NEBOSH

NEBOSH HSE Certificate in Process Safety

Management
NEBOSH
Element 1
Process safety leadership
1. Process safety management meaning
2. Process safety leadership
3. Organisational learning
4. Management of change
5. Worker engagement
6. Competence
NEBOSH
Element 2
Management of process risk
1. Establishing a process safety management system
2. Risk management techniques used within the process industries
3. Asset management and maintenance strategies
4. Role, purpose and features of a permit-to-work system
5. Safe shift handover
6. Contractor management
NEBOSH

Element 3
Process safety hazard control
1. Operating Procedures
2. Safe start-up and shut-down
3. Safety critical performance standards
4. Utilities
5. Electricity/static electricity
6. Dangerous substances
7. Reaction hazards
8. Bulk storage operations
NEBOSH

Element 4
Fire protection and emergency
response
1. Fire hazards
2. Fire and explosion control
3. Dust explosions
4. Emergency preparedness
 Assessment
• The NEBOSH HSE Certificate in Process Safety Management is
assessed by a 90 minute exam consisting of 40 multiple-choice
questions.
• 10 of the questions are extended scenario questions which will be
randomly distributed throughout the paper.
• Each question is worth one mark and has 1 correct and 3 incorrect
responses available. The question paper covers the whole syllabus
with at least one question per element and all questions are
compulsory.
• There is no practical element to this qualification.
• The pass standard for the unit/qualification is 60% (24 correct
questions out of 40). The only grade available for successfully
completing this qualification is ‘Pass’.
NEBOSH
Element 1
Process safety leadership
1. Process safety management meaning
2. Process safety leadership
3. Organisational learning
4. Management of change
5. Worker engagement
6. Competence
NEBOSH

Q1
Process safety mainly deals with:
A. high frequency, high severity risks.
B. low frequency, high severity risks.
C. low frequency, low severity risks.
D. high frequency, low severity risks.
NEBOSH

Q1
Process safety mainly deals with:
A. high frequency, high severity risks.
B. low frequency, high severity risks.
C. low frequency, low severity risks.
D. high frequency, low severity risks.
NEBOSH

Q2
Within a management of change procedure, final
approval for removal of a safety critical device
should be given by a:
A. senior manager.
B. lead operator.
C. chemical engineer.
D. process technician.
NEBOSH

Q2
Within a management of change procedure, final
approval for removal of a safety critical device
should be given by a:
A. senior manager.
B. lead operator.
C. chemical engineer.
D. process technician.
NEBOSH

Q3
Benchmarking is used to identify good practice
across similar:
A. committees.
B. organisations.
C. techniques.
D. procedures.
NEBOSH

Q3
Benchmarking is used to identify good practice
across similar:
A. committees.
B. organisations.
C. techniques.
D. procedures.
NEBOSH
Q4
What is the most important benefit of involving
workers when carrying out risk assessments?
A. to reduce resistance and conflict when risk assessments
are introduced.
B. to make sure there is a balanced representation of
workers and managers.
C. to enable employer and employees to comply fully with
legal requirements.
D. to gather detailed practical knowledge about workplace
hazards and risks.
NEBOSH
Q4
What is the most important benefit of involving
workers when carrying out risk assessments?
A. to reduce resistance and conflict when risk assessments
are introduced.
B. to make sure there is a balanced representation of
workers and managers.
C. to enable employer and employees to comply fully with
legal requirements.
D. to gather detailed practical knowledge about workplace
hazards and risks.
NEBOSH
Q5
Which of the following is the most direct evidence
of worker competence?
A. consistently performing a work-related task correctly to
the required standard.
B. signing a document to confirm that a procedure was read
and understood.
C. completing an attendance form following a process
safety toolbox talk.
D. carrying out a work-related task without harming
themselves or others.
NEBOSH
Q5
Which of the following is the most direct evidence
of worker competence?
A. consistently performing a work-related task correctly to
the required standard.
B. signing a document to confirm that a procedure was read
and understood.
C. completing an attendance form following a process
safety toolbox talk.
D. carrying out a work-related task without harming
themselves or others.
NEBOSH
Element 2
Management of process risk
1. Establishing a process safety management system
2. Risk management techniques used within the process industries
3. Asset management and maintenance strategies
4. Role, purpose and features of a permit-to-work system
5. Safe shift handover
6. Contractor management
NEBOSH
Process organisations have in place a wide range of
mitigation measures designed to reduce the consequences
of a major incident. Which risk management technique is
especially suited to assess the effectiveness of these
mitigation measures?
A. Failure Mode Effects Analysis (FMEA)
B. Event Tree Analysis (ETA)
C. Risk assessment (RA)
D. Hazard Identification (HAZID)
NEBOSH
Process organisations have in place a wide range of
mitigation measures designed to reduce the consequences
of a major incident. Which risk management technique is
especially suited to assess the effectiveness of these
mitigation measures?
A. Failure Mode Effects Analysis (FMEA).
B. Event Tree Analysis (ETA)
C. Risk assessment (RA).
D. Hazard Identification (HAZID).
NEBOSH
Which of the following is an example of planned
preventive maintenance?
A. daily visual inspections of process plant.
B. greasing of pump bearings.
C. regular sampling of product.
D. testing of stack emissions.
NEBOSH
Which of the following is an example of planned
preventive maintenance?
A. daily visual inspections of process plant.
B. greasing of pump bearings.
C. regular sampling of product.
D. testing of stack emissions.
NEBOSH
Quantitative risk assessment differs from qualitative risk
assessment because it is more:
A. adaptive.
B. objective.
C. subjective.
D. detective.
NEBOSH
Quantitative risk assessment differs from qualitative risk
assessment because it is more:
A. adaptive.
B. objective.
C. subjective.
D. detective.
NEBOSH
A proactive maintenance strategy associated with asset
integrity is:
A. condition monitoring.
B. breakdown maintenance.
C. inherent safe design.
D. redundancy.
NEBOSH
A proactive maintenance strategy associated with asset
integrity is:
A. condition monitoring.
B. breakdown maintenance.
C. inherent safe design.
D. redundancy.
NEBOSH
The key elements of a process safety management system
follow the Plan Do Check Act model. Implementation and
operations aligns with which part of the model?
A. Plan.
B. Do.
C. Check.
D. Act.
NEBOSH
The key elements of a process safety management system
follow the Plan Do Check Act model. Implementation and
operations aligns with which part of the model?
A. Plan.
B. Do.
C. Check.
D. Act.
NEBOSH
What would be discussed between a permit issuer and a
contract worker before the commencement of a hot work
permit?
A. location of rest facilities.
B. how to apply first aid to burns.
C. operation of fire extinguishers.
D. simultaneous operations.
NEBOSH
What would be discussed between a permit issuer and a
contract worker before the commencement of a hot work
permit?
A. location of rest facilities.
B. how to apply first aid to burns.
C. operation of fire extinguishers.
D. simultaneous operations.
NEBOSH
Shift handover is important. The most important aspect of
handover is because:
A. expected production rate needs to be understood by
incoming staff.
B. process related accidents have occurred due to a failure of
communication at shift handover.
C. staff needs to know about any management audits or
inspections that are being undertaken.
D. a verbal report is the most effective way for
communicating to incoming shifts any issues affecting a
plant.
NEBOSH
Shift handover is important. The most important aspect of
handover is because:
A. expected production rate needs to be understood by
incoming staff.
B. process related accidents have occurred due to a failure of
communication at shift handover.
C. staff needs to know about any management audits or
inspections that are being undertaken.
D. a verbal report is the most effective way for
communicating to incoming shifts any issues affecting a
plant.
NEBOSH
A preferred method of conducting a shift handover is:
A. face-to-face using verbal and written communication.
B. by telephone using verbal communication.
C. via a log book using written communication.
D. by radio using verbal communication.
NEBOSH
A preferred method of conducting a shift handover is:
A. face-to-face using verbal and written communication.
B. by telephone using verbal communication.
C. via a log book using written communication.
D. by radio using verbal communication.
NEBOSH
Two separate work permits had been issued for the maintenance work on a pump.
One was for repair of the pump and one was for removal and servicing of the
pressure relief valve on the discharge side of the pump. The pump repair had been
completed but the servicing of the pressure relief valve had not been completed by
the end of the shift. In place of the pressure relief valve a ‘blank’ had been loosely
installed. During shift handover, the maintenance work and return to service of the
pump was discussed, but no mention was made of the servicing work being carried
out on its pressure relief valve. The pump was then started, allowing flammable
liquids to leak from the ‘blank’. This vapour cloud ignited, causing a fire.
Which of the following actions during shift handover would have been most effective
in preventing this accident?
A. verbal communication in a quiet place between incoming and outgoing workers.
B. confirmation of permits signed off as completed.
C. discussion of the recorded process checks undertaken by the outgoing workers.
D. a physical demonstration of the plant state between incoming and outgoing
workers.
NEBOSH
Two separate work permits had been issued for the maintenance work on a pump.
One was for repair of the pump and one was for removal and servicing of the
pressure relief valve on the discharge side of the pump. The pump repair had been
completed but the servicing of the pressure relief valve had not been completed by
the end of the shift. In place of the pressure relief valve a ‘blank’ had been loosely
installed. During shift handover, the maintenance work and return to service of the
pump was discussed, but no mention was made of the servicing work being carried
out on its pressure relief valve. The pump was then started, allowing flammable
liquids to leak from the ‘blank’. This vapour cloud ignited, causing a fire.
Which of the following actions during shift handover would have been most effective
in preventing this accident?
A. verbal communication in a quiet place between incoming and outgoing workers.
B. confirmation of permits signed off as completed.
C. discussion of the recorded process checks undertaken by the outgoing workers.
D. a physical demonstration of the plant state between incoming and outgoing
workers.
NEBOSH
Which of the following is the most important consideration
when selecting contractors?
A. proving that they have no previous or pending
enforcement actions.
B. providing method statements, risk assessments and
safety policies.
C. evidence of previous safe working and understanding
their impact on others.
D. membership of a professional body and adequate
insurance cover for the work.
NEBOSH
Which of the following is the most important consideration
when selecting contractors?
A. proving that they have no previous or pending
enforcement actions.
B. providing method statements, risk assessments and
safety policies.
C. evidence of previous safe working and understanding
their impact on others.
D. membership of a professional body and adequate
insurance cover for the work.
NEBOSH
Documents such as risk assessments, previous work history,
qualifications, licenses, method statements and health and
safety policy determine contractor:
A. performance.
B. tendering.
C. selection.
D. monitoring
NEBOSH
Documents such as risk assessments, previous work history,
qualifications, licenses, method statements and health and
safety policy determine contractor:
A. performance.
B. tendering.
C. selection.
D. monitoring
NEBOSH

Element 3
Process safety hazard control
1. Operating Procedures
2. Safe start-up and shut-down
3. Safety critical performance standards
4. Utilities
5. Electricity/static electricity
6. Dangerous substances
7. Reaction hazards
8. Bulk storage operations
NEBOSH

Parameters that contain a controlled reaction, which

prescribed upper and lower limits, enabling safe operation
of processes are safe operating:
A. permits.
B. practices.
C. envelops.
D. systems.
NEBOSH

Parameters that contain a controlled reaction, which

prescribed upper and lower limits, enabling safe operation
of processes are safe operating:
A. permits.
B. practices.
C. envelops.
D. systems.
NEBOSH
Standard operating procedures are:
A. an assessment of hazards and evaluation of risk associated
with an activity.
B. a breakdown of a process into nodes to identify deviations
from normal activity.
C. a signed authority for a high risk maintenance activity.
D. detailed step by step written procedure documenting an
activity.
NEBOSH
Standard operating procedures are:
A. an assessment of hazards and evaluation of risk associated
with an activity.
B. a breakdown of a process into nodes to identify deviations
from normal activity.
C. a signed authority for a high risk maintenance activity.
D. detailed step by step written procedure documenting an
activity.
NEBOSH

One control adopted for safe start-up of plant is:

A. closing of all valves.
B. closing of drain valves.
C. opening of all valves.
D. opening of drain valves.
NEBOSH
One control adopted for safe start-up of plant is:
A. closing of all valves.
B. closing of drain valves.
C. opening of all valves.
D. opening of drain valves.
NEBOSH
In terms of safety critical performance standards, what does
the abbreviation ‘FARSI’ stand for?
A. functionality, availability, resource, survivability,
interdependency.
B. functionality, asset integrity, reliability, survivability,
interdependency.
C. functionality, asset integrity, reliability, systemic,
interdependency.
D. functionality, availability, reliability, survivability,
interdependency.
NEBOSH
In terms of safety critical performance standards, what does
the abbreviation ‘FARSI’ stand for?
A. functionality, availability, resource, survivability,
interdependency.
B. functionality, asset integrity, reliability, survivability,
interdependency.
C. functionality, asset integrity, reliability, systemic,
interdependency.
D. functionality, availability, reliability, survivability,
interdependency.
NEBOSH

What is saturated steam?

A. where all the water has been converted to steam.
B. where some liquid water is still retained in the steam.
C. steam under very high pressure.
D. steam with a temperature in excess of 200˚C.
NEBOSH

What is saturated steam?

A. where all the water has been converted to steam.
B. where some liquid water is still retained in the steam.
C. steam under very high pressure.
D. steam with a temperature in excess of 200˚C.
NEBOSH

What is hydrostatic testing?

A. a means to test water quality to be used in a process.
B. a means to ensure equipment is safe and will not leak.
C. a means to ensure the supply of cooling water.
D. a means to ensure that there are no blockage within
process pipework.
NEBOSH
What is hydrostatic testing?
A. a means to test water quality to be used in a process.
B. a means to ensure equipment is safe and will not leak.
C. a means to ensure the supply of cooling water.
D. a means to ensure that there are no blockage within
process pipework.
NEBOSH

Legionellae bacteria grow at temperatures between:

A. -10°C and -5°C.
B. 20°C and 55°C.
C. 60°C and 70°C.
D. 70°C and 100°C.
NEBOSH

Legionellae bacteria grow at temperatures between:

A. -10°C and -5°C.
B. 20°C and 55°C.
C. 60°C and 70°C.
D. 70°C and 100°C.
NEBOSH
What are the characteristics of inert gas?
A. odourless, colourless, with very low chemical reactivity.
B. odourless, colourless, with very high reactivity.
C. odourless with very high reactivity.
D. odourless, colourless, with very high reactivity.
NEBOSH
What are the characteristics of inert gas?
A. odourless, colourless, with very low chemical reactivity.
B. odourless, colourless, with very high reactivity.
C. odourless with very high reactivity.
D. odourless, colourless, with very high reactivity.
NEBOSH
The severity of injury received as a result of contact with
electricity is minimised by:
A. high current and low body resistance.
B. low current and high voltage.
C. low current and high body resistance.
D. high current and high voltage.
NEBOSH
The severity of injury received as a result of contact with
electricity is minimised by:
A. high current and low body resistance.
B. low current and high voltage.
C. low current and high body resistance.
D. high current and high voltage.
NEBOSH
A thermal runaway reaction can be controlled by
emergency:
A. alarms.
B. evacuation.
C. stops.
D. cooling.
NEBOSH
A thermal runaway reaction can be controlled by
emergency:
A. alarms.
B. evacuation.
C. stops.
D. cooling.
NEBOSH
With regard to process safety management, chemical
warehouses should be managed and routinely inspected to
ensure that:
A. production is not affected is stock runs low.
B. incompatible materials are kept separated.
C. material can be stockpiled ready for use.
D. stock is not left outside where it could become
contaminated.
NEBOSH
With regard to process safety management, chemical
warehouses should be managed and routinely inspected to
ensure that:
A. production is not affected is stock runs low.
B. incompatible materials are kept separated.
C. material can be stockpiled ready for use.
D. stock is not left outside where it could become
contaminated.
NEBOSH

Element 4
Fire protection and emergency
response
1. Fire hazards
2. Fire and explosion control
3. Dust explosions
4. Emergency preparedness
NEBOSH
Q1
Which of the following best describes a Zone 1 hazardous area?
A. a place in which an explosive mixture in the form of a cloud of
combustible dust in air is likely to occur in normal operation
occasionally.
B. a place in which an explosive atmosphere in the form of a cloud of
flammable gas in air is likely to occur in normal operation occasionally.
C. a place in which an explosive atmosphere in the form of a cloud of
combustible dust in air is not likely to occur in normal operation, but if
it does occur, will persist for a short period only.
D. a place in which an explosive atmosphere in the form of a flammable
gas in air is not likely to occur in normal operation, but if it does occur,
will persist for a short period only.
NEBOSH
Q1
Which of the following best describes a Zone 1 hazardous area?
A. a place in which an explosive mixture in the form of a cloud of
combustible dust in air is likely to occur in normal operation
occasionally.
B. a place in which an explosive atmosphere in the form of a cloud of
flammable gas in air is likely to occur in normal operation occasionally.
C. a place in which an explosive atmosphere in the form of a cloud of
combustible dust in air is not likely to occur in normal operation, but if
it does occur, will persist for a short period only.
D. a place in which an explosive atmosphere in the form of a flammable
gas in air is not likely to occur in normal operation, but if it does occur,
will persist for a short period only.
NEBOSH
Q2
An external fire directly heats a vessel containing a
flammable liquid. The liquid begins to boil, increasing the
pressure which opens an integral pressure relief valve. The
liquid level inside the vessel lowers and the fire now begins
to heat the vessel above the liquid level. The vessel metal
thins, weakens and ruptures. What type of explosion does
this describe?
A. a confined vapour cloud explosion.
B. a secondary explosion.
C. a boiling liquid expanding vapour explosion.
D. an unconfined vapour cloud explosion.
NEBOSH
Q2
An external fire directly heats a vessel containing a
flammable liquid. The liquid begins to boil, increasing the
pressure which opens an integral pressure relief valve. The
liquid level inside the vessel lowers and the fire now begins
to heat the vessel above the liquid level. The vessel metal
thins, weakens and ruptures. What type of explosion does
this describe?
A. a confined vapour cloud explosion.
B. a secondary explosion.
C. a boiling liquid expanding vapour explosion.
D. an unconfined vapour cloud explosion.
NEBOSH
Q3
Development of an emergency plan should consider areas
that are:
A. on-site only.
B. either on-site or off-site.
C. off-site only.
D. on-site and off-site.
NEBOSH
Q3
Development of an emergency plan should consider areas
that are:
A. on-site only.
B. either on-site or off-site.
C. off-site only.
D. on-site and off-site.
NEBOSH
Q4
Which is the preferred fire extinguishing media in a typical
process control room?
A. chemical powder.
B. foam deluge.
C. carbon dioxide.
D. water deluge.
NEBOSH
Q4
Which is the preferred fire extinguishing media in a typical
process control room?
A. chemical powder.
B. foam deluge.
C. carbon dioxide.
D. water deluge.
NEBOSH
Q5
In processes that involve combustible dusts, why is it
especially important to maintain good housekeeping?
A. dust can build up on a variety of flat and irregular surfaces
which can spontaneously ignite.
B. dust on surfaces can be disturbed by a primary explosion
causing a larger secondary explosion.
C. dust build up on surfaces can be clearly seen by visitors
and gives a poor image of the company
D. dust will adversely affect limit sensors and proximity
switches causing them to malfunction.
NEBOSH
Q5
In processes that involve combustible dusts, why is it
especially important to maintain good housekeeping?
A. dust can build up on a variety of flat and irregular surfaces
which can spontaneously ignite.
B. dust on surfaces can be disturbed by a primary explosion
causing a larger secondary explosion.
C. dust build up on surfaces can be clearly seen by visitors
and gives a poor image of the company
D. dust will adversely affect limit sensors and proximity
switches causing them to malfunction.
NEBOSH
Q6
Flammable liquid leaked from a storage vessel into the bund which
surrounded it. The liquid began to fill the bund. Liquid also began
to leak through cracks in the bund and flow towards a faulty
electrical pump usually used to empty the bund of rain water.
Within minutes the entire bund was on fire, taking several hours
to extinguish. What is the best description of this type of fire?
A. jet fire.
B. pool fire.
C. flash fire.
D. secondary fire.
NEBOSH
Q6
Flammable liquid leaked from a storage vessel into the bund which
surrounded it. The liquid began to fill the bund. Liquid also began
to leak through cracks in the bund and flow towards a faulty
electrical pump usually used to empty the bund of rain water.
Within minutes the entire bund was on fire, taking several hours
to extinguish. What is the best description of this type of fire?
A. jet fire.
B. pool fire.
C. flash fire.
D. secondary fire.
NEBOSH

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