How to standardize operational behavior? How to identify risk factors? Key knowledge points that frontline workers in chemical plants should master are here

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1. Cultivate good operating practices (1) Routine checks before operation: It is essential to ensure that mechanical equipment always operates in a normal condition. Conduct routine inspections of mechanical equipment before working each day. If any abnormality is detected, workers should promptly inform the management; work can only resume after repairs are carried out and safety is confirmed. 　　 (2) Thoroughly master signal communication: When working in collaboration with two or more people, it is sometimes necessary to establish communication signals and act according to those signals. In positions with communication signals, workers must keep the specified signals in mind and only begin working after confirming and understanding their meaning. 　　 (3) Strictly follow the operating procedures. Simplifying or omitting the prescribed procedures out of a desire to avoid hassle often leads to many accidents. Therefore, workers must strictly adhere to operating procedures. 　　 (4) Report promptly in case of unconventional operations. When product deformation occurs on the production line, or when minor faults arise and it becomes necessary to carry out operations that are not specified in the standard procedures (i.e., unconventional operations) such as machine calibration, maintenance, or oiling, it is necessary to report to the management promptly. 2. Absolutely prohibited unsafe operating practices
1. Incorrect operation of machinery and equipment, improper handling of objects; objects are not securely supported. 2. Approaching or entering dangerous areas, such as operating machinery or lifted goods. 3. Clean, lubricate, or service mechanical devices that are in operation, powered on, or heated. 4. Starting the machine suddenly, moving vehicles or objects or proceeding with further operations without giving a signal or confirming safety first. 5. Improper selection, misuse, or defects in the mechanical device. 6. Leaving a machine that is still in operation, thereby putting the machine or materials in an unsafe condition or location. 7. Acts of removing or rendering ineffective safety devices. 8. Climbing on or off vehicles or machines, or using hands instead of the designated tools for work. 9. Failure to use personal protective equipment, or using the wrong type, or wearing it in an unsafe manner. 10. Do not touch unknown chemicals casually. 11. Entering a confined space recklessly. 12. Rush to rescue in the event of an accident. 3. How to quickly identify hazard sources at work? A hidden danger refers to a concealed threat, that is, something or disaster that is not visible and poses a high risk of occurring. Potential accident hazards refer generally to unsafe human behaviors, unsafe conditions of equipment and materials, and management deficiencies within a production system that can lead to accidents. 4. Potential accident hazards can be categorized into 21 main types: fires, explosions, poisoning and asphyxiation, water-related hazards, collapses, landslides, leaks, corrosion, electric shocks, falls, mechanical injuries, coal and gas outbursts, hazards related to highway facilities, hazards related to road vehicles, hazards related to railway facilities, hazards related to railway vehicles, hazards related to water transportation, hazards related to ports and docks, hazards related to air transportation, hazards related to airports, and other types of hazards. During enterprise safety inspections, attention should be paid to the following commonly existing accident hazards: 5. There are 11 main types of unsafe human behaviors, which are also the primary direct causes of accidents in production. 1. Ignoring safety, ignoring warnings, and making operational errors. 2. Intentionally causing the safety device to fail. 3. Using unsafe equipment. 4. Use hands instead of tools for operation. 5. Improper storage of objects. 6. Risking entry into dangerous places. 7. Climbing or sitting in unsafe positions. 8. There are distracting and diverting behaviors. 9. Ignoring the use of individual labor protection equipment and tools, or failing to use them correctly. 10. Unsafe attire. Baijia Management 11: Errors in handling and dealing with flammable, explosive, and other hazardous materials. 6. There are mainly 4 categories of unsafe conditions of objects, which are also the primary direct causes of object-related accidents in production safety incidents. 1. Devices for protection, insurance, signaling, etc., are missing or defective. 2. The equipment, facilities, tools, and accessories are defective. 3. Lack of or defective personal protective equipment. 4. The working environment at the production (construction) site is poor. 7. There are mainly 7 types of management deficiencies, which are also the primary indirect causes of management-related accidents in production. 1. Defects in technology and design. 2. Insufficient safety production education and training. 3. Unreasonable labor organization. 4. Lack of inspection or incorrect guidance regarding on-site work. 5. There are no safety production management regulations and safety operating procedures, or they are inadequate. 6. There are no accident prevention and emergency response measures, or they are inadequate. 7. Inadequate rectification of potential accident hazards; funds are not allocated. 8. Identification of hazardous and harmful factors: Hazardous factors refer to those that can cause injury or death to people, or sudden damage to objects ； Harmful factors refer to those that can affect a person’s physical health, cause diseases, or lead to chronic damage. Normally, the two are not distinguished from each other and are collectively referred to as dangerous and harmful factors. 9. Classification of hazardous and harmful factors: Classifying hazardous and harmful factors is the basis for their analysis and identification. There are many methods for classifying dangerous and harmful factors, with the following two being the main ones: 1. Classification based on the direct causes of accidents and occupational hazards. (1) Physical dangerous and harmful factors: 1) Defects in equipment and facilities such as insufficient strength, poor stiffness, lack of stability, poor sealing, stress concentration, design flaws, exposed moving parts, brake defects, and other issues with equipment and facilities. 2) Protection deficiencies include lack of protection, defects in protective devices and facilities, inadequate protection, improper support, insufficient protection distance, and other protection deficiencies. 3) Exposed energized parts, electric leakage, lightning, static electricity, electric sparks, and other electrical hazards. 4) Noise: mechanical noise, electromagnetic noise, hydrodynamic noise, other noises. 5) Vibration: mechanical vibration, electromagnetic vibration, hydrodynamic vibration, other vibrations. 6) Electromagnetic and ionizing radiation: X-rays, gamma rays, alpha particles, beta particles, protons, neutrons, high-energy electron beams, etc ； Non-ionizing radiation: ultraviolet light, lasers, radiofrequency radiation, ultra-high voltage electric fields. 7) Solid projectiles from moving objects, liquid splashes, rebounding objects, soil and rock slippage, pile slippage, air currents, impact ground pressure, and other hazards caused by moving objects. 8) Open flames 9) High-temperature substances that can cause burns: high-temperature gases, high-temperature solids, high-temperature liquids, and other high-temperature substances. 10) Low-temperature substances that can cause frostbite: low-temperature gases, low-temperature solids, low-temperature liquids, and other low-temperature substances. 11) Dusts and aerosols do not include explosive and toxic dusts and aerosols. 12) Poor working environment: Messy working environment, foundation settlement, defective safety walkways, poor lighting and illumination, harmful light exposure, inadequate ventilation, oxygen deficiency, poor air quality, faulty water supply and drainage systems, water ingress, forced body postures, excessively high or low temperatures, excessively high or low air pressure, high temperature and humidity, natural disasters, and other poor working conditions. 13) Signal defects include the absence of signal facilities, inappropriate selection of signals, incorrect signal placement, unclear signals, inaccurate signal display, and other signal deficiencies. 14) Marking defects include no marking, unclear markings, non-standard markings, inappropriate selection of markings, defects in marking location, and other marking defects. 15) Other physical hazards and harmful factors (2) Chemical hazards and harmful factors 1) Flammable and explosive substances: flammable and explosive gases, flammable and explosive liquids, flammable and explosive solids, flammable and explosive dusts and aerosols, other flammable and explosive substances. 2) Spontaneously combustible materials 3) Toxic substances: toxic gases, toxic liquids, toxic solids, toxic dusts and aerosols, other toxic substances. 4) Corrosive substances: corrosive gases, corrosive liquids, corrosive solids, other corrosive substances. 5) Other chemical hazards and harmful factors (3) Biological hazards and harmful factors 1) Pathogenic microorganisms: Bacteria, viruses, and other pathogenic microorganisms. 2) Vectors of infectious diseases 3) Harmful animals 4) Harmful plants 5) Other biological hazards and harmful factors (4) Psychological and physiological hazards and harmful factors 1) Excessive loads: excessive physical load, excessive hearing load, excessive visual load, other types of excessive loads. 2) Abnormal health condition 3) Engaging in prohibited types of work 4) Psychological abnormalities such as abnormal emotions, a tendency for risk-taking, excessive stress, and other psychological issues. 5) Identify perception delays in functional defects, recognition errors, and other functional defect issues. 6) Other psychological and physiological risks and harmful factors (5) Behavioral risks and harmful factors 1) Incorrect command: mistakes in giving commands, unlawful command, other command errors. 2) Operational errors, improper operations, violations of procedures, and other operational mistakes. 3) Supervision errors 4) Other mistakes 5) Other behavioral hazards and harmful factors 6) Other hazards and harmful factors 2. Classification according to accident types: (1) Object strikes refer to situations where objects move due to gravity or other external forces and strike human bodies, resulting in injuries or deaths; this does not include object strikes caused by mechanical equipment, vehicles, lifting machinery, collapses, etc. (2) Vehicle-related injuries refer to accidents caused by corporate motor vehicles in operation, such as falls of people and collapses, drops, or crushes of objects, and do not include accidents that occur during the lifting by lifting equipment, when pulling vehicles, or when vehicles are stationary. (3) Mechanical injuries refer to injuries such as pinching, collision, shearing, entanglement, twisting, crushing, cutting, and piercing caused by the direct contact between moving (or stationary) parts of mechanical equipment, tools, and workpieces with the human body; these do not include mechanical injuries caused by vehicles or lifting machinery. (4) Lifting injuries refer to crushes, falls, impacts by (lifting tools and loads), and electric shocks that occur during various lifting operations (including crane installation, maintenance, and testing). (5) Electric shock includes injuries and deaths caused by lightning strikes. (6) Drowning includes drowning due to falling from a height; it does not include drowning caused by water ingress in mines or underground workings. (7) Burns refer to burns caused by flames, scalds from hot objects, chemical burns (burns inside and outside the body caused by acids, alkalis, salts, and organic substances), and physical burns (burns inside and outside the body caused by light or radioactive substances). This does not include electrical burns or burns resulting from fires. (8) Fire (9) Fall from height refers to injury or death accidents caused by falling during work at heights, excluding accidents resulting from electric shock. (10) Collapse refers to an accident that occurs when an object, under the action of external forces or gravity, exceeds its strength limit or experiences a loss of structural stability, such as soil and rock collapse during trenching, scaffold collapse, or the collapse of piled materials. It does not apply to roof and slope failures in mines, nor to collapses caused by vehicles, lifting equipment, or blasting. (11) Roof and sidewall collapse; (12) Water inrush; (13) Blasting accidents refer to casualties that occur during blasting operations. (14) **Explosions** refer to **explosion accidents that occur to explosives and their products during production, processing, transportation, and storage.** (15) Gas explosion (16) Boiler explosion (17) Container explosion (18) Other explosions (19) Poisoning and asphyxiation (20) Other injuries 10. Methods for identifying hazardous and harmful factors 1. Visual experience analysis method (1) Comparison and experience method: The comparison and experience method involves using relevant standards, regulations, checklists, or relying on the analytical skills of the analyst, along with experience and judgment, to analyze the hazardous and harmful factors in a company. (2) Analogical method: The analogical method involves using experience from identical or similar engineering systems or working conditions, along with statistical data on occupational safety and health, to infer and analyze the hazardous and harmful factors in a company. 2. System safety analysis methods: System safety analysis methods involve the use of certain techniques from system safety engineering evaluation to identify hazardous and harmful factors. System safety analysis methods are often used for new systems that are complex and lack accident experience. Common system safety analysis methods include event trees, fault trees, etc. 11. Main contents of identifying dangerous and harmful factors 1. Site selection: Analysis is carried out from aspects such as engineering geology, topography and landforms, hydrology, natural disasters, surrounding environment, meteorological conditions, transportation facilities, and fire protection support. 2. Plant layout (1) General plan: Zonal arrangement of functions (production, management, auxiliary production, living areas) ； Layout of facilities for high temperatures, hazardous substances, noise, radiation, and flammable and explosive materials ； Process flow layout ； Layout of buildings and structures ； Orientation, wind direction, fire protection distance, safety distance, health protection distance, etc. (2) Transportation routes and docks: plant roads, plant railways, hazardous materials loading/unloading areas, plant docks. 3. Fire resistance rating, structure, fire protection, explosion protection, safe evacuation, orientation, lighting, access routes, etc., of buildings and structures. 4. Production process parameters: materials (toxic, corrosive, flammable, and explosive materials), temperature, pressure, speed, operating and control conditions, as well as accident and out-of-control scenarios. 5. Production equipment and installations (1) Chemical engineering equipment and installations: high temperature, low temperature, corrosion, high pressure, vibration, critical equipment, control, operation, maintenance, as well as emergency situations in case of failures or mistakes. (2) Mechanical equipment: moving parts and workpieces, operating conditions, maintenance tasks, abnormal operation, and misoperation. (3) Electrical equipment: power outages, electric shocks, fires, explosions, misoperation and incorrect handling, static electricity, lightning. (4) Equipment with high risk, and equipment for working at heights. (5) Special monomer equipment and installations: boiler rooms, acetylene stations, oxygen stations, oil depots, hazardous materials warehouses, etc. (6) Hazardous working environments such as dust, toxins, noise, vibration, radiation, high temperatures, and low temperatures. (7) Management facilities, emergency rescue facilities for accidents, and auxiliary production and living hygiene facilities.