Discussion on shutting down or stopping operations in emergency situations
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Recently, when studying accident cases, it has been found that there is a short period of time between the detection of a hazard and the occurrence of an accident, during which urgent action can be taken. Yet, we often fail to seize this optimal timing, which leads to the occurrence or escalation of accidents. In many cases, it’s not that the people on site lack the ability to act decisively; rather, they are afraid to stop the machinery or operations. They tend to need to seek approval first, which results in missing the best opportunity for action. The problem is that our leaders do not grant us such authority, or fail to clarify what actions should be taken in emergency situations. As a result, if we take initiative and take correct action to prevent an accident, we may still face punishment for not reporting to superiors first. So, how should this authority be defined?
Generally, large-scale continuous production facilities are equipped with automatic shutdown protection in the event of an accident. For small-scale devices, technicians can shut down the equipment according to the actual situation.
5.5.4.6 The handling of emergencies in an enterprise’s production facilities shall comply with the following requirements: 1) Upon detecting or experiencing an emergency, it shall be handled properly in accordance with the principle of avoiding harm to personnel, while reporting to the relevant parties at the same time； 2) In the event of abnormalities in the processes or mechanical and electrical equipment, appropriate measures shall be taken, and the relevant personnel shall be notified to coordinate the handling; if necessary, the system shall be shut down urgently according to the established procedures. 5.5.4.7 Hazardous chemicals discharged from a company’s production facility’s pressure relief system or venting system should be directed to a safe location and properly treated. 5.5.4.8 Enterprise operators shall strictly follow the operating procedures, promptly analyze any deviations in the operation of process parameters, ensure that these parameters remain within safe limits, and correct such deviations as soon as possible.
The handling of emergencies still relies largely on the work experience of employees, and the emergency response plans in organizations often address general issues or situations that may arise, resulting in limited practical value. As normally explained to the original poster, an accident always develops over a certain period of time; detecting it early and dealing with it promptly may help prevent the accident from occurring. This can entirely be handled by the operators, so they should have both the right and the obligation to deal with emergencies.
This issue seems simple in theory but is actually very complex in practice. The quality of employees is crucial, including their awareness, skills, and sense of responsibility. It is necessary to enhance their education and improve their capabilities and awareness, while also providing them with a good working environment and fair treatment, so that they feel it is worthwhile to contribute to the company. Companies and employees share a common destiny – success or failure. A few days ago, a fire broke out at one of the companies in the vicinity; an ethanol recovery unit leaked and caught fire, and the fire gradually grew larger. Four or five workers who were nearby saw the fire and ran away, which resulted in a serious fire accident. The company had to suspend operations for repairs, and the employees naturally lost their jobs
In my actual work experience, I encountered such a problem that it remains unsolved to this day... The solution I proposed at the time was: 1. Clarify the authorities in various emergency situations; in other words, determine what level of orders can be given by certain positions, or under what circumstances certain people can be granted temporary authority； This is something that must be clarified first... The so-called alignment of responsibilities and rights... 2. Develop or improve emergency response plans, specifying the procedures or steps to be followed ； 3. Strengthen training on the contingency plan, and it is best to conduct practical operations. It sounds simple, but in practice it’s extremely complicated, which is why I still haven’t solved this problem...
For such hazardous locations, safety operating procedures should be improved and emergency cards for each position should be established. This is the basis for operators to take corresponding actions!
This issue seems simple in theory, but is actually quite complex in practice. The quality of employees is crucial, including their awareness, skills, and sense of responsibility. It is necessary to strengthen education in order to improve their abilities and awareness, while also providing them with a good working environment and fair treatment; only then will employees feel that it is worthwhile to contribute to the company. Companies and employees share a common destiny. Accidents in production are often unpredictable, and as long as efforts can be made to prevent such accidents and save lives and property, even if penalties are imposed, one can feel at peace. I believe that leaders are sensible enough to not only impose penalties but also offer rewards.
Rules and regulations can specify under what circumstances employees are allowed to initiate an emergency shutdown without seeking permission from any supervisor.