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Analysis of human unsafe behaviors in chemical production

2016-07-24View Original

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Chemical production involves hazardous factors such as flammability and explosiveness, high temperatures and pressures, and toxicity; a slight carelessness can lead to serious accidents. Therefore, safety in chemical production is of utmost importance. Managers at all levels involved in chemical production must treat the management of potential accident hazards as a top priority, eliminating them at the earliest possible stage. Accidents are usually caused by unsafe human behaviors and unsafe conditions of objects. A large amount of statistical data shows that unsafe human behaviors are the main cause of accidents; therefore, to prevent accidents, it is necessary to focus on correcting such unsafe behaviors. According to behavioral science, human behavior is influenced by various factors such as the environment and mental state. Based on my years of work experience and by applying the analytical methods of systems engineering, I have studied and analyzed a large number of instances of unsafe human behavior. It was found that the factors that lead to such behavior can be summarized as follows: 1. Not knowing what one should know – failing to understand rules and regulations, operating procedures, or realizing that one’s actions constitute unsafe behavior that can lead to accidents, thereby unintentionally causing accidents. For example: On August 3, 1995, a fitter in our company used welding equipment without permission, which led to an explosion. 2. Lack of attention to regulations and rules: Failing to take these regulations and rules seriously, treating them as something trivial and believing they are unnecessary; not realizing that such regulations and rules are the result of painful lessons learned, as well as a summary and warning based on extensive experience. For example: On November 2, 2005, one of our company’s maintenance workers fell from a scaffold 2.5 meters high while repairing a water tank in a carbonization tower. Since he was not wearing a safety helmet, he suffered head injuries and developed a concussion. 3. Knowing but not fully understanding: The perpetrator has only a superficial knowledge of the regulations and does not strive to understand them thoroughly; they have a vague understanding of them. In actual operations, even though they are aware of the dangerous conditions, they ignore them and, relying on their limited knowledge, engage in risky activities that lead to accidents. For example: On July 4, 1987, a colleague in our company who was responsible for operating the compressor damaged the compressor’s valves due to unfamiliarity with the operating procedures and careless handling. 4 Disconnection between theory and practice: Although the operators understand the operating procedures in theory, and may even know them by heart, they lack practical experience. When problems arise during operation, they become panicked and at a loss, and may even make mistakes in their operations, leading to accidents. For example: On August 20, 1997, an operator from our company who worked on the ice machine, due to a lack of practical experience and delayed response, allowed copper melt to enter the machine, resulting in its damage. 5 Emotional impulse: The perpetrator desires to obtain something they need, or is affected by some disturbance, which leads to feelings of annoyance and anxiety. Such emotions can distract a person’s attention and result in faulty behavior. For example, in October 1986, a desulfurization operator was not focused while at work; he mistook the signal indicating a reduction in output for a signal to stop the machine, which resulted in the shutdown of the entire plant. Investigations revealed that family problems were causing emotional fluctuations in his state of mind, leading to a lack of concentration and thus the accident. 6 Excessive confidence: The perpetrator is blindly confident, believing that this is the way things have always been done; they take it for granted, become complacent, and rely on luck. For example, during a maintenance task on a vulcanization tank in April 1983, the worker was working at a height of 2.5 meters; thinking it wasn’t very high, he did not wear a safety belt and fell, resulting in injuries. 7. I don’t understand the relationship between randomness and necessity. Acting on so-called experience, if one commits a violation without an accident occurring, they mistake that randomness for necessity and continue to violate regulations; this will inevitably lead to accidents. For example, in April 1987, the anchor bolts of the Roots blower became loose and required welding. In the past, welders would carry out the work without shutting down the machine, but the safety officer insisted on stopping the machine first for welding; however, the workers acted on their past experience and proceeded regardless, which resulted in a fire and forced the shutdown of the entire factory. 8 Improper management and technical measures: The perpetrator acts in accordance with incorrect procedures or instructions, thereby causing accidents. In the production process, when there is a conflict between production and safety, the principle of putting safety first is often not upheld. 9 Conclusion: From numerous accident investigations and studies, it has been determined that the factors contributing to unsafe human behavior are the main causes of accidents; therefore, corresponding systems must be established based on these factors in order to eliminate such unsafe behaviors. Firstly, it is essential to follow the principle of \"safety first, prevention foremost\" and attach great importance to safe production; secondly, it is necessary to establish and improve a comprehensive set of sound safety management systems. Examples include safety education systems, safety regulations, no-fire policies in production areas, and safety management systems for key positions, etc. Workers are given enhanced safety training to ensure they know what is required of them, and on-site training is carried out in conjunction with simulations to predict potential accidents. Strictly enforce various rules and regulations, act in accordance with scientific principles; strengthen labor discipline and improve management. Make use of pre-shift and post-shift meetings as well as routine inspections. Understand the mental state of employees, eliminate sources of insecurity, prevent accidents, safeguard the safety and health of employees, and ensure the smooth progress of production and construction.

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