically due to an unexpected and sudden
pressure increase so it was outside of standard operating conditions.

What type of shutdown is this an example of?

Staged
Planned
Your answer is correct
Emergency
Delayed
Overall explanation
Question clearly says about unexpected and sudden pressure
increase It was outside of standard operating conditions. So it is an
emergency shut down
Question 31Correct
What is normally included in the periodic review of the safety performance of
contractors working on site?
A request for method statements, risk assessments and official
licenses
Scrutiny of contractor health and safety policy and previous
prosecutions
Analysis of contractor training records, qualifications and past
experience
Your answer is correct
Inspections to check compliance and accident data review meetings
Overall explanation
Periodic review of contractor safety performance

It is important to maintain a close working relationship with contractors, and

to be comfortable and satisfied with their safety performance. This will
require regular reviews of the activities of contractors, which may include:
carrying out site inspections to check compliance with the method
statements and risk assessments; carrying out safety tours to monitor
general standards, including housekeeping; attending regular meetings with
contractors to discuss any issues and review accident data.

Question 32Correct
You are trying to convince your Board to adopt a safety management
system. You are using the argument that a safety management system can
help you avoid needless and preventable deaths and Injuries.

What type of argument is this usually known as?

Municipal
Morale
Your answer is correct
Moral
Medical
Overall explanation
Moral responsibility is one of the requirements of the top management. So
the argument shall be based on the moral responsibility.
Question 33Correct
During a major incident the primary plant audible warning system was
activated, but management subsequently issued an instruction to switch it
off shortly after.

Switching the primary plant audible warning system off in these

circumstances was primarily a

chance to test back-up warning systems.

decision to reduce nuisance alarms.
necessity to prevent noise pollution.
Your answer is correct
deviation from a standard operating procedure.
Overall explanation
From the text book,

Ensuring operating procedures remain current and accurate

For a variety of reasons, procedures may become outdated or applied with a

degree of laxity. One cause is human frailty, often summed up in the
expression “familiarity breeds contempt”. If the operator finds that missing a
step or not applying part of the SOP is easier or quicker and there is no
adverse consequence, then over time the SOP becomes ‘revised’. This
revised SOP is, of course, at variance with the intended SOP that was
designed to keep both the process and the individual operator safe, for good
reasons. This drift away from the designed SOP then becomes the
common practice, but because it is not now based on an appropriate risk
assessment, there is a grave likelihood that at some point the
deviation from the expected SOP will have dangerous
consequences.

Question 34Correct
Which form of risk assessment is most appropriate when the risk is
potentially intolerable?
Qualitative
Semi-quantitative
Your answer is correct
Quantitative
Dynamic
Overall explanation
In the text book, Refer to the figure in the topic " Qualitative, quantitative
and semi-quantitative risk assessments"

Question 35Correct
The site that you work on has a series of reactors in a line, one of which is
found to be leaking. To keep production going, it is decided that a bypass
pipe needs to be installed on the leaking reactor to keep production going.

What is the most important thing you should do before installing the bypass
pipe?

Develop a preventive maintenance programme

Your answer is correct
Review implications of the proposed change
Use the correct grade of steel for the process
Consult the relevant international standard
Overall explanation
Review implications of the proposed change means the review of the
material of construction of the pipe, suitability to the working pressure and
media, the joining of the metals ( welded or flange joint) and test for the
rated pressure and flow.
Question 36Correct
You are working on a site that handles combustible dusts. You have already
taken precautions to reduce the chances of a primary dust explosion.
However, you are worried about the risks of a secondary dust explosion,

Which is the best way to reduce this risk?

Avoid ignition sources

Your answer is correct
Good housekeeping
Explosion suppression
Explosion relief
Overall explanation
Refer to the text book, under the topic " Dust explosion" and the sub topic "
Good housekeeping"

Good housekeeping

Another example of simple solutions is to maintain an environment where

there is little or no dust lying on surfaces through good
housekeeping. This will reduce the risk of secondary explosions
occurring.

Question 37Correct
What is the main reason for sharing lessons learnt from major incidents with
other organisations?
Accident investigations are more effective in determining immediate
and root causes
Your answer is correct
Potential benefits are much greater for the process safety industry
as a whole
Integration of quality, environmental and health and safety
management systems
Operating procedures are standardised so that workers have a
consistent approach
Overall explanation
Arrangements with other relevant organisations in sharing lessons learnt
Because major incidents are extremely rare, it is very limiting if
organisations only look internally to learn lessons. A particular organisation
may never have suffered a major incident, but there may be several
examples out there of similar organisations, running similar processes, with
similar control arrangements, who have had major incidents or near misses.
If this information were shared, the potential benefits are much greater
for the process industry as a whole. Process safety regulators and
industry groups actively encourage information sharing in this way.
Question 38Correct
Hot gases from fires naturally rise through voids and ducts. This behaviour is
known as
Radiation
Your answer is correct
convection
Conduction
direct burning.
Overall explanation
From the text book,

convection - hot fluids (liquids or gases) rise and cold fluids sink, and as
this happens, heat is spread upwards from the seat of the fire. Inside
buildings, this results in a hot layer of gases trapped at ceiling
level, whereas outdoors, the hot gases continue to rise carrying embers
away from the fire, possibly causing them to cool and fall to the ground as
new ignition sources;

Question 39Correct
The key elements of a process safety management system follow the Plan
Do Check Act model. ‘Management review’ aligns with which part of the
model
Do
Your answer is correct
Act
Check
Plan
Overall explanation
From the text book,

In process safety management systems, the same basic structure is

followed: policy (plan); planning (plan); implementation and operation (do);
checking and corrective action (check); management review
(act); continual improvement (act).

Question 40Correct
An accident report detailed that similar plants owned by the same
organisation in other international locations were built downwind of cities.
This was as a result of previous incidents where smaller quantities of toxic
gas had been released into the atmosphere. This chemical plant was built
upwind of a city.

This is primarily an example of a failure in

operational control.
Your answer is correct
organisational learning.
asset management.
management of change.
Overall explanation
Refer to the text book , the topic " Organisational learning". If the learnings
are not communicated or reviewed by the organisation before designing
another industry of similar industry, the mistakes could be repeated again.