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Health and Safety Laboratory

Annual Report and Accounts

2006 / 2007

ONE SIMPLE VISION

AND A WEALTHOF WORLD CLASSEXPERTISE

ALL WORKING TOSAVE ANDIMPROVE THELIVES OFWORKERS

HEALTH & SAFETY LABORATORY REPORT & ACCOUNTS 2006 / 2007 03

Contents

04 Chief Executive’s Foreword

06 Introducing HSL

08 Improving health

12 Controlling hazards

18 Choosing the best

27 Highlights of 2006 / 07

29 Management Commentary

41 Accounts 2006 / 07

48 Notes to the Accounts

04 Chief Executive’s Foreword

06 Introducing HSL

08 Improving health

12 Controlling hazards

18 Choosing the best

27 Highlights of 2006 / 07

29 Management Commentary

41 Accounts 2006 / 07

48 Notes to the Accounts

Contents

AND A WEALTH OF WORLD CLASS EXPERTISE

ALL WORKING TO SAVE AND IMPROVE THE LIVES OF WORKERS


≈ The board from left to right:

Andrew Curran, Ruth Gilbody, John Verney,

David Kershaw-Wright, Eddie Morland, Sue Ion,

Peter Watson and Karen Russ


The laboratory continues to focus on

the key areas of keeping things healthy

and safe, winning new business,

delivering it and investing for the future.

Foreword

By the Chief Executive Eddie Morland

As HSL enters its second decade as

an agency of the Health and Safety

Executive, I am pleased to be able to

report that the Laboratory is busier

than ever before. This achievement

is all the more remarkable given the

significant re-structuring of the

organisation, including wholesale

changes to the make-up of the HSL

Board that we undertook during

the year. Furthermore, the significant

increase in earned revenues was

achieved with increased efficiency,

improved financial contribution and,

as you will see in the body of this

report, with scientific excellence across

an amazingly diverse set of industrial

sectors and disciplines. I would

therefore like to take this opportunity,

up front, to thank all staff at HSL for

their tremendous performance and

commitment throughout the year.

The structure of the Laboratory has

been simplified to improve business

efficiency and also to ‘map’ more

closely on to our customers’ needs.

The former six ‘discipline-focused’

operating groups of HSL have now

been consolidated into three, larger,

‘solution-focused’ groups.

These are:

Health Improvement:

focused on the health and safety

of workers

Hazard Reduction:

focused on the safety of industrial plant

Human Factors:

focused on individual human and

social-group interactions which

affect either workers or plant safety

In another change, each of the new

operating Groups is now represented

on the HSL Board. I am therefore

pleased to welcome Dr Andrew

Curran, Mr David Kershaw-Wright

and Dr Karen Russ as the new Group

Directors of Health Improvement,

Hazard Reduction and Human Factors

respectively. Andrew was promoted

internally from a senior management

position in HSL. David joined us in

September from the Building Research

Establishment and Karen joined at

the same time from Pilkington Plc.

Karen also holds the additional role

of Director of Technical Programmes,

focused on cross-HSL operational

processes, and is my official Deputy.

Mr Graham Ince, former Head of

Business Infrastructure, retired during

the year and we thank him for

his services to the Laboratory over

many years. Graham’s areas of

responsibility have been re-distributed

among the remaining Directors.

The Laboratory continues to focus

on the key areas of keeping things

healthy and safe, winning new

business, delivering it and investing

for the future.

In terms of health, I am pleased to

report that absence due to sickness

was 1.3 days better than target, at an

average of 4.9 days per person over

the year. Working closely with our

colleagues in HSE, we instigated new

procedures to improve rehabilitation

of staff returning from long-term

sickness and more pro-active initiatives

such as automated self-service DSE

assessment and advice. Regarding

safety indicators, Board-level safety

walkabouts were all completed to

target and encouragingly we achieved

higher levels of reporting of both

near misses and accidents than last

year. Disappointingly, however, we did

have four RIDDOR events during the

year, thereby missing our target of no

more than two. In response to this,

we shall increase both the frequency

and extent of risk assessment

training across the whole laboratory.

Finally, working with our PFI

partners, we have instigated new

standards and requirements for the

management of contractors’ safety,

including a DVD-based introduction

to working at HSL and a mandatory

test which must be passed before

contractors can begin work on site.

In terms of winning new business,

HSL had its most successful year

ever in securing new contracts,

from both HSE and non-HSE

customers. In particular, we have

worked very closely with HSE during

the year to develop a new strategic

partnership with them and this is

embodied in a new Framework

Document. On non-HSE business,

our strategy of ‘focus’ on key market

sectors and areas of technology is

paying dividends.

We are seeing both repeat business

and ‘cross-buying’ from our largest

customers, and the growing visibility

of HSL resulted in not only a record

value of contracts won during the year,

but also a strong forward order book.

In terms of delivering contracted

work, HSL improved still further on

last year’s record performance.

Overall, the Laboratory delivered

revenues of £34.1m, a rise of 7.5%

on the previous year. HSE revenues

were up by £1.2m (4.5%) and non-

HSE revenues by £1.2m (25.0%).

As already mentioned, this work was

delivered more efficiently, with the ratio

of non-chargeable to total available

staff time reducing by 2.7% against a

target improvement of 2%. Expenditure

was also well managed, with the

result that HSL significantly reduced

its requirement for transition funding

from HSE - down to £1.4m from

£3.7m last year. As a consequence,

HSE’s gross spend on HSL reduced

by around £1m compared to last year.

In looking after the longer-term future

of the Laboratory, we have enhanced

management processes in addition

to continued investment. We have

now successfully implemented a new

process for identifying and managing

arising intellectual property (IP) and

have concluded an IP ‘concordat’

with HSE to formalise arrangements.

We have also established a formal

investment committee as a sub

group of the HSL Board, both to better

align capital investment plans with

strategic objectives and to monitor

the forward business performance

of new facilities.

Taking all of this together, HSL has

had a very successful year. Not only

has the Laboratory secured and

delivered record levels of business,

it has done so more efficiently,

at lower total cost to HSE and with

a wider direct benefit to non-HSE

customers. However, while the

financial performance undoubtedly

shows that we are realising the great

potential of our new facility, the real

‘pay-off’ is that HSL is extending

its sustainable contribution to the

health, safety and productivity of

work in the United Kingdom.

04 HEALTH & SAFETY LABORATORY REPORT & ACCOUNTS 2006 / 2007

By the Chief Executive Eddie Morland

Foreword


As HSL enters its second decade as

an agency of the Health and Safety

Executive, I am pleased to be able to

report that the Laboratory is busier

than ever before. This achievement

is all the more remarkable given the

significant re-structuring of the

organisation, including wholesale

changes to the make-up of the HSL

Board that we undertook during

the year. Furthermore, the significant

increase in earned revenues was

achieved with increased efficiency,

improved financial contribution and,

as you will see in the body of this

report, with scientific excellence across

an amazingly diverse set of industrial

sectors and disciplines. I would

therefore like to take this opportunity,

up front, to thank all staff at HSL for

their tremendous performance and

commitment throughout the year.

The structure of the Laboratory has

been simplified to improve business

efficiency and also to ‘map’ more

closely on to our customers’ needs.

The former six ‘discipline-focused’

operating groups of HSL have now

been consolidated into three, larger,

‘solution-focused’ groups.

These are:

Health Improvement:

focused on the health and safety

of workers

Hazard Reduction:

focused on the safety of industrial plant

Human Factors:

focused on individual human and

social-group interactions which

affect either workers or plant safety

In another change, each of the new

operating Groups is now represented

on the HSL Board. I am therefore

pleased to welcome Dr Andrew

Curran, Mr David Kershaw-Wright

and Dr Karen Russ as the new Group

Directors of Health Improvement,

Hazard Reduction and Human Factors

respectively. Andrew was promoted

internally from a senior management

position in HSL. David joined us in

September from the Building Research

Establishment and Karen joined at

the same time from Pilkington Plc.

Karen also holds the additional role

of Director of Technical Programmes,

focused on cross-HSL operational

processes, and is my official Deputy.

Mr Graham Ince, former Head of

Business Infrastructure, retired during

the year and we thank him for

his services to the Laboratory over

many years. Graham’s areas of

responsibility have been re-distributed

among the remaining Directors.

The Laboratory continues to focus

on the key areas of keeping things

healthy and safe, winning new

business, delivering it and investing

for the future.

In terms of health, I am pleased to

report that absence due to sickness

was 1.3 days better than target, at an

average of 4.9 days per person over

the year. Working closely with our

colleagues in HSE, we instigated new

procedures to improve rehabilitation

of staff returning from long-term

sickness and more pro-active initiatives

such as automated self-service DSE

assessment and advice. Regarding

safety indicators, Board-level safety

walkabouts were all completed to

target and encouragingly we achieved

higher levels of reporting of both

near misses and accidents than last

year. Disappointingly, however, we did

have four RIDDOR events during the

year, thereby missing our target of no

more than two. In response to this,

we shall increase both the frequency

and extent of risk assessment

training across the whole laboratory.

Finally, working with our PFI

partners, we have instigated new

standards and requirements for the

management of contractors’ safety,

including a DVD-based introduction

to working at HSL and a mandatory

test which must be passed before

contractors can begin work on site.

In terms of winning new business,

HSL had its most successful year

ever in securing new contracts,

from both HSE and non-HSE

customers. In particular, we have

worked very closely with HSE during

the year to develop a new strategic

partnership with them and this is

embodied in a new Framework

Document. On non-HSE business,

our strategy of ‘focus’ on key market

sectors and areas of technology is

paying dividends.

We are seeing both repeat business

and ‘cross-buying’ from our largest

customers, and the growing visibility

of HSL resulted in not only a record

value of contracts won during the year,

but also a strong forward order book.

In terms of delivering contracted

work, HSL improved still further on

last year’s record performance.

Overall, the Laboratory delivered

revenues of £34.1m, a rise of 7.5%

on the previous year. HSE revenues

were up by £1.2m (4.5%) and non-

HSE revenues by £1.2m (25.0%).

As already mentioned, this work was

delivered more efficiently, with the ratio

of non-chargeable to total available

staff time reducing by 2.7% against a

target improvement of 2%. Expenditure

was also well managed, with the

result that HSL significantly reduced

its requirement for transition funding

from HSE - down to £1.4m from

£3.7m last year. As a consequence,

HSE’s gross spend on HSL reduced

by around £1m compared to last year.

In looking after the longer-term future

of the Laboratory, we have enhanced

management processes in addition

to continued investment. We have

now successfully implemented a new

process for identifying and managing

arising intellectual property (IP) and

have concluded an IP ‘concordat’

with HSE to formalise arrangements.

We have also established a formal

investment committee as a sub-

group of the HSL Board, both to better

align capital investment plans with

strategic objectives and to monitor

the forward business performance

of new facilities.

Taking all of this together, HSL has

had a very successful year. Not only

has the Laboratory secured and

delivered record levels of business,

it has done so more efficiently,

at lower total cost to HSE and with

a wider direct benefit to non-HSE

customers. However, while the

financial performance undoubtedly

shows that we are realising the great

potential of our new facility, the real

‘pay-off’ is that HSL is extending

its sustainable contribution to the

health, safety and productivity of

work in the United Kingdom.

The laboratory continues to focus on

the key areas of keeping things healthy

and safe, winning new business,

delivering it and investing for the future.

≈ The board from left to right:

Andrew Curran, Ruth Gilbody, John Verney,

David Kershaw-Wright, Eddie Morland, Sue Ion,

Peter Watson and Karen Russ


Keeping people healthy and safe

Our twin focus on the needs of

Government and business is central

to how we operate. At its simplest,

we provide the scientific services they

need to improve health and safety at

both a national and international level.

As the in-house laboratory of the

Health and Safety Executive (HSE),

we make a very important

contribution to delivering the

Government's strategy for improving

health and safety in Great Britain.

This is defined in the Health and

Safety Commission's (HSC) Strategy

for Workplace Health and Safety in

Great Britain to 2010 and Beyond.

Our main role is to provide HSE with

the scientific assistance it needs to

meet its Public Service Agreement

(PSA) targets and its enforcement

and other statutory duties.

The PSA targets concentrate on

progressively improving risk control

for measurably better health and

safety at work by 2008. This chiefly

means delivering on its two Strategic

Delivery Programmes (SDPs):

≥ Fit for work, fit for life, fit for

tomorrow (Fit3) focuses on

reducing injuries, ill-health and

days lost due to work activity

≥ Major Hazards regulates and

assures safe management of

those industries where failure to

manage risks can have

catastrophic effects

At the Health and Safety Laboratory

(HSL), we have a simple but very

important vision – to use our brains

to save and improve the lives of

workers.

We do this by focusing all aspects

of science onto the diverse range of

health and safety issues that arise

in the workplace. We use our

experience and know-how to identify

the problems and propose solutions

that work. We focus on improving

processes and plant and their

interactions with, and effects on,

people. This is our strategic goal,

the driving force behind our mission

to improve people's health and control

the hazards they face at work.

Our work concentrates on two main

areas. First, we are helping deliver

the Government's objectives –

improving the nation's economy and

competitiveness in a global market

through a healthy, safe and highly

productive workforce.

Second, we are meeting the needs

of industry and commerce –

reducing plant failures and staff

absences due to work-related ill-

health or injury to increase productivity

and maximise competitiveness.

Our record makes us internationally

recognised as one of the world's

premier health and safety

laboratories. This is because we

have a diverse range of scientific,

engineering and technical specialists

and health professionals to draw on,

improving health and reducing risk.

And the scope of our attention is

vast too, from fire, explosion and

process safety to occupational

health and environmental sciences,

safety engineering and human factors.

We are closely involved in HSE's

enabling activities that support the

SDPs - these include working in

partnership with local authorities,

promoting the benefits of sensible

health and safety management and

worker involvement. We also fulfil a

vital role helping to deliver the

evidence base in support of HSE's

inspection and enforcement activities.

But our scientific services are not

restricted to HSE. An increasingly

important part of our business is

our work for other organisations in

both the public and private sectors.

This continues to grow strongly as

we help Government and industry

meet their objectives by bringing

business, workers and the national

economy the benefits of well-

managed, sensible, health and

safety processes.

This report tells the story of HSL’s

activities in 2006-07 – a story of

applying science to make workplaces

healthier, safer and more productive.

In short, delivering our vision of

using our brains to save and improve

the lives of workers.


We are internationally recognised

as one of the world's premier health

and safety laboratories. This is because

we have a diverse range of scientific,


and health professionals to draw on.

INTRODUCING HSL

AT THE HEALTH AND SAFETY

LABORATORY, OUR SIMPLE

BUT VERY IMPORTANT VISION

REMAINS THE SAME OVER THE

YEARS – TO USE OUR BRAINS TO

SAVE AND IMPROVE THE LIVES

OF WORKERS.


INTRODUCING HSL

AT THE HEALTH AND SAFETY

LABORATORY, OUR SIMPLE

BUT VERY IMPORTANT VISION

REMAINS THE SAME OVER THE

YEARS – TO USE OUR BRAINS TO

SAVE AND IMPROVE THE LIVES

OF WORKERS.


At the Health and Safety Laboratory

(HSL), we have a simple but very

important vision – to use our brains

to save and improve the lives of

workers.

We do this by focusing all aspects

of science onto the diverse range of

health and safety issues that arise

in the workplace. We use our We are internationally recognised experience and know-how to identify

the problems and propose solutions

that work. We focus on improving

processes and plant and their

interactions with, and effects on,

people. This is our strategic goal,

the driving force behind our mission

to improve people's health and control

the hazards they face at work.

Our work concentrates on two main

areas. First, we are helping deliver

the Government's objectives –

improving the nation's economy and

competitiveness in a global market

through a healthy, safe and highly

productive workforce.

Second, we are meeting the needs

of industry and commerce –

reducing plant failures and staff

absences due to work-related ill-

health or injury to increase productivity

and maximise competitiveness.

Our record makes us internationally

recognised as one of the world's

premier health and safety

laboratories. This is because we

have a diverse range of scientific,


and health professionals to draw on,

improving health and reducing risk.

And the scope of our attention is

vast too, from fire, explosion and

process safety to occupational

health and environmental sciences,

safety engineering and human factors.

as one of the world's premier health

and safety laboratories. This is because

we have a diverse range of scientific,


and health professionals to draw on.

Keeping people healthy and safe

Our twin focus on the needs of

Government and business is central

to how we operate. At its simplest,

we provide the scientific services they

need to improve health and safety at

both a national and international level.

As the in-house laboratory of the

Health and Safety Executive (HSE),

we make a very important

contribution to delivering the

Government's strategy for improving

health and safety in Great Britain.

This is defined in the Health and

Safety Commission's (HSC) Strategy

for Workplace Health and Safety in

Great Britain to 2010 and Beyond.

Our main role is to provide HSE with

the scientific assistance it needs to

meet its Public Service Agreement

(PSA) targets and its enforcement

and other statutory duties.

The PSA targets concentrate on

progressively improving risk control

for measurably better health and

safety at work by 2008. This chiefly

means delivering on its two Strategic

Delivery Programmes (SDPs):

≥ Fit for work, fit for life, fit for

tomorrow (Fit3) focuses on


days lost due to work activity

≥ Major Hazards regulates and




catastrophic effects

We are closely involved in HSE's

enabling activities that support the

SDPs - these include working in

partnership with local authorities,

promoting the benefits of sensible

health and safety management and

worker involvement. We also fulfil a

vital role helping to deliver the

evidence base in support of HSE's

inspection and enforcement activities.

But our scientific services are not

restricted to HSE. An increasingly

important part of our business is

our work for other organisations in

both the public and private sectors.

This continues to grow strongly as

we help Government and industry

meet their objectives by bringing

business, workers and the national

economy the benefits of well-

managed, sensible, health and

safety processes.

This report tells the story of HSL’s

activities in 2006-07 – a story of

applying science to make workplaces

healthier, safer and more productive.

In short, delivering our vision of

using our brains to save and improve

the lives of workers.


CWH – a partnershipfor excellence


Today, the Centre for Workplace Health

(CWH) is recognised as a national

centre of excellence in occupational

health and safety research, training

and service provision.

Its progress has been rapid – it was

created in September 2005, when,

to cement our long-standing

partnership, we signed a

memorandum of understanding

with the University of Sheffield and

the Sheffield Teaching Hospitals

NHS Foundation Trust.

The unique blend of expertise,

experience and facilities shared by

the three partners and our

associates enables CWH to provide

practical solutions to workplace ill-

health problems – all based on

high-quality science.

With the recent announcement of a

number of groundbreaking

government initiatives, CWH is

facing exciting times in the world of

occupational health and safety.

It has secured widespread support

and is currently involved in large

programmes of work focusing on a

broad range of occupational health

issues, including respiratory disease,

rehabilitation and ageing workers.

Improving health

Workplace injuries and ill- This work is wide-ranging,

health can have serious bringing together many

consequences, both for business scientific disciplines from

and the individuals concerned. social science to clinical

medicine, analytical chemistry

For the past year, we have to psychology. We can only

applied our expertise to include a few examples here,

supporting HSE in delivering but the pieces that follow

its Fit3 strategic programme illustrate how we have helped

and its statutory duties. to improve the health of

And we have provided workers and those affected by

occupational health solutions

to other customers, including

government departments and

private sector organisations.

work activities.

Stress consultancy at RAF Wyton

Work-related stress is one of the

biggest causes of working days lost.

Some 10.5 million days were lost in

2005/06, with one person in six

saying that they found their work

very or extremely stressful.

We helped produce the Management

Standards for Work-related Stress,

launched by HSE in 2004.

Based on recognised good

management practice, these use a

risk assessment process to manage

and reduce the risks of stress.

HSL offers a range of bespoke

services to help organisations

implement the standards, including

help with setting up and briefing

Work-related stress is one of the biggest causes of working days lost. Some 10.5 million days were lost in 2005/06, with one person in six saying that they found their work very or extremely stressful.

steering groups, tailoring the HSE

questionnaire (called the ‘Indicator

Tool’) to the needs of their business,

analysing data, facilitating focus

groups and training their people as

facilitators. Once results have been

presented to the steering groups

and management, we can also help

them develop action plans to

address any issues identified during

the risk assessment process.

One such organisation was RAF

Wyton, part of the Ministry of Defence,

who asked for help after attending an

HSL training course on work-related

stress. First, we used the Indicator

Tool to identify key areas of work

design which may lead to ill-health

if not managed properly, sending

questionnaires to over 2,000 staff

with a 60% response rate.

We analysed the results, looking at

location, grade, gender, hours of

work, teams and types of personnel,

and identified both areas of concern

and aspects of good practice,

which RAF Wyton could learn from

and share with other teams.

Following a full report to the

Director General and project team,

RAF Wyton is now keen for us to

train some of their staff in

facilitating focus groups so they can

continue the process themselves.



Work-related stress is one of the biggest causes ofworking days lost. Some 10.5 million days were lostin 2005/06, with one person in six saying that theyfound their work very or extremely stressful.

Improving health

Work-related stress is one of the

biggest causes of working days lost.

Some 10.5 million days were lost in

2005/06, with one person in six

saying that they found their work

very or extremely stressful.

We helped produce the Management

Standards for Work-related Stress,

launched by HSE in 2004.

Based on recognised good

management practice, these use a

risk assessment process to manage

and reduce the risks of stress.

HSL offers a range of bespoke

services to help organisations

implement the standards, including

help with setting up and briefing

steering groups, tailoring the HSE

questionnaire (called the ‘Indicator

Tool’) to the needs of their business,

analysing data, facilitating focus

groups and training their people as

facilitators. Once results have been

presented to the steering groups

and management, we can also help

them develop action plans to

address any issues identified during

the risk assessment process.

One such organisation was RAF

Wyton, part of the Ministry of Defence,

who asked for help after attending an

HSL training course on work-related

stress. First, we used the Indicator

Tool to identify key areas of work

design which may lead to ill-health

if not managed properly, sending

questionnaires to over 2,000 staff

with a 60% response rate.

Stress consultancyat RAF Wyton

Workplace injuries and ill-

health can have serious

consequences, both for business

and the individuals concerned.

For the past year, we have

applied our expertise to

supporting HSE in delivering

its Fit3 strategic programme

and its statutory duties.

And we have provided

occupational health solutions

to other customers, including

government departments and

private sector organisations.

This work is wide-ranging,

bringing together many

scientific disciplines from

social science to clinical

medicine, analytical chemistry

to psychology. We can only

include a few examples here,

but the pieces that follow

illustrate how we have helped

to improve the health of

workers and those affected by

work activities.

We analysed the results, looking at

location, grade, gender, hours of

work, teams and types of personnel,

and identified both areas of concern

and aspects of good practice,

which RAF Wyton could learn from

and share with other teams.

Following a full report to the

Director General and project team,

RAF Wyton is now keen for us to

train some of their staff in

facilitating focus groups so they can

continue the process themselves.

CWH – a partnership for excellence

Today, the Centre for Workplace Health

(CWH) is recognised as a national

centre of excellence in occupational

health and safety research, training

and service provision.

Its progress has been rapid – it was

created in September 2005, when,

to cement our long-standing

partnership, we signed a

memorandum of understanding

with the University of Sheffield and

the Sheffield Teaching Hospitals

NHS Foundation Trust.

The unique blend of expertise,

experience and facilities shared by

the three partners and our

associates enables CWH to provide

practical solutions to workplace ill-

health problems – all based on

high-quality science.

With the recent announcement of a

number of groundbreaking

government initiatives, CWH is

facing exciting times in the world of

occupational health and safety.

It has secured widespread support

and is currently involved in large

programmes of work focusing on a

broad range of occupational health

issues, including respiratory disease,

rehabilitation and ageing workers.


In the past, most occupational

diseases have arisen from physical

hazards such as toxic chemicals or

physically demanding jobs.

Today, things are not as clear cut.

Psychological and social factors are

now thought to be increasingly

important, with the transition from

manual to desk-based jobs driving

a significant increase in the

prevalence of conditions such as

stress, musculoskeletal disorders,

anxiety and depression.

HSE asked HSL to undertake a

large-scale review of the available

literature to examine how approaches

based on a new ‘biopsychosocial’

view can usefully be applied to

managing the risks associated with

contemporary occupational health.

The biopsychosocial approach to

health takes an holistic view,

regarding it as the interplay between

The ‘biopsychosocial’view of occupational health


metal-working fluids, and the

largest single outbreak of

occupational asthma.

But the story did not end there.

The collaboration resulted in

significant advances in

understanding the complex factors

involved, as well as close co-

operation with industry – the British

Lubricants Association in particular.

HSE produced new guidance,

contacted all large UK users to

check standards, and where

necessary pursued enforcement to

improve management standards.

It also launched a publicity

campaign to raise awareness of the

health risks associated with metal-

working fluids, culminating in a

press conference in early 2006.

Early suspicions focused on thepossibility of microbiologicalcontamination of metal-working fluidsused in the machining process.

Understandinglung diseaseoutbreak

biological (e.g. physical stress on

tissues), psychological (e.g. coping

strategies, personality) and social

(e.g. social support, organisational

culture) and macro (e.g. socio-

economic policies) factors.

HSL’s review will help equip HSE and

its partners with a flexible framework

for more effective handling of 21st

century occupational health issues.

When it was reported that a number

of people working at a car

manufacturing plant in England

were suffering from a respiratory

disease, early suspicions focused on

the possibility of microbiological

contamination of metal-working fluids

used in the machining process.

HSE began an investigation of the

plant, with a multi-disciplinary team

from HSL, the Birmingham Chest

Clinic and Warwick University.

This involved a full assessment of

how metal-working fluids and oils

were managed, an occupational

hygiene investigation and the

detailed clinical and immunological

investigation of staff.

By the time the company entered

receivership in 2005, the investigation

had obtained all the significant

information it needed. This showed

that some 10% of the car-

manufacturing workforce met a pre-

defined case definition for

respiratory disease (extrinsic allergic

alveolitis, occupational asthma and/

or humidifier fever). It also

implicated microbial contamination

of the metal-working fluids.

With 101 cases, this is thought to be

the world’s largest outbreak of

occupational lung disease linked to

Understanding noise and vibration from sanders and polishers

Painful and disabling disorders of

the hands and arms can result from

regular exposure to the vibration

caused by hand-held power tools.

Without proper controls, the excessive

noise they produce can lead to

permanent hearing damage.

Manufacturers are required to provide

noise and vibration emission

information to help users assess the

exposure risks. But while standards

for evaluating vibration emissions

are currently being improved,

there is little available information

on the relationship between

manufacturers’ data and the actual

risks of noise exposure.

As part of its programme of work on noise and

hand-arm vibration, HSE asked HSL to look at workplace

exposures and assess the quality of the emission

data that sander and polisher manufacturers provide.

As part of its programme of work on

noise and hand-arm vibration,

HSE asked HSL to look at workplace

exposures and assess the quality of

the emission data that sander and

polisher manufacturers provide.

First we measured noise and

vibration emissions in our anechoic

chamber, surrounding the tools with

microphones and fitting vibration

transducers to the handles.

To gain representative measurements,

we needed to place the transducers

in the best location on the handles.

We achieved this by first studying

the vibration deflection shapes of

the handles while in use, enabling

us both to avoid spots where

vibration levels were untypically low

or high and to understand the

rotational vibration modes of the tools.

To provide comparative data with

our laboratory results, we then

measured noise and vibration levels

in real workplaces, such as vehicle

and furniture manufacturers,

yacht builders and the automotive

and train body repair industry.

Our work is now helping HSE to

understand problems with

manufacturers’ current data and to

improve the underlying standards

for testing machine emissions.

This is particularly important

following the recent introduction of

new UK regulations for the control

of workplace noise and vibration,

that encourage employers to use

manufacturers’ data in their own

risk assessments.



To provide comparative data with

our laboratory results, we then

measured noise and vibration levels

in real workplaces, such as vehicle

and furniture manufacturers,

yacht builders and the automotive

and train body repair industry.

Our work is now helping HSE to

understand problems with

manufacturers’ current data and to

improve the underlying standards

for testing machine emissions.

This is particularly important

following the recent introduction of

new UK regulations for the control

of workplace noise and vibration,

that encourage employers to use

manufacturers’ data in their own

risk assessments.

As part of its programme of work on

noise and hand-arm vibration,

HSE asked HSL to look at workplace

exposures and assess the quality of

the emission data that sander and

polisher manufacturers provide.

First we measured noise and

vibration emissions in our anechoic

chamber, surrounding the tools with

microphones and fitting vibration

transducers to the handles.

To gain representative measurements,

we needed to place the transducers

in the best location on the handles.

We achieved this by first studying

the vibration deflection shapes of

the handles while in use, enabling

us both to avoid spots where

vibration levels were untypically low

or high and to understand the

rotational vibration modes of the tools.

Painful and disabling disorders of

the hands and arms can result from

regular exposure to the vibration

caused by hand-held power tools.

Without proper controls, the excessive

noise they produce can lead to

permanent hearing damage.

Manufacturers are required to provide

noise and vibration emission

information to help users assess the

exposure risks. But while standards

for evaluating vibration emissions

are currently being improved,

there is little available information

on the relationship between

manufacturers’ data and the actual

risks of noise exposure.

Understanding noise andvibration from sanders and polishers

As part of its programme of work on noise and

hand-arm vibration, HSE asked HSL to look at workplace

exposures and assess the quality of the emission

data that sander and polisher manufacturers provide.

In the past, most occupational

diseases have arisen from physical

hazards such as toxic chemicals or

physically demanding jobs.

Today, things are not as clear cut.

Psychological and social factors are

now thought to be increasingly

important, with the transition from

manual to desk-based jobs driving

a significant increase in the

prevalence of conditions such as

stress, musculoskeletal disorders,

anxiety and depression.

that some 10% of the car-

manufacturing workforce met a pre

defined case definition for

respiratory disease (extrinsic allergic

alveolitis, occupational asthma and/

or humidifier fever). It also

implicated microbial contamination

of the metal-working fluids.

With 101 cases, this is thought to be

the world’s largest outbreak of

occupational lung disease linked to

The ‘biopsychosocial’ view of occupational health

HSE asked HSL to undertake a

large-scale review of the available

literature to examine how approaches

based on a new ‘biopsychosocial’

view can usefully be applied to

managing the risks associated with

contemporary occupational health.

The biopsychosocial approach to

health takes an holistic view,

regarding it as the interplay between

metal-working fluids, and the

largest single outbreak of

occupational asthma.

But the story did not end there.

The collaboration resulted in

significant advances in

understanding the complex factors

involved, as well as close co

operation with industry – the British

Lubricants Association in particular.

HSE produced new guidance,

contacted all large UK users to

check standards, and where

necessary pursued enforcement to

improve management standards.

It also launched a publicity

campaign to raise awareness of the

health risks associated with metal

working fluids, culminating in a

press conference in early 2006.

Understanding lung disease outbreak

When it was reported that a number

of people working at a car

manufacturing plant in England

were suffering from a respiratory

disease, early suspicions focused on

the possibility of microbiological

contamination of metal-working fluids

used in the machining process.

HSE began an investigation of the

plant, with a multi-disciplinary team

from HSL, the Birmingham Chest

Clinic and Warwick University.

This involved a full assessment of

how metal-working fluids and oils

were managed, an occupational

hygiene investigation and the

detailed clinical and immunological

investigation of staff.

By the time the company entered

receivership in 2005, the investigation

had obtained all the significant

information it needed. This showed

biological (e.g. physical stress on

tissues), psychological (e.g. coping

strategies, personality) and social

(e.g. social support, organisational

culture) and macro (e.g. socio

economic policies) factors.

HSL’s review will help equip HSE and

its partners with a flexible framework

for more effective handling of 21st

century occupational health issues.

Early suspicions focused on the possibility of microbiological contamination of metal-working fluids used in the machining process.



Recent major accidentinvestigations in the UKand abroad have reportedshortcomings in operators’systems to monitor themanagement of their majorhazard risks.

Controlling hazards

Some believe that improving safety is an unwarranted burden on

industry, making products more expensive and eating into profits.

In reality, it is the unplanned downtime of plant and machinery

that has a great impact on profitability. And failure to manage risk A key lesson from these effectively – particularly in major hazard industries – can have investigations was that companies

devastating consequences for workers and the public. should develop and maintain a set

As a major incident investigator for HSE, we understand a great

deal about how and why incidents happen. We can apply this

expertise in many ways to help industry – assessing the robustness

of systems, identifying weaknesses and advising on improvements.

In this section you will find some examples of how we are helping

HSE deliver its major hazards strategic programme, and some of

our work with other agencies and industry. These examples

of key performance indicators (KPIs)

for their major hazards and ensure

that process safety performance is

monitored and reported against

defined targets.

Identifying such KPIs and

encouraging their use is an

important element of HSE’s Major

Hazards strategic programme,

which HSL has supported with a

number of projects.

illustrate the importance of considering not just the physical and One such project is helping

organisations ensure that the areas engineering sciences, but the human factors as well. where they are most vulnerable

receive adequate coverage. We have

In this way, they demonstrate HSL’s key strength in bringing

together a wide range of specialisms to make industry not only

safer, but more profitable too.

Major hazards performance indicators

Management systems, like any other

system, can deteriorate over time,

particularly in areas where

performance monitoring is not

sufficiently robust. The results of

poor performance monitoring

systems can be particularly

devastating in the major hazard

industries such as oil and gas,

where failures can be catastrophic.

Recent major accident investigations

in the UK and abroad have reported

shortcomings in operators’ systems

to monitor the management of their

major hazard risks, with an over

reliance on conventional lost-time

injury performance. This can lead to

false confidence that these risks are

being managed effectively.

helped develop a framework to assist

organisations to benefit from the

implementation of ‘dual assurance’

indicators in line with HSE Guidance

HSG254: Developing Process Safety

Indicators: A step-by-step guide for

chemical and major hazard

industries. Under the dual assurance

approach, both ‘leading’ (process or

input) and ‘lagging’ (outcome)

indicators are monitored. In developing

the framework, we studied current

practice in major hazard industries,

identified generic principles for

setting indicators, explored scoring

mechanisms for benchmarking

performance and recommended a

common terminology.

We continue to work with HSE and

industry on developing such

indicators – particularly those

relating to measures of safety culture,

using techniques currently being

evaluated in the nuclear industry.

As more organisations develop

indicators, the framework will enable

benchmarking between partners

and across major hazard industry

sectors, thus promoting dialogue

and improved knowledge-sharing

among duty holders. This will

increase assurance that major hazard

management systems are performing

in a sustained, appropriate manner.


Controlling hazards

Some believe that improving safety is an unwarranted burden on

industry, making products more expensive and eating into profits.

In reality, it is the unplanned downtime of plant and machinery

that has a great impact on profitability. And failure to manage risk

effectively – particularly in major hazard industries – can have

devastating consequences for workers and the public.

As a major incident investigator for HSE, we understand a great

deal about how and why incidents happen. We can apply this

expertise in many ways to help industry – assessing the robustness

of systems, identifying weaknesses and advising on improvements.

In this section you will find some examples of how we are helping

HSE deliver its major hazards strategic programme, and some of

our work with other agencies and industry. These examples

illustrate the importance of considering not just the physical and

engineering sciences, but the human factors as well.

In this way, they demonstrate HSL’s key strength in bringing

together a wide range of specialisms to make industry not only

safer, but more profitable too.

Management systems, like any other

system, can deteriorate over time,

particularly in areas where

performance monitoring is not

sufficiently robust. The results of

poor performance monitoring

systems can be particularly

devastating in the major hazard

industries such as oil and gas,

where failures can be catastrophic.

Recent major accident investigations

in the UK and abroad have reported

shortcomings in operators’ systems

to monitor the management of their

major hazard risks, with an over

reliance on conventional lost-time

injury performance. This can lead to

false confidence that these risks are

being managed effectively.

Major hazardsperformanceindicators

A key lesson from these

investigations was that companies

should develop and maintain a set

of key performance indicators (KPIs)

for their major hazards and ensure

that process safety performance is

monitored and reported against

defined targets.

Identifying such KPIs and

encouraging their use is an

important element of HSE’s Major

Hazards strategic programme,

which HSL has supported with a

number of projects.

One such project is helping

organisations ensure that the areas

where they are most vulnerable

receive adequate coverage. We have

helped develop a framework to assist

organisations to benefit from the

implementation of ‘dual assurance’

indicators in line with HSE Guidance

HSG254: Developing Process Safety

Indicators: A step-by-step guide for

chemical and major hazard

industries. Under the dual assurance

approach, both ‘leading’ (process or

input) and ‘lagging’ (outcome)

indicators are monitored. In developing

the framework, we studied current

practice in major hazard industries,

identified generic principles for

setting indicators, explored scoring

mechanisms for benchmarking

performance and recommended a

common terminology.

We continue to work with HSE and

industry on developing such

indicators – particularly those

relating to measures of safety culture,

using techniques currently being

evaluated in the nuclear industry.

As more organisations develop

indicators, the framework will enable

benchmarking between partners

and across major hazard industry

sectors, thus promoting dialogue

and improved knowledge-sharing

among duty holders. This will

increase assurance that major hazard

management systems are performing

in a sustained, appropriate manner.


Recent major accident investigations in the UK and abroad have reported shortcomings in operators’ systems to monitor the management of their major hazard risks.


Engineers play a vital role in managing

risks, including those relating to

workplace health and safety. While it

is essential that engineering graduates

are properly prepared for this

responsibility, degree courses across

the UK vary widely in the content of

risk management concepts.

In particular, the teaching they receive

does not always match the risk that

graduates may be responsible for

managing in their professional lives.

Professional and educational bodies

have recognised this important

knowledge gap, and HSE has

sponsored HSL, in partnership with

others, to develop suitable teaching

materials.

HSL has been working with the

University of Liverpool on a project

to incorporate risk education into

the curriculum of an undergraduate

engineering degree course.

An early step was the design of a

questionnaire to determine students’

understanding of risk issues. Its use

during a class test has confirmed it to

be a reliable indicator of their

awareness. Results were used to help

set the appropriate level of tuition on

the undergraduate course, and the

questionnaire will be used in future

to evaluate the effectiveness of the

new syllabus.

Further achievements include the

embedding of risk topics into core

engineering modules, through formal

and keynote lectures on professional

practice. Together, we also designed

a new ‘virtual laboratory’ exercise,

based on a real-life accident

investigation at Port Ramsgate.

In association with the chair of the UK

Engineering Inter-Institutional Group

on Health and Safety and a software

development house, we have produced

a multi-media CD to demonstrate a

sample of e-learning materials.

The project’s results have been

presented at a number of professional

forums to promote this approach to

other educational institutions.

Nuclear site licences require the holder

to produce a detailed safety case for

all operations that may affect safety.

It is the responsibility of HSE’s Nuclear

Safety Directorate (NSD) to assess

these safety cases, which need to be

revised regularly in the light of new

challenges and emerging scientific

knowledge.

An important element of the safety

case for Advanced Gas-Cooled

Reactors (AGRs) is the structural

integrity of the graphite core. It must

include scientific evidence that shows

acceptable densities for the graphite

and the prevalence of any defects

within the graphite moderator bricks.

A previously unseen class of defects

was observed in 2004 at an AGR

power station. This involved two cracks

within a single moderator brick, a

phenomenon that in sufficient

numbers could affect core safety

functions. Current safety cases

therefore specify acceptable limits on

the prevalence of such defects.

For safety-related inspections to be

conducted on the graphite core, the

reactors need to be shut down and

fuel moved into storage before visual

and mechanical equipment can be

inserted into the fuel channels for data

recording. These checks are disruptive,

time-consuming and expensive, so

any improvement in efficiency that

does not compromise safety is an

important advance.

For some time, the periodic collection

of data from a sample of fuel channels

in different reactors has been used to

establish whether safety criteria are

being challenged, without needing to

assess the entire reactor core.

Recently, HSL scientists have been

working with NSD and British Energy

on developing complex mathematical

models that describe the development

of cracks over time, based on data

from periodic inspections of four AGR

stations between 1985 and 2006.

We have shown that reactors will not

challenge defined safety criteria

regarding the number of moderator

bricks containing two cracks in the

short-term future and that proposed

future inspection regimes, monitoring

the structural integrity of the graphite

core, are adequate for this purpose.

Risk education

Mathematical modelling forthe nuclear industry


Controlling third-party damage to Major Accident Hazard Pipelines

Regular maintenance and upgrading of the UK’s MAHPs has revealed unsatisfactory levels of ‘near miss’ reporting as well as several instances where damage to pipelines has not been reported.

The latest figures estimate that every

year utility companies dig some four

million holes – and this excludes

any excavations undertaken by the

construction industry. So it is not

surprising that third-party damage to

underground services of all kinds is a

significant source of potential danger.

When that service is a Major Accident

Hazard Pipeline (MAHP), the

consequences of a rupture can be

devastating for people and the

environment. Indeed, 24 people were

killed in Ghislenghien, Belgium in

2004, when nearby construction work

damaged a gas pipeline.

The potential for such third party

damage is considerable unless

adequate control is exercised over

excavation works close to pipelines.

This potential rises sharply where

pipelines enter urban areas or are

sited close to communication routes.

Regular maintenance and upgrading

of the UK’s MAHPs has revealed

unsatisfactory levels of ‘near miss’

reporting as well as several instances

where damage to pipelines has not

been reported to the operator.

Recognising that there was little

understanding of the human factors

potentially involved in such

infringements, HSE commissioned

HSL to work on a pilot project designed

to identify the main factors.

With the help of three major

contractors, we used a qualitative

approach to collecting data, including

observation, focused group

discussions and semi-structured

interviews with a range of personnel

from the contractors.

Key findings identified poor

communication between utility

companies as an important factor, and

highlighted the important role of

supervisors in balancing the demands

of safety with production.

All parties were pleased with the range

and depth of the information gathered,

which now helps HSE influence

companies to improve their

management of excavations near

pipelines.


Controlling third-party damageto Major Accident Hazard Pipelines


The latest figures estimate that every

year utility companies dig some four

million holes – and this excludes

any excavations undertaken by the

construction industry. So it is not

surprising that third-party damage to

underground services of all kinds is a

significant source of potential danger.

When that service is a Major Accident

Hazard Pipeline (MAHP), the

consequences of a rupture can be

devastating for people and the

environment. Indeed, 24 people were

killed in Ghislenghien, Belgium in

2004, when nearby construction work

damaged a gas pipeline.

The potential for such third party

damage is considerable unless

adequate control is exercised over

excavation works close to pipelines.

This potential rises sharply where

pipelines enter urban areas or are

sited close to communication routes.

Regular maintenance and upgrading

of the UK’s MAHPs has revealed

unsatisfactory levels of ‘near miss’

reporting as well as several instances

where damage to pipelines has not

been reported to the operator.

Recognising that there was little

understanding of the human factors

potentially involved in such

infringements, HSE commissioned

HSL to work on a pilot project designed

to identify the main factors.

With the help of three major

contractors, we used a qualitative

approach to collecting data, including

observation, focused group

discussions and semi-structured

interviews with a range of personnel

from the contractors.

Key findings identified poor

communication between utility

companies as an important factor, and

highlighted the important role of

supervisors in balancing the demands

of safety with production.

All parties were pleased with the range

and depth of the information gathered,

which now helps HSE influence

companies to improve their

management of excavations near

pipelines.

Regular maintenanceand upgrading of the UK’sMAHPs has revealedunsatisfactory levels of‘near miss’ reporting aswell as several instanceswhere damage to pipelineshas not been reported.

Risk education

Engineers play a vital role in managing

risks, including those relating to

workplace health and safety. While it

is essential that engineering graduates

are properly prepared for this

responsibility, degree courses across

the UK vary widely in the content of

risk management concepts.

In particular, the teaching they receive

does not always match the risk that

graduates may be responsible for

managing in their professional lives.

Professional and educational bodies

have recognised this important

knowledge gap, and HSE has

sponsored HSL, in partnership with

others, to develop suitable teaching

materials.

HSL has been working with the

University of Liverpool on a project

to incorporate risk education into

the curriculum of an undergraduate

engineering degree course.

An early step was the design of a

questionnaire to determine students’

understanding of risk issues. Its use

during a class test has confirmed it to

be a reliable indicator of their

awareness. Results were used to help

set the appropriate level of tuition on

the undergraduate course, and the

questionnaire will be used in future

to evaluate the effectiveness of the

new syllabus.

Further achievements include the

embedding of risk topics into core

engineering modules, through formal

and keynote lectures on professional

practice. Together, we also designed

a new ‘virtual laboratory’ exercise,

based on a real-life accident

investigation at Port Ramsgate.

In association with the chair of the UK

Engineering Inter-Institutional Group

on Health and Safety and a software

development house, we have produced

a multi-media CD to demonstrate a

sample of e-learning materials.

The project’s results have been

presented at a number of professional

forums to promote this approach to

other educational institutions.

Mathematical modelling for the nuclear industry

Nuclear site licences require the holder

to produce a detailed safety case for

all operations that may affect safety.

It is the responsibility of HSE’s Nuclear

Safety Directorate (NSD) to assess

these safety cases, which need to be

revised regularly in the light of new

challenges and emerging scientific

knowledge.

An important element of the safety

case for Advanced Gas-Cooled

Reactors (AGRs) is the structural

integrity of the graphite core. It must

include scientific evidence that shows

acceptable densities for the graphite

and the prevalence of any defects

within the graphite moderator bricks.

A previously unseen class of defects

was observed in 2004 at an AGR

power station. This involved two cracks

within a single moderator brick, a

phenomenon that in sufficient

numbers could affect core safety

functions. Current safety cases

therefore specify acceptable limits on

the prevalence of such defects.

For safety-related inspections to be

conducted on the graphite core, the

reactors need to be shut down and

fuel moved into storage before visual

and mechanical equipment can be

inserted into the fuel channels for data

recording. These checks are disruptive,

time-consuming and expensive, so

any improvement in efficiency that

does not compromise safety is an

important advance.

For some time, the periodic collection

of data from a sample of fuel channels

in different reactors has been used to

establish whether safety criteria are

being challenged, without needing to

assess the entire reactor core.

Recently, HSL scientists have been

working with NSD and British Energy

on developing complex mathematical

models that describe the development

of cracks over time, based on data

from periodic inspections of four AGR

stations between 1985 and 2006.

We have shown that reactors will not

challenge defined safety criteria

regarding the number of moderator

bricks containing two cracks in the

short-term future and that proposed

future inspection regimes, monitoring

the structural integrity of the graphite

core, are adequate for this purpose.


Passive fire protection

We participated during the year with

MMI Engineering Ltd on a project

designed to develop acceptance

criteria for damaged and repaired

passive fire protection (PFP) coatings.

These coatings protect structures and

plant from the effects of severe fires.

The performance of ageing,

weathered, damaged or repaired

PFPs is a major concern, particularly

offshore where it is often a safety-

critical factor.

The two most commonly used types

of PFP materials are cementitious

and intumescent. Cementitious

PFPs work initially by holding the

temperature of the substrate to

around 100°C until all the bound

water has been driven off and then

act as passive insulators.

Intumescent PFPs have an organic

base which, when subjected to fire,

expands to produce a stable char with

good thermal insulating properties.

The collaborative project was

sponsored by several offshore

operators and specialist

manufacturers. Our role was to

undertake jet fire resistance tests

and expert analysis, using different

methodologies to investigate the

performance of typical damaged

and repaired test pieces.

The project’s findings are providing

important input into a new

procedure for identifying when

repair or replacement is necessary,

and which forms of repair are most

effective. Results have also been

presented at a seminar attended by

some 100 industry and regulatory

representatives.


Gap analysis for the Maritime and Coastguard Agency

As more and more people each year

spend part of their leisure time in or

on the water, inland and on the sea,

demands on the emergency services

for water-safety interventions are

increasing.

Knowledge of the numbers involved

in water-based leisure is improving,

as is our understanding of the risks

involved. For the Maritime and

Coastguard Agency (MCA)

the UK’s maritime regulatory

authority - ready access to high-

quality information on fatalities,

injuries and accident causation is a

necessity as it seeks to minimise

the risks more effectively,

in partnership with such groups as

the National Water Safety Forum.

MCA, responsible through HM

Coastguard for initiating and co

ordinating maritime search and

rescue operations in the UK,

commissioned HSL to provide a

snapshot of current UK data and

make recommendations on how it

could be improved.

This research revealed a complex

picture. A gap analysis showed that,

while the presence of at least one

emergency service ensures that

current reporting systems do

capture all fatal accidents, data

collection on other incidents and

near misses is sporadic and

opportunist. It is therefore likely

that large quantities of information

are being overlooked.

Looking at the overall situation we

suggested an entirely new model

for future data collection.

We recommended building on

established links with key

organisations to ensure a flow of

accident data to a central

depository. We also proposed that

sports governing bodies should

encourage the reporting of

incidents and near misses with the

use of a standardised report form.

Recommendations have also been

provided to the National Water

Safety Forum as a means of

supporting their work.

For the Maritime and

Coastguard Agency

(MCA) - the UK’s maritime

regulatory authority

ready access to high-

quality information on

fatalities, injuries and

accident causation is

a necessity.

1616 HH EEALALTH & SAFTH & SAFETETY LY LABORABORAATTORORY RY REEPPOORRTT & A& A CCCCOOUUNNTS 2TS 2006 / 2006 / 2000077

As more and more people each year

spend part of their leisure time in or

on the water, inland and on the sea,

demands on the emergency services

for water-safety interventions are

increasing.

Knowledge of the numbers involved

in water-based leisure is improving,

as is our understanding of the risks

involved. For the Maritime and

Coastguard Agency (MCA) -

the UK’s maritime regulatory

authority - ready access to high-

quality information on fatalities,

injuries and accident causation is a

necessity as it seeks to minimise

the risks more effectively,

in partnership with such groups as

the National Water Safety Forum.

Gap analysis for the Maritimeand Coastguard Agency


MCA, responsible through HM

Coastguard for initiating and co-

ordinating maritime search and

rescue operations in the UK,

commissioned HSL to provide a

snapshot of current UK data and

make recommendations on how it

could be improved.

This research revealed a complex

picture. A gap analysis showed that,

while the presence of at least one

emergency service ensures that

current reporting systems do

capture all fatal accidents, data

collection on other incidents and

near misses is sporadic and

opportunist. It is therefore likely

that large quantities of information

are being overlooked.

Looking at the overall situation we

suggested an entirely new model

for future data collection.

We recommended building on

established links with key

organisations to ensure a flow of

accident data to a central

depository. We also proposed that

sports governing bodies should

encourage the reporting of

incidents and near misses with the

use of a standardised report form.

Recommendations have also been

provided to the National Water

Safety Forum as a means of

supporting their work.

For the Maritime and

Coastguard Agency

(MCA) - the UK’s maritime

regulatory authority -

ready access to high-

quality information on

fatalities, injuries and

accident causation is

a necessity.


Passive fire protection

We participated during the year with

MMI Engineering Ltd on a project

designed to develop acceptance

criteria for damaged and repaired

passive fire protection (PFP) coatings.

These coatings protect structures and

plant from the effects of severe fires.

The performance of ageing,

weathered, damaged or repaired

PFPs is a major concern, particularly

offshore where it is often a safety-

critical factor.

The two most commonly used types

of PFP materials are cementitious

and intumescent. Cementitious

PFPs work initially by holding the

temperature of the substrate to

around 100°C until all the bound

water has been driven off and then

act as passive insulators.

Intumescent PFPs have an organic

base which, when subjected to fire,

expands to produce a stable char with

good thermal insulating properties.

The collaborative project was

sponsored by several offshore

operators and specialist

manufacturers. Our role was to

undertake jet fire resistance tests

and expert analysis, using different

methodologies to investigate the

performance of typical damaged

and repaired test pieces.

The project’s findings are providing

important input into a new

procedure for identifying when

repair or replacement is necessary,

and which forms of repair are most

effective. Results have also been

presented at a seminar attended by

some 100 industry and regulatory

representatives.


HSL was called to the scene at an

early stage in both investigations.

In London, our mechanical

engineers and specialist

photographers spent seven days on

site, carrying out a detailed

examination of the collapsed

structure and observing recovery

operations. The jib slewing rig and

sections of the mast were brought to

HSL for further examination,

a major logistical exercise involving

a fleet of seven lorries.

A similar HSL team was onsite at

Liverpool for nine days. Here the

recovery operation was hampered by

high winds and the need to free

some of the evidence from concrete

that had set after the collapse.

We continue to examine the jib and

counterbalance platform.

Both investigations are complex and

will take several months to complete.


Each year we are asked by HSE

and other organisations to

provide forensic support to over

200 serious industrial accident

investigations.

Choosing the best

HSL has been leading the way was awarded an Honorary Sheffield for his work on

in health and safety since Fellowship by the Faculty of in vitro metabolism of industrial

1911 – and our acknowledged

expertise, incident investigation

record and years of partnership

with HSE and industry make

us the UK’s leading provider of

health and safety services.

Occupational Medicine.

Others who achieved significant

personal success last year

include process safety

specialists, Laurence Cusco,

chemicals. Steve Stagg gained

his Diploma in Occupational

Hygiene from the University

of Manchester.

But qualifications and

who became a Fellow of the fellowships are only part of the

But it is vital to recruit and Institution of Chemical story. Here we look at more of

develop people with the Engineers, and Ju Lynne Saw the year’s achievements at

necessary skills and experience who became a Member of this HSL, many of them award-

if we are to maintain this Institution and a Chartered winning, and some leading

position, and deliver our vision

of ‘using our brains to save and

improve the lives of workers’.

More than 85% of our scientific

staff are educated to degree level

or higher, and we are committed

to encouraging them to expand

their knowledge further and

gain recognition from relevant

professional bodies.

This is just as true of the Board

as those delivering frontline

services. So in 2006 it was

very satisfying to see Eddie

Morland, Chief Executive and

Karen Russ, Director of Human

Factors and Technical

Programmes, both awarded

Fellowships of the Institute of

Physics. Eddie also became a

Fellow of the Royal Society of

Medicine, and Andrew Curran,

Director of Health Improvement,

Chemical Engineer.

Johanna Beswick, David Fox,

Nadine Mellor and Kirsten

Rogers all achieved Chartered

Occupational Psychologist

status with the British

Psychological Society.

Nadine also gained a

distinction in her MSc from

Leicester University for her

work on the effects of

leadership behaviours on

employee absence through

sickness.

Jeremy Ferreira was admitted

as a Registered Member of the

Ergonomics Society and Leanne

Stanley attained a distinction

in her MSc in ergonomics from

the University of Surrey.

Craig Sams was awarded a

PhD from the University of

areas of research in fields

including the health and safety

aspects of nanomaterials and

alternative fuels.

Investigating tower crane failures

Each year we are asked by HSE and

other organisations to provide

forensic support to over 200 serious

industrial accident investigations.

The work is as varied as our own

expertise and covers the full range

of industry sectors from factories

and farms to petrochemical plants

and offshore installations.

The last year was busier than ever,

with work continuing to establish the

cause of the incident at the Buncefield

Oil Storage Depot and a number of

new, high profile investigations.

On the engineering front, our work

has been dominated by the collapse

of two tower cranes in less than four

months at sites in south London and

Liverpool, which tragically took the

lives of two workers and one

member of the public. The same

company supplied both cranes,

and HSE took the precaution of

prohibiting the use of cranes of this

type until their safety could be

independently demonstrated.


Each year we are asked by HSE and

other organisations to provide

forensic support to over 200 serious

industrial accident investigations.

The work is as varied as our own

expertise and covers the full range

of industry sectors from factories

and farms to petrochemical plants

and offshore installations.

The last year was busier than ever,

with work continuing to establish the

cause of the incident at the Buncefield

Oil Storage Depot and a number of

new, high profile investigations.

On the engineering front, our work

has been dominated by the collapse

of two tower cranes in less than four

months at sites in south London and

Liverpool, which tragically took the

lives of two workers and one

member of the public. The same

company supplied both cranes,

and HSE took the precaution of

prohibiting the use of cranes of this

type until their safety could be

independently demonstrated.

Investigating towercrane failures


Choosing the best

HSL has been leading the way

in health and safety since

1911 – and our acknowledged

expertise, incident investigation

record and years of partnership

with HSE and industry make

us the UK’s leading provider of

health and safety services.

But it is vital to recruit and

develop people with the

necessary skills and experience

if we are to maintain this

position, and deliver our vision

of ‘using our brains to save and

improve the lives of workers’.

More than 85% of our scientific

staff are educated to degree level

or higher, and we are committed

to encouraging them to expand

their knowledge further and

gain recognition from relevant

professional bodies.

This is just as true of the Board

as those delivering frontline

services. So in 2006 it was

very satisfying to see Eddie

Morland, Chief Executive and

Karen Russ, Director of Human

Factors and Technical

Programmes, both awarded

Fellowships of the Institute of

Physics. Eddie also became a

Fellow of the Royal Society of

Medicine, and Andrew Curran,

Director of Health Improvement,

was awarded an Honorary

Fellowship by the Faculty of

Occupational Medicine.

Others who achieved significant

personal success last year

include process safety

specialists, Laurence Cusco,

who became a Fellow of the

Institution of Chemical

Engineers, and Ju Lynne Saw

who became a Member of this

Institution and a Chartered

Chemical Engineer.

Johanna Beswick, David Fox,

Nadine Mellor and Kirsten

Rogers all achieved Chartered

Occupational Psychologist

status with the British

Psychological Society.

Nadine also gained a

distinction in her MSc from

Leicester University for her

work on the effects of

leadership behaviours on

employee absence through

sickness.

Jeremy Ferreira was admitted

as a Registered Member of the

Ergonomics Society and Leanne

Stanley attained a distinction

in her MSc in ergonomics from

the University of Surrey.

Craig Sams was awarded a

PhD from the University of

Sheffield for his work on

in vitro metabolism of industrial

chemicals. Steve Stagg gained

his Diploma in Occupational

Hygiene from the University

of Manchester.

But qualifications and

fellowships are only part of the

story. Here we look at more of

the year’s achievements at

HSL, many of them award-

winning, and some leading

areas of research in fields

including the health and safety

aspects of nanomaterials and

alternative fuels.

Each year we are asked by HSE

and other organisations to

provide forensic support to over

200 serious industrial accident

investigations.

HSL was called to the scene at an

early stage in both investigations.

In London, our mechanical

engineers and specialist

photographers spent seven days on

site, carrying out a detailed

examination of the collapsed

structure and observing recovery

operations. The jib slewing rig and

sections of the mast were brought to

HSL for further examination,

a major logistical exercise involving

a fleet of seven lorries.

A similar HSL team was onsite at

Liverpool for nine days. Here the

recovery operation was hampered by

high winds and the need to free

some of the evidence from concrete

that had set after the collapse.

We continue to examine the jib and

counterbalance platform.

Both investigations are complex and

will take several months to complete.


We successfully secured funding in

2006, under the DTI’s Public Sector

Research Exploitation (PSRE) scheme,

to help us commercialise and add

value to the intellectual property we

develop.

The PSRE fund was established

following the publication of the

Baker Report (August 1999) on

realising the economic potential of

public sector research

establishments. The fund enables

such organisations to maximise the

impact of their science and technology

through improved commercial

exploitation, and provides seed

capital for the very early stages of any

business arising from new ideas.

We are concentrating on two main

areas – implementing a

commercialisation process and

targeting investment into prioritised

projects.

Our first step was to establish a

Commercialisation Steering Group,

which meets regularly to oversee

implementation. It has already

achieved a great deal – most

importantly, we now have a better

definition of the process by which

ideas may be considered, including

agreed criteria for independently

assessing commercial opportunities.

We have also run workshops for our

staff to explain the process and

show how we are protecting our

intellectual property.

Six of the 25 opportunities we have

identified this year are now at

various stages of development,

including one at the full business

planning stage. This progress has

been made possible by the PSRE

fund, which is demonstrating the

critical importance of early stage

backing for scientific discoveries,

new technologies and novel

solutions, further supporting HSL’s

mission and preventing opportunities

from being overlooked.

Transferring ourknowledge –HSL training

Transferring ourknowledge –the PSRE fund


The commercial training courses we

deliver provide a highly effective way

of sharing our health and safety

expertise as well as contributing

towards HSE’s goals – our manual

handling courses, for example,

directly support their injury

reduction targets.

2006 saw rapid expansion of our

training delivery, following the launch

of our dedicated Training and

Conference Unit in 2005. We have

introduced many new topics, ranging

from biological monitoring to drug

and alcohol policy implementation,

from gas safety to lone working and

human reliability assessment.

Of our more established offerings,

our course on health surveillance for

Hand-Arm Vibration Syndrome

(accredited by the Faculty of

Occupational Medicine) continues to

be particularly well received.

One delegate called it “one of the

best, most professionally presented

courses I have been on.”

Commenting on the growth of our

training portfolio, Jill De Nardo,

head of our Training and Conference

Unit, said: “I want HSL to be seen as

the first port of call for training.

After all, delegates can be sure that

their training is being delivered by

top experts in their field.”

≥ Paul Grant

HSL’s Commercialisation Manager

The PSRE fundwas establishedfollowing thepublication of theBaker Report(August 1999) onrealising theeconomic potentialof public sectorresearchestablishments.

Highly commended rail investigation

Our investigative work received

particular praise in September 2006,

when the Chief Constable of British

Transport Police (BTP) formally

commended two of our staff at a

ceremony in Manchester for their work

on the Tebay rail accident investigation.

This followed the tragedy of

15 February 2004, when four men

died in Cumbria after being struck

by a runaway trailer at Tebay.

The ensuing BTP and Railway

Inspectorate investigation relied

heavily on our engineering and

scientific expertise, resulting in

manslaughter convictions at

Newcastle Crown Court.

Although many of our staff were

involved, Terry Gee and Ed Hollis

were specifically commended for

their role in specifying and

manufacturing the physical models

used to explain to the jury the

technical aspects of the

investigation. These models were

outstanding in their attention to

detail, and were of great importance

in presenting the case.


Our investigative work received

particular praise in September 2006,

when the Chief Constable of British

Transport Police (BTP) formally

commended two of our staff at a

ceremony in Manchester for their work

on the Tebay rail accident investigation.

This followed the tragedy of

15 February 2004, when four men

died in Cumbria after being struck

by a runaway trailer at Tebay.

The ensuing BTP and Railway

Inspectorate investigation relied

heavily on our engineering and

scientific expertise, resulting in

manslaughter convictions at

Newcastle Crown Court.

Although many of our staff were

involved, Terry Gee and Ed Hollis

were specifically commended for

their role in specifying and

manufacturing the physical models

used to explain to the jury the

technical aspects of the

investigation. These models were

outstanding in their attention to

detail, and were of great importance

in presenting the case.

Highly commendedrail investigation


Transferring our knowledge – the PSRE fund

We successfully secured funding in

2006, under the DTI’s Public Sector

Research Exploitation (PSRE) scheme,

to help us commercialise and add

value to the intellectual property we

develop.

The PSRE fund was established

following the publication of the

Baker Report (August 1999) on

realising the economic potential of

public sector research

establishments. The fund enables

such organisations to maximise the

impact of their science and technology

through improved commercial

exploitation, and provides seed

capital for the very early stages of any

business arising from new ideas.

We are concentrating on two main

areas – implementing a

commercialisation process and

targeting investment into prioritised

projects.

Our first step was to establish a

Commercialisation Steering Group,

which meets regularly to oversee

implementation. It has already

achieved a great deal – most

importantly, we now have a better

definition of the process by which

ideas may be considered, including

agreed criteria for independently

assessing commercial opportunities.

We have also run workshops for our

staff to explain the process and

show how we are protecting our

intellectual property.

Six of the 25 opportunities we have

identified this year are now at

various stages of development,

including one at the full business

planning stage. This progress has

been made possible by the PSRE

fund, which is demonstrating the

critical importance of early stage

backing for scientific discoveries,

new technologies and novel

solutions, further supporting HSL’s

mission and preventing opportunities

from being overlooked.

≥ Paul Grant

HSL’s Commercialisation Manager

Transferring our knowledge – HSL training

The commercial training courses we

deliver provide a highly effective way

of sharing our health and safety

expertise as well as contributing

towards HSE’s goals – our manual

handling courses, for example,

directly support their injury

reduction targets.

2006 saw rapid expansion of our

training delivery, following the launch

of our dedicated Training and

Conference Unit in 2005. We have

introduced many new topics, ranging

from biological monitoring to drug

and alcohol policy implementation,

from gas safety to lone working and

human reliability assessment.

Of our more established offerings,

our course on health surveillance for

Hand-Arm Vibration Syndrome

(accredited by the Faculty of

Occupational Medicine) continues to

be particularly well received.

One delegate called it “one of the

best, most professionally presented

courses I have been on.”

Commenting on the growth of our

training portfolio, Jill De Nardo,

head of our Training and Conference

Unit, said: “I want HSL to be seen as

the first port of call for training.

After all, delegates can be sure that

their training is being delivered by

top experts in their field.”

The PSRE fund was established following the publication of the Baker Report (August 1999) on realising the economic potential of public sector research establishments.



3. Exposure assessment and control

Tried and tested control systems are

vital to ensure workers are not

exposed to potentially harmful

nanoparticles. Well-validated

measurement methods to assess

exposure are equally important.

We are currently focusing on

improving methods of generating

nanoparticle aerosols so that we can

investigate the performance of

control and measurement devices.

This work includes the development

of new sampling methods and

techniques to assess nanomaterial

dustiness.

A report by the Royal Society and

Royal Academy of Engineering

(‘Nanoscience and Nanotechnologies:

Opportunities and uncertainties’)

identified university and research

laboratory researchers as the people

most likely to be exposed to

airborne nanoparticles. For this

reason, our initial attention is on

measuring airborne engineered

nanoparticles in university

nanoparticle research laboratories.

This work is also contributing to

NANOSH, a larger, Europe-funded

project on the inflammatory and

genotoxic effects of engineered

nanoparticles.

Meeting the nanochallenge

Nanotechnology – a fast-moving science that covers a very wide range of technologies and materials with one thing in common: their very small size. Nanomaterials have at least one dimension of less than 100 nanometres.

If we are to maintain our ‘best in class’

position, it is vital for HSL to stay at

the forefront of the health and

safety risks represented by new

technologies.

Nowhere is this truer than in the

growing field of nanotechnology –

a fast-moving science that covers a

very wide range of technologies and

materials with one thing in common:

their very small size. Nanomaterials

have at least one dimension of less

than 100 nanometres.

As the production and use of

nanomaterials grows in innovative

products as diverse as sports

equipment, IT applications and

cosmetics, so the potential for

worker exposure increases. But the

risks of such exposure are currently

far from understood.

Last year, we reported on

Nanochallenge, the three-year

programme of work on

nanomaterials that we established

under our Investment Research

Programme. Below, we describe

progress made to date under its

three main streams of work.

1. The explosion risk

Fine powders, particularly organic

and metallic materials, are a serious

explosion risk when dispersed in air.

While much is known about the

explosion properties of materials at

the micron scale, little knowledge

exists on the behaviour of

nanomaterials in the presence of

ignition sources.

Assessing their explosion risks

poses many challenges. As particles

approach molecular size, the energy

needed to ignite them may become

too small to measure using

conventional dust-cloud apparatus.

Furthermore, extrapolating data

from micron-scale to nano-scale

particles cannot be carried out with

any degree of confidence, because

of marked differences in their

chemical and physical properties.

In standard tests for fine powders,

we use compressed air to disperse

the materials in test apparatus.

The large surface-to-volume ratio of

nanomaterials, however, means that

on exposure to air many are

spontaneously flammable or surface

oxidisation changes their properties.

There is therefore a need for

smaller-scale equipment that avoids

oxidisation until the point of

ignition. No such equipment is

commercially available, and during

the last year we reviewed all existing

knowledge on test methods to see

what has been attempted.

We are now actively developing

specialist equipment capable of

measuring both the ignition energy

and explosion characteristics of

these very fine materials.

2. The toxicity risk

While we know that nanoparticles’

very large surface area (relative to

their mass) can affect their toxicity

compared with larger counterparts,

there is little information on the

human health effects of exposure to

manufactured nanoparticles.

Various strategies to improve our

knowledge have been proposed,

including the use of human or animal

cells grown in the laboratory (in vitro)

and testing on animals (in vivo).

There are obvious advantages to

in vitro testing for screening new

materials – not least, reduced

animal suffering – but its predictability

is unknown.

HSL is now developing a novel

in vitro test that uses whole human

blood, in which we are following effects

on different blood cells, using

biomarkers of cellular stress,

inflammation and death. Unlike most

in vitro models that use only one cell

type, this approach is enabling us to

reproduce the response to

nanoparticles of a whole tissue,

which may depend on interactions

between different cells.

We presented this strategy in

February 2007 at an event in the

House of Commons, attended by

over 30 MPs, organised by the

National Centre for the Replacement,

Refinement and Reduction of

Animals in Research (NC3Rs) to

showcase its work. We are now NC3Rs’

ambassador for nanotechnology,

providing them with relevant

information on this fast-moving field.

We have also drafted a report on

‘In Vitro Methods for Assessing the

Toxicity of Nanoparticles’ for the

Nanotechnology Research Co

ordination Group (NRCG). The

report is published on the Defra

website as part of the Government’s

progress report.



Meeting thenanochallenge

If we are to maintain our ‘best in class’

position, it is vital for HSL to stay at

the forefront of the health and

safety risks represented by new

technologies.

Nowhere is this truer than in the

growing field of nanotechnology –

a fast-moving science that covers a

very wide range of technologies and

materials with one thing in common:

their very small size. Nanomaterials

have at least one dimension of less

than 100 nanometres.

As the production and use of

nanomaterials grows in innovative

products as diverse as sports

equipment, IT applications and

cosmetics, so the potential for

worker exposure increases. But the

risks of such exposure are currently

far from understood.

Last year, we reported on

Nanochallenge, the three-year

programme of work on

nanomaterials that we established

under our Investment Research

Programme. Below, we describe

progress made to date under its

three main streams of work.

1. The explosion risk

Fine powders, particularly organic

and metallic materials, are a serious

explosion risk when dispersed in air.

While much is known about the

explosion properties of materials at

the micron scale, little knowledge

exists on the behaviour of

nanomaterials in the presence of

ignition sources.

Assessing their explosion risks

poses many challenges. As particles

approach molecular size, the energy

needed to ignite them may become

too small to measure using

conventional dust-cloud apparatus.

Furthermore, extrapolating data

from micron-scale to nano-scale

particles cannot be carried out with

any degree of confidence, because

of marked differences in their

chemical and physical properties.

In standard tests for fine powders,

we use compressed air to disperse

the materials in test apparatus.

The large surface-to-volume ratio of

nanomaterials, however, means that

on exposure to air many are

spontaneously flammable or surface

oxidisation changes their properties.

There is therefore a need for

smaller-scale equipment that avoids

oxidisation until the point of

ignition. No such equipment is

commercially available, and during

the last year we reviewed all existing

knowledge on test methods to see

what has been attempted.

We are now actively developing

specialist equipment capable of

measuring both the ignition energy

and explosion characteristics of

these very fine materials.

2. The toxicity risk

While we know that nanoparticles’

very large surface area (relative to

their mass) can affect their toxicity

compared with larger counterparts,

there is little information on the

human health effects of exposure to

manufactured nanoparticles.

Various strategies to improve our

knowledge have been proposed,

including the use of human or animal

cells grown in the laboratory (in vitro)

and testing on animals (in vivo).

There are obvious advantages to

in vitro testing for screening new

materials – not least, reduced

animal suffering – but its predictability

is unknown.

HSL is now developing a novel

in vitro test that uses whole human

blood, in which we are following effects

on different blood cells, using

biomarkers of cellular stress,

inflammation and death. Unlike most

in vitro models that use only one cell

type, this approach is enabling us to

reproduce the response to

nanoparticles of a whole tissue,

which may depend on interactions

between different cells.

We presented this strategy in

February 2007 at an event in the

House of Commons, attended by

over 30 MPs, organised by the

National Centre for the Replacement,

Refinement and Reduction of

Animals in Research (NC3Rs) to

showcase its work. We are now NC3Rs’

ambassador for nanotechnology,

providing them with relevant

information on this fast-moving field.

We have also drafted a report on

‘In Vitro Methods for Assessing the

Toxicity of Nanoparticles’ for the

Nanotechnology Research Co-

ordination Group (NRCG). The

report is published on the Defra

website as part of the Government’s

progress report.

Nanotechnology – a fast-moving science that coversa very wide range of technologies and materialswith one thing in common: their very small size.Nanomaterials have at least one dimension of lessthan 100 nanometres.

3. Exposure assessment and control

Tried and tested control systems are

vital to ensure workers are not

exposed to potentially harmful

nanoparticles. Well-validated

measurement methods to assess

exposure are equally important.

We are currently focusing on

improving methods of generating

nanoparticle aerosols so that we can

investigate the performance of

control and measurement devices.

This work includes the development

of new sampling methods and

techniques to assess nanomaterial

dustiness.

A report by the Royal Society and

Royal Academy of Engineering

(‘Nanoscience and Nanotechnologies:

Opportunities and uncertainties’)

identified university and research

laboratory researchers as the people

most likely to be exposed to

airborne nanoparticles. For this

reason, our initial attention is on

measuring airborne engineered

nanoparticles in university

nanoparticle research laboratories.

This work is also contributing to

NANOSH, a larger, Europe-funded

project on the inflammatory and

genotoxic effects of engineered

nanoparticles.


Prize winningresearch on IBCs

Intermediate bulk containers (IBCs)

have had many uses for over a

decade now, including the storage of

flammable and combustible liquids.

However, until a recent project in

which HSE asked us to investigate

the issue, no one had looked at how

IBCs containing flammable liquids

behave when exposed to fire.

The results of a series of

experiments carried out by our fire

specialists were quite startling.

Vulnerable parts of the container,

such as the valve, are very easily

ignited. As the fire develops, the

contents of up to a tonne are lost in

a few tens of seconds. A tonne of

burning liquid released in this way

spreads fire at an unusually rapid

rate, giving little chance for

successful fire-fighting.

The project has generated

considerable interest. A paper on

the earlier stages of the work by

HSL’s Sean O‘Sullivan won an award

for the best paper by a young

chemical engineer in 2004.

In 2006, a conference paper on the

subject by HSL’s Graham Atkinson

and Nigel Riley of HSE’s Hazardous

Installations Directorate received a

top award from the Institution of

Chemical Engineers for the best

research paper presented that year.

On such an important risk it is vital

that research results can be easily

and quickly disseminated. HSL

therefore produced a DVD on the

subject which is now in great demand.

The DVD demonstrates not only the

consequences of a fire involving IBCs,

but also how simple measures can

mitigate their effects or prevent them

altogether. An important contribution

to loss prevention, the DVD could

also prove to be a real life-saver.


A conference paper on the subject

received a top award from the Institution

of Chemical Engineers for the best

research paper presented in 2006.

Hydrogen and fuel cell applications

The EC and HSE-

funded HyPer project

was launched in

November 2006 to

address a range of

issues concerning fuel

cell systems powered

by hydrogen, natural

gas or other fuels.

Curbing greenhouse gas emissions

and securing cheap, environmentally

friendly energy supplies are major

economic and social drivers that can

be met by hydrogen and fuel cell

technologies. This is widely accepted,

and small stationary hydrogen and

fuel cell systems are an important

part of the proposed future energy

infrastructure and economy.

This is the background to the EC

and HSE-funded HyPer (Installation

Permitting Guidance for Hydrogen

and Fuel Cell Stationary Applications)

project, launched in November

2006 to address a range of issues

concerning fuel cell systems powered

by hydrogen, natural gas or other fuels.

HSL led the technical development

and is the technical co-ordinator of

the project, with much of the

experimental work making use of

our unique facilities. The University

of Manchester is administrative co

ordinator.

The project will develop and agree a

comprehensive installation process

for developers, design engineers,

manufacturers, installers and

authorities to provide guidance for

fast-tracking the approval of safety

and procedural issues.

HyPer has brought together a

consortium of interested parties

from Europe, the USA and Russia,

comprising 27 organisations (15

partners and 12 supporting group

members) that include hydrogen

system and fuel cell manufacturers,

installers, operators, regulators,

research laboratories, gas companies

and universities.

Our main roles at HSL are: (i) to carry

out experiments looking at the

hazards posed by hydrogen storage,

fuel cell system components such as

fuel cell stacks, fuel reformers,

compressors and auxiliary parts; and

(ii) to write the installation guidance.

The project will make use of a high-

pressure (1,000 bar) hydrogen release

system, which is being developed

on our extensive site as part of

HSL’s investment programme.

This system is unique in Europe and

will be used within HyPer, and on

other projects, to simulate potential

faults and test components from

current and future hydrogen storage

systems and technologies.

The need for guidance is urgent,

so the project will be completed

within two years, with guidance

available in late 2008. Once

published, this will be maintained

by HySafe, a European Network of

Excellence of which we are a part.


Hydrogen andfuel cell applications

Curbing greenhouse gas emissions

and securing cheap, environmentally

friendly energy supplies are major

economic and social drivers that can

be met by hydrogen and fuel cell

technologies. This is widely accepted,

and small stationary hydrogen and

fuel cell systems are an important

part of the proposed future energy

infrastructure and economy.

This is the background to the EC

and HSE-funded HyPer (Installation

Permitting Guidance for Hydrogen

and Fuel Cell Stationary Applications)

project, launched in November

2006 to address a range of issues

concerning fuel cell systems powered

by hydrogen, natural gas or other fuels.

HSL led the technical development

and is the technical co-ordinator of

the project, with much of the

experimental work making use of

our unique facilities. The University

of Manchester is administrative co-

ordinator.

The project will develop and agree a

comprehensive installation process

for developers, design engineers,

manufacturers, installers and

authorities to provide guidance for

fast-tracking the approval of safety

and procedural issues.

HyPer has brought together a

consortium of interested parties

from Europe, the USA and Russia,

comprising 27 organisations (15

partners and 12 supporting group

members) that include hydrogen

system and fuel cell manufacturers,

installers, operators, regulators,

research laboratories, gas companies

and universities.

Our main roles at HSL are: (i) to carry

out experiments looking at the

hazards posed by hydrogen storage,

fuel cell system components such as

fuel cell stacks, fuel reformers,

compressors and auxiliary parts; and

(ii) to write the installation guidance.

The project will make use of a high-

pressure (1,000 bar) hydrogen release

system, which is being developed

on our extensive site as part of

HSL’s investment programme.

This system is unique in Europe and

will be used within HyPer, and on

other projects, to simulate potential

faults and test components from

current and future hydrogen storage

systems and technologies.

The need for guidance is urgent,

so the project will be completed

within two years, with guidance

available in late 2008. Once

published, this will be maintained

by HySafe, a European Network of

Excellence of which we are a part.


The EC and HSE-

funded HyPer project

was launched in

November 2006 to

address a range of

issues concerning fuel

cell systems powered

by hydrogen, natural

gas or other fuels.

Prize winning research on IBCs

Intermediate bulk containers (IBCs)

have had many uses for over a

decade now, including the storage of

flammable and combustible liquids.

However, until a recent project in

which HSE asked us to investigate

the issue, no one had looked at how

IBCs containing flammable liquids

behave when exposed to fire.

The results of a series of

experiments carried out by our fire

specialists were quite startling.

Vulnerable parts of the container,

such as the valve, are very easily

ignited. As the fire develops, the

contents of up to a tonne are lost in

a few tens of seconds. A tonne of

burning liquid released in this way

spreads fire at an unusually rapid

rate, giving little chance for

successful fire-fighting.

The project has generated

considerable interest. A paper on

the earlier stages of the work by

HSL’s Sean O‘Sullivan won an award

for the best paper by a young

chemical engineer in 2004.

In 2006, a conference paper on the

subject by HSL’s Graham Atkinson

and Nigel Riley of HSE’s Hazardous

Installations Directorate received a

top award from the Institution of

Chemical Engineers for the best

research paper presented that year.

On such an important risk it is vital

that research results can be easily

and quickly disseminated. HSL

therefore produced a DVD on the

subject which is now in great demand.

The DVD demonstrates not only the

consequences of a fire involving IBCs,

but also how simple measures can

mitigate their effects or prevent them

altogether. An important contribution

to loss prevention, the DVD could

also prove to be a real life-saver.

A conference paper on the subject

received a top award from the Institution

of Chemical Engineers for the best

research paper presented in 2006.



Highlights of 2006/07

We received visits from two

Government ministers last year,

including the Rt Hon John Hutton

MP, Secretary of State for Work and

Pensions, who visited us in the

company of High Peak MP Tom Levitt.

After talking with staff about our

research on respiratory disease and

work on older workers, return to

work and sickness absence for the

Department of Work and Pensions

(DWP) and HSE, Mr Hutton and

Mr Levitt watched some research in

action on our outdoor facilities.

Wearing hi-visibility vests and

hearing protection, they viewed a

dust explosion on our specialist test

range – part of a European-funded

project developing computational

fluid dynamics for use with dust

explosions.

Speaking about his visit, Mr Hutton

commented: “It was fantastic to

have such an illustrative display of

the important work HSL does. I fully

support the Laboratory’s dedication

to all health and safety matters,

from the health of workers to the

protection of the general public.”

Lord Mackenzie of Luton, the newly

appointed Parliamentary

Undersecretary (Lords) at DWP with

ministerial responsibility for health

and safety, also visited the Laboratory.

On seeing first hand some of our

work on occupational asthma and

lung disease, and receiving a brief

on our role in the Buncefield

investigation, he said: “HSL is truly

fascinating. I’m not a scientist,

but it’s impossible not to recognise

the professionalism here. There’s some

really ground-breaking occupational

health work going on.”

Ministerial visits

Professor Dame Carol Black, the

Government’s first National Director

for Health and Work, emphasised

her commitment to improving the

health and well-being of the UK’s

working population during a visit to

HSL in late 2006.

This was an important visit to the

Laboratory by a high profile

government figure who will steer

key national strategies aimed at

improving the health and opportunities

for the working age population.

After an overview of HSL given by

Eddie Morland, she talked to a

number of scientists about current

research, training and service

National Director forHealth and Work visits HSL

delivery during a tour of the

Laboratory. In the afternoon,

attention moved to the Centre for

Workplace Health (see page 9 of this

report), with a visit to Sheffield’s

Royal Hallamshire Hospital where

Dame Carol met other CWH Board

members including Professor

Moira White (University of Sheffield),

Chris Linacre and Chris Welsh

(Sheffield Teaching Hospitals).

Dame Carol showed great interest in

the research activities of HSL and

CWH, particularly the concept of

using quality science to provide

practical solutions. She praised the

partnership approach adopted by

CWH and offered her future support.

Award winning local authority project

The Health and Safety Commission (HSC) set a new strategic direction for Great Britain’s health and safety system in 2004. This included a programme designed to enable closer working partnerships between HSC’s two enforcing authorities – HSE and local authorities (LAs).

One of the first partnership activities won a national award in 2006. The Midlands Builders’ Merchants project was a joint winner of the Innovation Award, presented in December 2006 at the HSE/LA partnership conference.

This involved collaboration between HSE and 74 local authorities in the Midlands to manage and deliver a series of Safety and Health Awareness Days (SHADs) for independent builders’ merchants. The events focused on four priorities: slips and trips; workplace transport; falls from height; and manual handling.

Public reporting

Every event involved each builders’ merchant producing an action plan to combat risk in each priority area.

As part of the partnership programme, HSC made funds available to LAs to help them investigate how their enforcement activities could be better supported through the increased use of science – HSL’s scientific resources in particular. Through this funding initiative, HSL was able to participate as part of the project team helping to develop the SHADs project. The team developed presentation materials including case studies, video, action plan templates and links to reference materials. Materials were collated, edited and produced on CD for distribution to all attendees. More than 200 CDs are now in circulation.

The project is still running, and follow-

As part of the

partnership programme,

HSC made funds

available to LAs to help

them investigate how

their enforcement

activities could be better

supported through the

increased use of science.

and accountability awards

up visits are due to be made over the next few months to all companies who attended.

It is not just HSL’s scientific and

technical work that has received

recognition this year.

Our 2004/05 Annual Report

reached the finals of the prestigious

Public Reporting and Accountability

(PRA) awards, run by the Chartered

Institute of Public Finance and

Accountability (CIPFA) and

PricewaterhouseCoopers. We were

delighted to receive a certificate

marking this achievement at an

awards ceremony in June 2006.

The PRA awards encourage

excellence in public reporting,

identifying and celebrating the

best practice organisations whose

imaginative approach helps achieve

real advances in accountability.

They are supported by HM Treasury,

the National Audit Office, the Audit

Commission, Audit Scotland and

the Northern Ireland Audit Office.


It is not just HSL’s scientific and

technical work that has received

recognition this year.

Our 2004/05 Annual Report

reached the finals of the prestigious

Public Reporting and Accountability

(PRA) awards, run by the Chartered

Institute of Public Finance and

Accountability (CIPFA) and

PricewaterhouseCoopers. We were

delighted to receive a certificate

marking this achievement at an

awards ceremony in June 2006.

The PRA awards encourage

excellence in public reporting,

identifying and celebrating the

best practice organisations whose

imaginative approach helps achieve

real advances in accountability.

They are supported by HM Treasury,

the National Audit Office, the Audit

Commission, Audit Scotland and

the Northern Ireland Audit Office.

The Health and Safety Commission(HSC) set a new strategic directionfor Great Britain’s health and safetysystem in 2004. This included aprogramme designed to enable closerworking partnerships between HSC’stwo enforcing authorities – HSE andlocal authorities (LAs).

One of the first partnership activitieswon a national award in 2006.The Midlands Builders’ Merchantsproject was a joint winner of theInnovation Award, presented inDecember 2006 at the HSE/LApartnership conference.

This involved collaboration betweenHSE and 74 local authorities in theMidlands to manage and deliver aseries of Safety and Health AwarenessDays (SHADs) for independentbuilders’ merchants. The eventsfocused on four priorities: slips andtrips; workplace transport; falls fromheight; and manual handling.

Award winning localauthority project

Public reportingand accountability awards


Every event involved each builders’merchant producing an action planto combat risk in each priority area.

As part of the partnershipprogramme, HSC made fundsavailable to LAs to help theminvestigate how their enforcementactivities could be better supportedthrough the increased use of science– HSL’s scientific resources inparticular. Through this fundinginitiative, HSL was able to participateas part of the project team helping todevelop the SHADs project. The teamdeveloped presentation materialsincluding case studies, video, actionplan templates and links to referencematerials. Materials were collated,edited and produced on CD fordistribution to all attendees. Morethan 200 CDs are now in circulation.

The project is still running, and follow-up visits are due to be made over thenext few months to all companieswho attended.

As part of the

partnership programme,

HSC made funds

available to LAs to help

them investigate how

their enforcement

activities could be better

supported through the

increased use of science.

Highlights of 2006/07

Ministerial visits

We received visits from two

Government ministers last year,

including the Rt Hon John Hutton

MP, Secretary of State for Work and

Pensions, who visited us in the

company of High Peak MP Tom Levitt.

After talking with staff about our

research on respiratory disease and

work on older workers, return to

work and sickness absence for the

Department of Work and Pensions

(DWP) and HSE, Mr Hutton and

Mr Levitt watched some research in

action on our outdoor facilities.

Wearing hi-visibility vests and

hearing protection, they viewed a

dust explosion on our specialist test

range – part of a European-funded

project developing computational

fluid dynamics for use with dust

explosions.

Speaking about his visit, Mr Hutton

commented: “It was fantastic to

have such an illustrative display of

the important work HSL does. I fully

support the Laboratory’s dedication

to all health and safety matters,

from the health of workers to the

protection of the general public.”

Lord Mackenzie of Luton, the newly

appointed Parliamentary

Undersecretary (Lords) at DWP with

ministerial responsibility for health

and safety, also visited the Laboratory.

On seeing first hand some of our

work on occupational asthma and

lung disease, and receiving a brief

on our role in the Buncefield

investigation, he said: “HSL is truly

fascinating. I’m not a scientist,

but it’s impossible not to recognise

the professionalism here. There’s some

really ground-breaking occupational

health work going on.”

National Director for Health and Work visits HSL

Professor Dame Carol Black, the

Government’s first National Director

for Health and Work, emphasised

her commitment to improving the

health and well-being of the UK’s

working population during a visit to

HSL in late 2006.

This was an important visit to the

Laboratory by a high profile

government figure who will steer

key national strategies aimed at

improving the health and opportunities

for the working age population.

After an overview of HSL given by

Eddie Morland, she talked to a

number of scientists about current

research, training and service

delivery during a tour of the

Laboratory. In the afternoon,

attention moved to the Centre for

Workplace Health (see page 9 of this

report), with a visit to Sheffield’s

Royal Hallamshire Hospital where

Dame Carol met other CWH Board

members including Professor

Moira White (University of Sheffield),

Chris Linacre and Chris Welsh

(Sheffield Teaching Hospitals).

Dame Carol showed great interest in

the research activities of HSL and

CWH, particularly the concept of

using quality science to provide

practical solutions. She praised the

partnership approach adopted by

CWH and offered her future support.



HSL was established as an in-house

Agency of the Health and Safety

Executive (HSE) on 1 April 1995 and

operates on “Next Steps Agency”

principles. Prior to this date the

Laboratory was a division of HSE.

HSE is a statutory body established,

together with the Health and Safety

Commission, by section 10 of the

Health and Safety at Work etc.

Act 1974. HSE is a Crown Non-

Departmental Public Body,

sponsored by the Department for

Work and Pensions.

The accounts have been prepared

in accordance with a direction given

by HSE. They are prepared on an

accruals basis and show the full

in-year resource costs of HSL.

The accounts of HSL are audited

by the Comptroller and Auditor

General. The audit is undertaken by

agreement, rather than because of

any statutory requirement, as HSL’s

transactions and balances are

included in the statutory accounts

of HSE, and this discharges

the responsibility to report to

Parliament. The audit provides an

opinion on whether the financial

statements provide a true and fair

view and have been properly

prepared in accordance with the

accounts direction given by HSE.

The cost reflected in the accounts

for audit services provided by NAO

for the year was £40,000 (2005/06

£35,811). No non-audit works were

carried out by NAO, nor were any

further assurance services provided.

Management commentary

HSL’s principal activities are:

≥ to carry out and publish

research and provide scientific

and forensic services to high

scientific and ethical standards

to meet the needs of its

customers in a cost-effective

way;

≥ to continue to maintain and

advance its scientific

competence and expert

knowledge of scientific

developments relevant to health

and safety world-wide to meet

the needs of its customers;

≥ to achieve the effective

exploitation of intellectual

property, in conjunction with

the relevant customers;

≥ to develop the business by

carrying out seed-corn research

and staff training to maintain

and improve its scientific

capability and expertise in

relevant key areas of technology.

The research and development work

of the Laboratory underpins the

activities of HSE, which are to

protect the health, safety and

welfare of employees and to

safeguard others, principally the

public, who may be exposed to

risks from work activities.

HSL’s forward strategy recognises

these principal activities and the

overwhelming importance of key

relationships between customers

and staff. The strategy is based on

three principal objectives:

1. Building a strategic relationship

between HSL and HSE which is

of growing benefit to both

entities

2. Growing sustainable and value-

adding non-HSE business

3. Growing HSL’s capability in

terms of expertise and delivery

Health and SafetyLaboratory (HSL) -Backgroundinformation Principal activities

The strategy is guided by our vision where we see ourselves

using our brains to save and improve the

lives of workers.

Our mission can therefore be simply stated:

To make the very best use of our resources

and expertise to improve the health and

safety of workers and reduce the hazards

arising from work in Great Britain.

“This meeting will be World Health Organisation – considered a key milestone

Meeting of European Collaborating in the implementation of Centres in Occupational Health WHO’s Global Plan of

HSL hosted the World Health

Organisation’s (WHO) fifth Network

Meeting of European Collaborating

Centres in Occupational Health in

March 2007.

WHO has dozens of collaborating

centres across the world, with specialist

expertise in a number of disciplines.

The various centres meet every

couple of years to discuss progress

and plans for the future. We have

been a collaborating centre in

occupational health and safety

research for four years.

“Let me congratulate and thank you cordially for the best meeting to date, which you and your staff organised so skilfully. As well as being highly professional, it was an excellent social event.”

Professor Jorma Rantanen,

President of the International

Commission on Occupational Health

Delegates attended from 26

European countries, alongside

representatives from the European

Commission, the International

Labour Organisation and the

International Commission on

Occupational Health.

Significant changes are sweeping

Europe. The network gives Eastern

European countries access to some

of the excellent work that is going

on both within and outside WHO.

For example, many are making use

of Britain’s Control of Substances

Hazardous to Health (COSHH)

regulations as a starting point for

their own legislation.

The meeting was organised by

Andrew Curran, Director of HSL’s

Health Improvement Group,

who said: “This has been a good

opportunity to network with sister

organisations in this country and

abroad, to share best practice and

to discuss research. It’s also allowed

us to influence the international

thinking and direction of

occupational health, and to apply

our experience to the benefit of

others around the world.”

Action on Workers’ Health, 2008 – 2017, in the European region.”

Dr Rokho Kim,

Programme Manager,

Occupational Health, WHO

Alternative fuels meeting

Our research on alternative fuels

received prominence in November

2006 when we hosted a special

meeting of the Institution of

Chemical Engineers Safety and

Loss Prevention Subject Group on

Alternative Fuels and Carbon Capture.

The drivers for new technologies to

change how energy is produced and

controlled are well known – rising

costs, security of supply and climate

change among them. In some new

technologies, safety issues are

prominent, while in others it is

environmental life cycle analysis that

commands the attention.

HSL’s Dr Laurence Cusco gave an

overview of the possible hazards in

biofuel processing and manufacture,

and presented information on

carbon capture and sequestration.

Dr Stuart Hawksworth, also of HSL,

described advances made in

investigating hydrogen safety and

our involvement for HSE in several

European hydrogen safety projects.

Other speakers included

representatives from major energy

companies.


Management commentary

Health and Safety Laboratory (HSL) Background information

HSL was established as an in-house

Agency of the Health and Safety

Executive (HSE) on 1 April 1995 and

operates on “Next Steps Agency”

principles. Prior to this date the

Laboratory was a division of HSE.

HSE is a statutory body established,

together with the Health and Safety

Commission, by section 10 of the

Health and Safety at Work etc.

Act 1974. HSE is a Crown Non-

Departmental Public Body,

sponsored by the Department for

Work and Pensions.

The accounts have been prepared

in accordance with a direction given

by HSE. They are prepared on an

accruals basis and show the full

in-year resource costs of HSL.

The accounts of HSL are audited

by the Comptroller and Auditor

General. The audit is undertaken by

agreement, rather than because of

any statutory requirement, as HSL’s

transactions and balances are

included in the statutory accounts

of HSE, and this discharges

the responsibility to report to

Parliament. The audit provides an

opinion on whether the financial

statements provide a true and fair

Principal activities

HSL’s principal activities are:

≥ to carry out and publish

research and provide scientific

and forensic services to high

scientific and ethical standards

to meet the needs of its

customers in a cost-effective

way;

≥ to continue to maintain and

advance its scientific

competence and expert

knowledge of scientific

developments relevant to health

and safety world-wide to meet

the needs of its customers;

≥ to achieve the effective

exploitation of intellectual

property, in conjunction with

the relevant customers;

≥ to develop the business by

carrying out seed-corn research

and staff training to maintain

and improve its scientific

capability and expertise in

relevant key areas of technology.

The research and development work

of the Laboratory underpins the

activities of HSE, which are to

protect the health, safety and

welfare of employees and to

safeguard others, principally the

public, who may be exposed to

risks from work activities.

HSL’s forward strategy recognises

these principal activities and the

overwhelming importance of key

relationships between customers

and staff. The strategy is based on

three principal objectives:

1. Building a strategic relationship

between HSL and HSE which is

of growing benefit to both

entities

2. Growing sustainable and value-

adding non-HSE business

3. Growing HSL’s capability in

terms of expertise and delivery

The strategy is guided by our vision where we see ourselves

view and have been properly

prepared in accordance with the using our brains to save and improve the accounts direction given by HSE. lives of workers. The cost reflected in the accounts

for audit services provided by NAO

for the year was £40,000 (2005/06

£35,811). No non-audit works were

carried out by NAO, nor were any

further assurance services provided.

Our mission can therefore be simply stated:

To make the very best use of our resources

and expertise to improve the health and

safety of workers and reduce the hazards

arising from work in Great Britain.


Service Performance

As part of its Framework Agreement, HSL is required to prepare

an Annual Performance Agreement, which lays down overall

objectives for key areas where service performance is then measured

against pre-defined targets. These objectives, and performance

against the targets are given below.

Service Objectives

A. Contribute to delivery of DWP’s

health and safety PSA targets

and other HSC/E priorities by

delivering fit-for-purpose

research projects and

information to agreed standards.

B. Achieve Financial/Efficiency

Targets agreed with HSE.

C. To transfer HSL knowledge to

others and to demonstrate

competitiveness by winning

non-HSE business.

Service Delivery Targets

To deliver research projects,

scientific intelligence and forensic

work to HSE in line with the HSC

Science Strategy and to other

customers

HSC’s Science Strategy 2005 to

2008 - Gathering Evidence;

Developing Understanding;

Identifying Solutions - supports the

delivery of HSE’s health and safety

Public Service Agreement targets

and other enforcement and

statutory duties. It sets out how HSE

will apply science to understand

problems and develop effective

practical solutions to control a range

of workplace risks; provide HSE with

evidence on the causes of ill-health

and incidents in the workplace;

and influence HSE’s priorities.

In 2006/07 HSL delivered a

wide range of research, forensic

investigation and other scientific

and technological services closely

aligned to HSE’s two Strategic

Delivery Programmes (SDPs),

four Strategic Enabling Programmes

(STEPs) and operational

investigation and enforcement

activities.

The figure on page 31 shows the

distribution of HSE’s spend with

HSL in 2006/07 and the three

previous years across HSE’s main

areas of science and technology

activity as follows:

≥ Fit3 Strategic Delivery

Programme - Fit for work, Fit for

life, Fit for tomorrow - aimed at


working days lost from work-

related injury and ill-health.

≥ Major Hazards Strategic Delivery

Programme - this regulates and




catastrophic effects.

≥ Mandatory Activities Programme

- this supports front line and

regulatory work and includes

forensic support to

investigations.

≥ Overarching and Underpinning

Research and Support work

(OURS) - this includes support

to HSE’s four STEPs

Worker Involvement,

Business Involvement,

Local Authority/HSE

Partnership, and Enforcement

Policy - as well as support for

underpinning work to ensure

HSE’s effectiveness, where such

work cuts across the SDPs and

STEPs. Examples are evaluation,

epidemiology and statistics,

horizon scanning and cross

cutting research.

≥ Nuclear Safety Programme

this is designed to achieve

effective and efficient nuclear

safety regulation.


Trends in HSE S&T spend with HSL by programme

16,000

14,000

12,000

10,000

8,000

6,000

4,000

2,000

0£ ’

00

0

Fit3 Major Mandatory OURS Nuclear Hazards

2003/04 2004/05 2005/06 2006/07

Note: Figures exclude investment research and key facilities spend. Fit3 programme began in 2005/06,

figures before that date relate to a similar programme of activity.

The figures show a continuing

increase in spend on Fit3, in line

with HSE’s increased programme of

work to reduce occupational ill-

health, the number of reportable

injuries and working days lost due

to ill-health. The upturn in OURS

Safety targets

To have no more than two RIDDOR

events.

There were four reportable events in

2006/07 (2005/06: one) under the

spend reflects HSL’s support for

horizon scanning and the HSE and

Local Authorities Working in

Partnership S&T Initiative launched

in May 2005. The changing pattern

of spend between major hazards

and mandatory activities is in part

Reporting of Injuries Diseases and

Dangerous Occurrences Regulations

(RIDDOR).

due to the tighter focus of the major

hazards programme on delivering

its PSA targets, with work of wider

application across industry being

funded by the mandatory

programme.


Financial Targets

To recover Full Economic Costs

(FEC) on an accruals basis taking

one year with another.

HSL is required to cover its FEC for

the services it provides to HSE and

other public and private sector

customers, taking one year with

another. At 1 April 2006, HSL had

accumulated surpluses brought

forward of £8,259,000 (see Note

12B. In year, HSL made a deficit of

£1,392,000 (2005/06:

£3,664,000), but as agreed

previously with HSE, HSL utilised

from the accumulated surplus an

amount equal to the deficit, in order

to reflect neither a surplus nor a

deficit within the year.

To reduce by 2 percentage points

the number of non-chargeable

hours as a proportion of total

available hours.

HSL achieved a reduction of 2.7

percentage points in the financial

year, and plans to continue to strive

to increase efficiency by further

reductions in each of the

subsequent three years.

To achieve non-HSE income of

£5.7m in 2006/07 with an aim of

20% (£7.7m) of turnover in

2007/08 from non-HSE sources.

Science and Technology income in

2006/07 from non-HSE customers

was £5.8m (17%) (2005/06: £4.6m

(15%)).

To install a process to generate

income from Intellectual Property

exploitation.

HSL successfully secured funding

in 2006, under the DTI’s Public

Sector Research Exploitation (PSRE)

scheme, to help it commercialise

and add value to the intellectual

property it develops.

A Commercialisation Steering

Group has been established to

oversee implementation of the

commercialisation process.

Future developments

In 2006/07, HSL’s scientific and

technical output to non-HSE

customers was increased by 2%

to 17%. In 2007/08 and beyond,

HSL will continue to seek increased

value-adding income from other

sources, whilst continuing to

develop its special relationship

with HSE as its prime supplier

for scientific services. To this end,

further changes have been made at

Board level.

A second non-executive director,

Dr Sue Ion, was appointed to the

Board from April 2006, to

strengthen further both governance

and business management

Early work of this group has focused

on setting out a better definition of

the process by which ideas may

be considered, including agreed

criteria for independently assessing

commercial opportunities.

Workshops have been run for staff

to explain the process and show

how to protect HSL’s intellectual

property. Six of the 25

opportunities identified this year

are now at various stages of

development, including one at

the full business planning stage.

Further details can be found on

page 21.

arrangements. HSL’s operational

management has been reinforced

by the appointment of three new

Board directors with line-

management responsibilities,

all being in place by September

2006. The new directors bring with

them substantial experience of

managing science and engineering

service organisations in the public

and private sectors. These changes

will enhance the commercial,

operational and governance

capability of the Board as HSL

moves into the next phase of its

development as a world-class public

sector research establishment.


Workforce matters - Human Resources (HR)

There have been considerable

changes in the provision of the HR

function over the past year, the key

one being the transfer of service

provision to the HSE HR Service

Centre, supported by a new

computer system, SAP HR.

HSL retains an HR Business

Employee numbers

Partner focusing on strategy and

HR support to the Board. The

introduction of two new externally

recruited Board members, including

one taking responsibility for HR,

has brought a different perspective

to career progression.

The average number of whole time equivalent employees during the year

was made up as follows:

2007 2006

Staff with a permanent (UK) contract

Professional/specialist staff 307 305

Non-specialist staff 80 83

Sub Total 387 388

Other staff engaged on HSL objectives

Professional/specialist staff - -

Non-specialist staff - 3

Total Staff 387 391

HSL has filled 14 posts, to replace

leavers and adjust the skill base to

fit business need. 40 staff left,

giving an end of year total staff in

post figure of 391 (2005/06: 417

(re-stated)). Turnover of staff for

2006/07 was 9.9% (2005/06: 5.9%).

Learning and development

HSL is recognised as an Investors in

People (IiP) organisation and,

building on action commenced in

2006/07, HSL will be further

developing a framework for

Learning & Development (L&D) in

2007/08. The annual corporate

training plan identifies L&D

priorities and individual employee

development plans provide the

detail. The HSL Local Career Review

Group manages the succession

plan, which identifies potential

successors for key positions and the

development they require to be

ready to fill these posts.


Diversity Health and Safety

HSL is actively participating in

HSE’s “Equal” forum, as part of the

HSE Equality Schemes Vision.

HSL’s new Board member

responsible for HR also brings

experience of diversity audits in two

major UK companies, allowing HSL

to benchmark with the private

sector. Diversity is discussed at the

monthly HSL Board meeting and,

as an equal opportunities employer,

HSL ensures everyone is treated

fairly irrespective of gender, age,

ethnic origin, religious belief, sexual

orientation or disability. HSL has a

new policy on young people,

allowing HSL to offer work

experience opportunities to those

aged 16 to 18. In addition,

HSL supports individual employees

working with school-age people to

promote scientific careers.

Employee involvement

HSL operates a system of quarterly

meetings with the recognised trade

unions. Between meetings the

unions are consulted on appropriate

issues as they arise. In addition,

there are various arrangements

for communicating with staff.

For example, the Chief Executive

makes half-yearly addresses to

staff during which he updates

people on plans, achievements

and challenges, frequent

“Communication Briefs” by email,

and the Chief Executive and Group

Directors visit sections on a regular

basis to discuss work issues and

listen to staff views.

There are quarterly meetings of the

Safety, Health and Environment

(SHE) committee, comprising

management and staff safety

representatives, to discuss progress

on the Health and Safety Plan,

accident and near miss statistics

and other SHE issues of concern to

staff (see right).

Safety, health and environmental

issues continue to be given a high

priority as HSL seeks to become a

Beacon of Excellence in Health,

Safety and the Environment.

In conducting its scientific

activities, HSL needs to control a

significant number of risks, ranging

from those normally associated with

the operation of a laboratory

through to those associated with

large scale field trials. Control of

these activities is achieved using a

safety management system based

on Health and Safety (Guidance)

publication HS(G)65.

Each year HSL reviews its

performance and sets a challenging

and measurable Health and Safety

Plan for improvement. A key aim

has been to improve: cooperation

and communication between HSL,

Investors in the Community (Buxton)

Limited ((ICB Ltd) - the PFI Special

Purpose Vehicle) and Interserve

Facilities Management ((IFM) - the

onsite facilities management

provider). Examples of initiatives

implemented are:

≥ The new Chief Executive of ICB

Ltd now attends the six monthly

high level safety, health and

environment meetings.

≥ There have also been changes

to the site Safety, Health and

Environment Committee with

the Chief Executive of ICB Ltd,

their General Manager and

their safety consultant regularly

attending meetings. This is in

addition to the IFM site Contract

Manager and one of their

employees who represent the

staff side.

≥ A joint HSL/ICB Ltd/IFM

workshop was held to discuss

ways of improving working

together.

All the HSL Board members

together with the Chair of ICB Ltd

successfully passed an IOSH

accredited Safety for Senior

Executives course.

We have been developing proposals

for looking at staff engagement in

the process of behaviour change at

HSL. The aim being to ensure all

employees at HSL are consistent,

unwavering and dedicated ‘Beacons

of Excellence’, in health, safety and

pro-environmental practices by

utilising effective staff engagement

and behaviour change processes.

A Liaison Action Group has been

established to facilitate moving

technical safety, health and

environmental issues forward and

to discuss accident/ill-health/near

miss reports and actions arising

from the SHE committee.

The group, with representation

from HSL, IFM and the staff side,

currently meets fortnightly.

All parties have found these

meetings very useful, and progress

has been made on a number

of issues.

Road safety is an area of concern

for HSL. An incident report form

has been produced to enable us

to capture and monitor driving

incidents. Replies are being

monitored to identify potential

accident black spots. In addition,

the approach road has been

identified as a problem area. Other

users of the road are being invited

to a meeting to discuss the issues.

HSL commissioned the Transport

Research Laboratory to assess

the approach road and make

recommendations for improvement.

HSL is considering their report.

HSL reported 47 events in

2006/07. Nine of the events

involved cases of ill-health, five

of which were DSE related.


Prompt payments Declaration

HSL is committed to the prompt

Four events were reportable under payment of bills for goods and

the Reporting of Injuries, Diseases services received, in accordance

and Dangerous Occurrences with the CBI Code of Prompt

Regulations (RIDDOR), one of Payments. Payments are normally

these was a dangerous occurrence made as specified in the contract.

concerning a fire within one of our If there is no contractual provision,

thermal chambers. HSL thus or other understanding, payment is

unfortunately missed its target of due to be made within 30 days of

no more than two RIDDOR events. the receipt of the goods or services

or presentation of a valid invoice or

In addition, 83 near misses were similar demand, whichever is later.

reported, up from 12 in 2005/06. In 2006/07 HSL achieved a

The increased level of near miss performance of 99.9% (2005/06:

events reflects the new system for 99.9%) of invoices paid within the

the reporting of minor near misses agreed credit period.

that was implemented during the

latter part of 2005/06. This new

system has provided a significant

improvement in reporting as well as

beneficial feedback on a wide range

of events.

Environment

HSL has continued to pursue and

promote best environmental

practice and to implement the

initiatives established by the

Government.

In particular, the Carbon Trust has

carried out an energy audit of the

site, and HSL is working with the

Trust to reduce HSL’s carbon

footprint. Measures undertaken have

included replacing light switches in

corridors with passive infra-red

sensors and installing photo-electric

sensors in other areas.

HSL has met the Derbyshire Wildlife

Trust to discuss the ecological and

nature management of the site. HSL

is a site of national/international

importance for fungi and also

provides a habitat for a number

of nationally and regionally rare

species of flora. A number of areas

of the site have been classed by

the Trust as Local Wildlife Sites.

So far as the accounting officer is

aware, there is no relevant audit

information of which the entity’s

auditors are unaware. The

accounting officer has taken all the

steps that he ought to have taken to

make himself aware of any relevant

audit information and to establish

that HSL’s auditors are aware of the

information.

Financial position and results for the year

With effect from 1 April 1996, HSL

has been controlled on the basis of

its Net Administration Costs. HSL is

required to recover its Full Economic

Costs, taking one year with another,

through charges it makes for the

services it provides to HSE and

other public and private sector

customers.


Results for the year - Income and Expenditure Account

During the year, HSL generated

sales of £34,023,000 (2005/06:

£31,651,000) against net costs of

£29,407,000 (2005/06:

£29,440,000), to achieve an

operating surplus of £4,616,000

(2005/06: £2,211,000). After

deducting interest payable and

similar charges, but before taking

account of an exceptional item of

transitional funding, HSL reported a

deficit of £1,392,000 (2005/06:

£3,664,000) for the financial year.

As previously agreed with HSE, HSL

has utilised, from a previously

accumulated surplus (see Note 12B

Reserves), an amount of transitional

funding equal to the calculated

in-year deficit, such that HSL

showed no surplus or deficit for the

financial year. The balance of

previously accumulated surplus

remaining at 31 March 2007 was

£6,867,000 (31 March 2006:

£8,259,000).

Note

Against Estimate, HSL’s Turnover

was broadly on target, though this

was accompanied by an increase in

Operating Surplus, mainly as a

result of a lower Cost of sales figure

and a reduction in Administrative

costs, resulting in the requirement

for Transitional Funding being

£598,000 lower than the Estimate.

Outturn Estimate Variance

£’000 £’000 £’000

Turnover 2 34,023 34,108 (85)

Cost of sales 3A 1,885 2,421 536

Gross surplus 32,138 31,687 451

Expenses – Administrative 3B 24,369 24,751 382

– Programme 3C 3,250 3,154 (96)

Total Expenses 27,619 27,905 286

Other operating income 4 97 70 27

Operating surplus 4,616 3,852 764

Interest payable & similar charges 5 6,008 5,842 (166)

(Deficit)/surplus on ordinary activities (1,392) (1,990) 598

Exceptional Item – Transitional Funding 12B 1,392 1,990 (598)

Surplus for the financial year 12A 0 0 0

Financial position - Balance sheet

Tangible fixed assets with a net

book value of £68.3m are a

significant component of the

balance sheet, comprising £60.6m

of land and buildings (see PFI

details below).

HSL’s balance sheet shows debtors

of £6.1m (the main item of which is

the £4.2m deferred proceeds for

the Sheffield buildings in 2004/05,

of which £4.1m falls due more than

12 months after 31 March 2007),

and creditors of £62.2m, of which

£60.1m relates to PFI obligations,

including deferred interest of

£3.7m.

HSL has an on-balance sheet PFI

contract for the provision of

serviced accommodation for

laboratory and support services at

the Buxton site. This is represented

on the balance sheet by the long-

term liability to pay finance lease

charges referred to above.

Cash flow

The cash flow statement shows cash

generated from operating activities

of £6,841,000 (2005/06

£3,729,000), reflecting principally

the improvements in Operating

Surplus and Creditors when

compared to the previous year.

Net cash outflow of £1.6m from

investing activities has, as the most

significant constituents, expenditure

on Plant & Machinery and IT asset

additions.


Remuneration report - Unaudited information

HSL management structure

The new Chief Executive was

appointed in open competition and

is retained on an open-ended

contract, which may be terminated

on 13 weeks notice from either side.

The remuneration of Board

members who are Senior Civil

Servants (SCS) is in line with the

recommendations by Cabinet Office

and the Senior Salaries Review

Body. Performance management

and reward, and the proportion of

remuneration subject to

performance conditions for SCS,

are managed within HSL in line

with the relevant recommendations

by the Senior Salaries Review Body.

The standard terms and conditions

defined by Cabinet Office for SCS

apply where appropriate, including

those applicable to the provision of

compensation for early retirement.

The remuneration of non SCS who

are members of the Board is dealt

with as part of HSE’s annual pay

negotiations. Their performance

management and reward, and the

proportion of remuneration subject

to performance conditions,

are managed in line with the HSE

appraisal policies and procedures.

The standard terms and conditions

defined by Cabinet Office for Civil

Servants apply where appropriate,

including those applicable to the

provision of compensation for early

retirement.

Remuneration report - Audited information

The HSL Board is responsible for the day to day running of the Agency’s operations and for ensuring that

customers’ requirements are met. Membership of the HSL Board in 2006/07, together with details of the service

contract for each Board member who has served on the Board during 2006/07, are shown below.

Name Position Board Membership Contract Unexpired Term Notice

From To Date @ 31.3.07 period

Mr Eddie Morland Chief Executive* 01/04/2006 31/03/2007 19/09/2005 Open ended 13 weeks

Dr Norman West Operations Director 01/04/2006 09/04/2006 ** ** **

Dr Andrew Curran Health Improvement 01/06/2006 31/03/2007 07/10/1991 Open ended 13 weeks

Group Director

Dr Karen Russ Human Factors & 04/09/2006 31/03/2007 04/09/2006 Open ended 13 weeks

Technical Programmes

Group Director

Mr David Hazard Reduction 04/09/2006 31/03/2007 04/09/2006 Open ended 13 weeks

Kershaw-Wright Group Director

Mr John Verney Head of Finance 01/04/2006 31/03/2007 08/05/1989 Open ended 13 weeks

Ms Ruth Gilbody Business 01/04/2006 31/03/2007 01/06/2005 2 months*** 5 weeks

Development Director

Mr Graham Ince Head of Business 01/04/2006 26/03/2007 01/04/1999 **** ****

Infrastructure Group

Dr Peter Watson Non-Executive 01/04/2006 31/03/2007 01/03/2006 1 year 11 months 13 weeks

Director

Dr Sue Ion Non-Executive 01/04/2006 31/03/2007 01/04/2006 2 years 13 weeks

Director

* Mr Morland is also a member of the HSE Board.

** Norman West retired on 9 April 2006.

*** Ruth Gilbody resigned in April 2007, her notice period expiring on 31 May 2007.

**** Graham Ince retired on 26 March 2007.


Chief Executive and Board Members – Salary and Pension Entitlements

Total actual emoluments of the Chief Executive

Salary band

Taxable benefits in kind

Real increase in pension at 60

Total accrued pension at 60 at 31 March

CETV at 31 March

Real increase in CETV

Eddie Morland

2006/07

£’000

120-125

£

4,800

£’000

55-57.5 + 0 lump sum

£’000

55-60 + 0

lump sum

£’000

834

£’000

816

2005/06

Joined 19/9/05

55-60 2,400 0-2.5 + 0 lump sum

0-5 + 0 lump sum

12 11

David Buchanan

2006/07

£’000

N/A

£

N/A

£’000

N/A

£’000

N/A

£’000

N/A

£’000

N/A

2005/06

Left 26/12/05

70-75 0 0-2.5 + 0-2.5 lump sum

10-15 + 30-35 lump sum

279 19

Notes

“Salary” includes gross salary; performance pay or bonuses, overtime; recruitment and retention allowances and any

other allowance to the extent that it is subject to UK taxation.

The taxable benefit amount for the current Chief Executive relates to the provision of a Private User Scheme car for

the year 2006/07 (the 2005/06 figure related to a part year).

As a member of the Premium pension scheme, no lump sum is payable to Mr E Morland


Total emoluments of other Board members were:

Salary band

Taxable benefits in kind

Real increase in

pension at 60

Total accrued pension at 60 at 31 March

CETV at 31 March

Real increase in CETV

2006/07 £’000 £ £’000 £’000 £’000 £’000

Dr N West Left 9/4/06

0-5 0 None 30-35 + 100-105 lump sum

812 0

Dr K Russ Started 4/9/06

40-45 0 0-2.5 + 0 lump sum

0-5 + 0 lump sum

8 7

Dr A Curran From 1/6/06

55-60 0 0-2.5 + 5-7.5 lump sum

10-15 + 30-35 lump sum

127 22

Mr D Kershaw-Wright Started 4/9/06

30-35 0 0-2.5 + 0 lump sum

0-5 + 0 lump sum

6 5

Mr J Verney 55-60 0 0-2.5 + 2.5-5 lump sum

25-30 + 80-85 lump sum

639 22

Ms R Gilbody 55-60 0 0-2.5 + 0 lump sum

0-5 + 0 lump sum

20 9

Mr G Ince Left 26/3/07

55-60 0 0-2.5 + 2.5-5 lump sum

25-30 + 80-85 lump sum

642 29

Dr P Watson 10-15 0 See Notes See Notes See Notes See Notes

Dr S Ion Started 3/4/06

10-15 0 See Notes See Notes See Notes See Notes

2005/06 £’000 £ £’000 £’000 £’000 £’000

Dr N West 65-70 0 0-2.5 + 2.5-5 lump sum

30-35 + 100-105 lump sum

836 18

Dr C Jackson Left 20/10/05

30-35 0 0-2.5 + 0-2.5 lump sum

25-30 + 75-80 lump sum

637 19

Mr J Verney 55-60 0 0-2.5 + 2.5-5 lump sum

25-30 + 75-80 lump sum

595 30

Ms R Gilbody Started 1/6/05

45-50 0 0-2.5 + 0 lump sum

0-5 + 0 lump sum

9 8

Mr G Ince From 3/10/05

25-30 0 0-2.5 + 2.5-5 lump sum

20-25 + 70-75 lump sum

602 36

Mr S Sampson Left 31/1/06


Dr P Watson Started 1/3/06


Notes

≥ “Salary” includes gross salary;

performance pay or bonuses,

overtime; recruitment and

retention allowances and any

other allowance to the extent

that it is subject to UK taxation.

≥ Dr Norman West’s accrued

pension details are as at

9 April 2006.

≥ Dr Peter Watson’s and

Dr Sue Ion’s appointments

as Non-Executive Directors

are non-pensionable.

≥ As members of the Premium

pension scheme, no lump sums

are payable to Ms R Gilbody,

Dr K Russ & Mr D Kershaw-Wright.

≥ HSL made payments during

2006/07 in respect of John

Verney, totalling £3,934

(2005/06 £15,740), in relation

to his relocation to the Buxton

area. Such payments were

available to all HSL staff who

were eligible for a move at

public expense.

≥ No significant awards were made

to past senior managers, nor

was any compensation payable

to former senior managers, nor

were any amounts payable to

third parties for services of a

senior manager.


Civil Service Pensions (CSP)

Pension benefits are provided

through the CSP arrangements.

From 1 October 2002, civil servants

may be in one of three statutory

based ‘final salary’ defined benefit

schemes (Classic, Premium,

and Classic Plus). The Schemes are

unfunded with the cost of benefits

met by monies voted by Parliament

each year. Pensions payable under

Classic, Premium, and Classic Plus

are increased annually in line with

changes in the Retail Price Index.

New entrants after 1 October 2002

may choose between membership

of the Premium scheme or joining

a good quality ‘money purchase’

stakeholder arrangement with a

significant employer contribution

(Partnership Pension account).

Employee contributions are set

at the rate of 1.5 per cent of

pensionable earnings for Classic

and 3.5 per cent for Premium and

Classic Plus. Benefits in Classic

accrue at the rate of 1/80th of

pensionable salary for each year of

service. In addition, a lump sum

equivalent to three years’ pension

is payable on retirement.

For Premium, benefits accrue at the

rate of 1/60th of final pensionable

earnings for each year of service.

Unlike Classic, there is no

automatic lump sum (but members

may give up (commute) some of

their pension to provide a lump

sum). Classic Plus is essentially

a variation of Premium, but with

benefits in respect of service before

1 October 2002 calculated broadly

as per Classic.

The Cash Equivalent Transfer Value (CETV)

This is the actuarially assessed

capitalised value of the pension

scheme benefits accrued by a

member at a particular point in

time. The benefits valued are the

members’ accrued benefits and any

contingent partner’s pension

payable from the scheme. A CETV

is a payment made by a pension

scheme or arrangement to secure

pension benefits in another pension

scheme or arrangement when the

member leaves a scheme and

chooses to transfer the pension

benefits they have accrued in their

former scheme. The pension figures

shown relate to the benefits that the

individual has accrued as a

consequence of their total

membership of the pension

scheme, not just their service in a

senior capacity to which disclosure

applies. The CETV figures, and

from 2003/04 the other pension

details, include the value of any

pension benefit in another scheme

or arrangement which the individual

has transferred to the CSP

The Partnership Pension account is

a stakeholder pension arrangement.

The employer makes a basic

contribution of between 3 per cent

and 12.5 per cent (depending on

the age of the member) into a

stakeholder pension product chosen

by the employee. The employee

does not have to contribute but

where they do make contributions,

the employer will match these up to

a limit of 3 per cent of pensionable

salary (in addition to the employer’s

basic contribution). Employers also

contribute a further 0.8 per cent of

pensionable salary to cover the cost

of risk benefit cover (death in

service and ill-health retirement).

Further details about the CSP

arrangements can be found

at the website:

www.civilservice-pensions.gov.uk

arrangements and for which the

Civil Superannuation Vote has

received a transfer payment

commensurate to the additional

pension liabilities being assumed.

They also include any additional

pension benefit accrued to the

member as a result of their

purchasing additional years of

pension service in the scheme at

their own cost. CETVs are calculated

within the guidelines and framework

prescribed by the Institute and

Faculty of Actuaries.

The real increase in the value of the CETV

This reflects the increase in CETV

effectively funded by the employer.

It takes account of the increase in

accrued pension due to inflation,

contributions paid by the employee

(including the value of any benefits

transferred from another pension

scheme or arrangement) and uses

common market valuation factors

for the start and end of the period.

Mr E Morland

Chief Executive, Health and Safety Laboratory

accounting officer 13 June 2007


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Health and Safety Laboratory

Harpur Hill

Buxton

Derbyshire SK17 9JN

United Kingdom

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F 01298 218590

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