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If I say that people can lie, you will surely agree, but if I say that equipment can also “lie,” most people probably won’t believe it. It was still early in my career; I was working at a torch plant, monitoring liquefied gas storage tanks, and my responsibility was to keep an eye on the liquid level. It was a harsh winter with temperatures well below zero degrees, and I was on duty. The supervisor is responsible for starting the pump to top up the liquid level, while I am in charge of carefully observing any changes in the liquid level. As I watched, I noticed that once the liquid level rose to a certain height, it stopped rising any further. I observed carefully for some time longer, but the liquid level didn’t change at all. Under normal circumstances, it should have been replenished by now. What’s going on today? Just as I was puzzled, the phone rang. I picked up the receiver and heard the team leader asking urgently, \"Xiao Duo, hasn’t the liquid level been replenished yet?\" I had no choice but to answer truthfully, \"It remains at 40 percent so far; there’s no change.\" ” “That’s not right; it should have been replenished by now... Maybe there’s a problem with the level gauge – it’s very likely that the displayed level is incorrect! “Incorrect level? How is that possible? The level has increased from 20 percent after all, it hasn’t stayed constant.” The team leader asked again, “Master Wang, are the flow rate and pressure of the filling pump working properly?” “Everything is normal. I just finished my inspection; it should have been replenished by now, but I still haven’t received any calls.” ”Master Wang replied. “Go and stop the pump immediately; it must be a false liquid level. ”On the other end of the phone, the team leader said again, \"Xiao Duo, go and shut off the inlet valve right away, then close the upper and lower valves of the level gauge. Use steam to purge the level gauge.\" ” I thought to myself, it can’t possibly be a fake liquid level; besides, is it really necessary to go to the trouble of using steam pipes just for such a small level gauge? “It’s enough to pour hot water on it – there’s no need for pipes at all; how troublesome!” I was full of complaints. ““Go and do it first; I’ll explain to you why steam is used instead of water after you’re done!” the squad leader said firmly. After introducing steam for cleaning, the liquid level rose to 80% in no time (the target value is 85%), and I had nothing more to say. I thought to myself that if the team leader had not promptly given the order to stop the pump, it was very likely that the safety valve would have activated, leading to a serious accident of pressure buildup in the tank. Thinking about the great dangers associated with liquefied gas, I can’t help but feel scared, and at the same time I feel grateful and admiring toward the team leader. I quickly asked the monitor, \"Monitor, could you tell me why we can’t use boiling water?\" \"On a day this cold, water will freeze on the level gauge, and if we pour boiling water on it, the glass of the level gauge will definitely shatter.\" ” After the team leader said that, I understood everything, and I also realized that equipment can indeed \"lie\", as well as how important valuable experience is for ensuring the safe operation of devices. In the days to come, I will pay close attention to every step taken by those experienced teachers; whenever I don’t understand something, I will ask several times why. Time has passed swiftly; it’s been over twenty years since that incident. Now, I am regarded as an experienced professional by others, and I share all the experience I’ve accumulated with new employees without reservation. I believe it is precisely because batch after batch of front-line workers selflessly pass on their valuable experience to new employees that our company continues to grow and develop, and that it is able to establish a formidable corporate culture.
The equipment isn’t ‘faking’ anything; it’s just that the work done by humans wasn’t thorough enough.
The valuable experience from the front lines of production is worth learning from and promoting
This brings up the issue of \"knowledge transfer\" by experienced workers. Some of these experts keep their experience to themselves as a bargaining tool for retirement or rehiring, and their departure represents a loss for the company.
A necessary path for newcomers to the chemical industry. . .
This often happens with the liquid level
The three elements of safety hazards are equipment, personnel, and management, among which human factors are actually a crucial element. If people have the right skills and handle the situation properly, then equipment issues pose no problem; but if they fail to do so, potential hazards remain, and accidents may occur