【Weekly Topic】Production Technology: Safety precautions on site? 2011.12.04~12.11

1. Electrical safety issues: Transformers pose a risk of electric shock. Exposed external cables can cause electric shock; it is prohibited to approach or touch them, as well as to perform any work on live circuits. 2. Store volatile raw materials in a warehouse to prevent explosions caused by the vapor of these materials when exposed to fire; ensure proper ventilation and avoid moisture exposure. 　(Precautionary measures: a. Prevent static electricity fires) ； b. Electrical wiring and lamps must be equipped with explosion-proof devices; c. It is strictly prohibited to bring open flames into the warehouse. ) 3. For stored materials, it is necessary to understand their properties in order to prevent leaks of materials with incompatible properties, which could lead to avoidable hazards. Implement emergency rescue measures for material leaks. 4. During the production of volatile products, prevent poisoning from raw material vapors or explosions caused by fires involving mixtures of vapors and air. During operations, wear appropriate personal protective equipment and handle items carefully to prevent sparks from occurring, which could lead to explosions. 5. When opening the workshop’s (hinge-type) doors, it is necessary to secure them to prevent strong winds from knocking them down and causing injury. 6. It is prohibited to randomly connect or splice electrical wires indoors. Pay attention to wear and electrical leakage at points where workshop wires come into contact with metal surfaces. 7. The use of open flames is prohibited in production areas; any hot work must be carried out under a “hot work reporting system”. 8. When storing gases such as nitrogen, oxygen, and acetylene, it is prohibited to keep them near heat sources. 9. From April to October each year, volatile raw materials and finished products are prohibited from being stored outdoors; minimal or no storage of such materials or products should be carried out. The produced products should be shipped in a timely manner. 10. Drinking water in areas where dust is generated is prohibited, to prevent dust from entering the mouth and causing harm to the body. 11. After production ends, one should pay attention to personal hygiene before meals; in particular, precautions must be taken before eating to prevent toxic substances from entering the mouth and causing poisoning incidents. 12. Vehicles entering the factory area should drive at a reduced speed, and fire shields should be used when necessary to prevent safety incidents. 13. After filling barrels with volatile products, the barrel lids must be tightened to prevent the liquid from evaporating and generating steam, which could pose a danger. 14. During thunderstorms, it is forbidden to approach lightning protection facilities and to use mobile phones to prevent lightning strikes. 15. When loading and unloading materials, intense collisions and friction should be avoided as much as possible. Unloading iron barrels should be done in a soft area. Of course, different materials have varying requirements regarding storage, use, and transportation; corresponding measures should be taken for each specific material.

On-site safety management is the lowest level of safety management activities, yet it serves as the \"cell\" that constitutes an enterprise’s safety management framework, and it ensures the implementation of other higher-level management activities. On-site safety management in enterprises is an important indicator of their overall safety management level. On-site safety management has its own characteristics: (1) Continuity: As long as production is ongoing, such safety management activities at the site must continue. (II) Inheritance: It refers to the continuation and functioning of the security management functions and their activities from the higher levels at this most fundamental level. Security management activities at this level are also a true reflection of the management functions at the higher level. In other words, all decisions, directives, organizational coordination efforts related to safety management must be implemented at this level in order to achieve results. In other words, management activities at this level do not occur spontaneously; rather, they are closely related to management directives from the higher level. (III) Duality: It is a subordinate and someone under supervision for the management at the higher level, and it is a manager and controller for the human-machine system it manages. Accept supervision while also exercising it. (IV) Directness: The management function acts directly on the management endpoints (people and machines), rather than relying on indirect operations involving simulated transmission of shutdown information; at this final stage, the information is transformed into concrete actions through the human-machine system. (V) Precision: Management activities at this level are refined as much as possible; the more detailed they are, the better. It requires meticulous experience and operational skills to supplement the vague provisions of the management rules, which necessitates making full use of the autonomy and flexibility of managers (operators) at this level. (VI) Specificity: The conditions at each production site should be addressed individually. On-site safety management should be closely integrated with equipment management, process management, layout management, and industrial hygiene management. Section 2: Contents of On-site Safety Management I. Strengthening human management and controlling unsafe behaviors Accidents are generally caused by the interaction between unsafe human behaviors and unsafe conditions of equipment and facilities. Injuries resulting from people’s unsafe behaviors are the primary cause, accounting for over 70% of all injury incidents; injuries caused by unsafe conditions of objects, management issues, and environmental factors account for less than 30%. This is because humans play a leading role in human-machine systems. Humans are different from machinery; they have a high degree of freedom, which makes them prone to unsafe behaviors. Furthermore, since human behavior is influenced by factors such as physiology, psychology, environment, and personal qualities, and the unsafe condition of objects is closely related to the operator’s behavior, it is difficult to control unsafe human behaviors. Unsafe behaviors by personnel generally take the following forms: 1. Violation of safety rules and regulations. 1. Personnel found on site working without having undergone three-level safety training; 2. Specialized workers operating without proper certification or failing to undergo periodic retraining; 3. Non-specialized workers performing specialized tasks; 4. Materials, products, and tools not being stored or stacked in accordance with regulations; 5. Newly installed equipment being put into use without undergoing a safety inspection; 6. Operating equipment without prior inspection, or operating equipment that has faults or lacks necessary safety devices ； 7. Objects are piled up around fire-fighting equipment, power distribution boxes, panels, and cabinets, violating the required stacking distance (≥1M). 8. Hazardous operations are carried out without approval, or although approved, the necessary safety measures are not implemented ； 9. Smoking in no-fire zones or carrying out welding/ignition work in violation of regulations ； 10. Eating, drinking, or smoking in workplaces with toxins, dust, etc ； Ventilation and dust removal equipment was not used as required ； 11. During hazardous operations, supervision measures are not implemented, and no warning area is established or warning signs are not posted ； 12. Identifying potential hazards without eliminating them, reporting them, or proceeding with work despite the risks ； 13. Those with occupational contraindications were not promptly reassigned to another job. (II) Violation of safety operation procedures: 1. Arbitrarily removing the safety devices, instruments, meters, and warning devices of the equipment ； 2. Equipment operates at excessive speed, temperature, or load ； 3. The feeding speed is too fast ； 4. While the equipment is in operation, step across or touch the moving parts ； 5. Failing to cut off the power supply when adjusting, maintaining, or cleaning equipment, and failing to stop the machine when measuring workpieces ； 6. Use hands instead of tools for operation (pulling by hand, blowing away iron shavings) ； 7. When performing stamping operations, keep hands out of the dangerous area ； 8. Climbing on objects being lifted, as well as walking or staying under the lifted objects or crane arms ； 9. Enable seized or scrapped equipment ； 10. Factory vehicles are not carrying passengers or goods as required ； 11. When a motor vehicle is in motion, people getting on and off it, as well as throwing objects ； 12. When working at heights, do not throw objects around arbitrarily ； 13. Failing to shut down the power supply, test for electricity, ground the equipment, and install warning signs when maintaining electrical equipment ； 14. Safety-voltage lamps do not comply with the operating voltage and requirements ； 15. Ventilation equipment was not used during operations inside the container ； 16. Random dumping or pouring of hot metal objects ； 17. Other behaviors that fail to comply with safety operating procedures. (III) Improper wearing (use) of protective equipment (tools): 1. Wearing high heels, sandals, or slippers at the production site ； Wearing hard-soled shoes for work at heights, and not wearing insulating shoes for electrical work ； 2. Wearing tank tops, shorts, skirts, loose clothing at the production site, as well as headscarves, scarves, ties, or having the upper body exposed and being bare-chested ； and other unsafe attire ； 3. Having long hair that extends beyond the base of the neck, wearing hair loose or in braids, while entering the production area without wearing a work cap or tucking the hair under the cap; 4. Operating rotating machinery while wearing gloves or without fastening sleeve cuffs; 5. Failing to wear safety goggles or face shields when particles may be ejected during work; 6. Wearing synthetic fiber clothing while working in environments where flammability, open flames, or high temperatures are present; 7. Failing to use safety belts or implement reliable safety measures as required during work at heights; 8. Not wearing safety helmets when performing work at heights or when working in areas where objects might fall from above; 9. Failing to wear protective masks as required during operations involving toxic or harmful substances; 10. Using non-qualified insulating tools when operating high-voltage disconnect switches or isolating switches while the circuit remains energized; 11. Using Class I portable electric tools without a residual current device (RCD), and failing to use Class III portable electric tools when performing maintenance inside damp and enclosed containers.

Controlling unsafe human behaviors: First, standardization and legalization of management must be achieved. It is necessary to resolutely correct tendencies such as ignoring laws, lax law enforcement, and violations of regulations. Factories must be managed strictly in accordance with the law; responsibilities should be clearly defined, systems made rigorous, discipline maintained, assessments conducted strictly, and overall management tightened. Second, education for all employees throughout all stages of work must be upheld and strengthened, so as to continuously enhance their awareness of laws and regulations, their sense of “I want to be safe,” and their ability to “act safely.” Raising workers’ safety awareness is the fundamental prerequisite for preventing unsafe human behaviors.

II. Strengthening equipment (tool) management to control unsafe conditions of objects: Unsafe conditions of objects mainly manifest as energy being released outward in various forms; this energy comes into contact with the human body, acts upon it, or is absorbed by it, thereby consuming energy and causing partial or total damage to physiological functions. Additionally, when people exceed normal physical limits during various activities and come into contact with or collide with operating equipment, they may sustain injuries. The unsafe conditions of objects generally take the following forms: (I) Defects in protective measures and safety devices: 1. No protective cover; 2. No safety interlocks; 3. No alarm devices; 4. No safety signs; 5. No guardrails or damaged guardrails; 6. Protective covers not in the proper position; 7. Safety devices not properly adjusted; 8. Inadequate explosion-proof measures; 9. (Electrical) components not grounded; 10. Poor insulation; 11. Defects in braking systems; 12. Inadequate support during tunneling or excavation work; 13. Insufficient safety distances during logging and material gathering operations; 14. Others. (II) Issues related to the placement of objects and the working environment: 1. Unsafe stacking of tools, equipment, and materials ； 2. Slippery surface ； 3. There is oil or other liquids on the ground ； 4. There are other slippery objects on the ground ； 5. Uneven ground ； 6. Covered in ice and snow ； 7. Others. (III) Defects in protective equipment and gear 1. Lack of personal protective equipment and gear ； 2. The protective gear and tools used do not meet safety requirements ； 3. Others. (IV) Defects in the working environment 1. Insufficient lighting ； 2. The work area is filled with smoke and dust, making it difficult to see clearly ； 3. Excessive light intensity ； 4. Poor ventilation ； 5. No ventilation ； 6. Low efficiency of the ventilation system ； 7. Windage short circuit ； 8. The work area is messy ； 9. Improper environmental temperature and humidity ； 10. No local noise suppression system, resulting in high noise levels ； 11. Others. (V) Deficiencies in working methods 1. Improper design; structure does not meet safety requirements ； 2. The design or configuration of the operational procedures is unsafe ； 3. The equipment is operating under abnormal conditions ； 4. The equipment is operating with defects ； 5、Overload operation ； 6. Repair and adjustment of defects ； 7、Equipment in poor condition ； 8. Improper maintenance leads to equipment failure ； 9. The configuration of traffic routes is unsafe ； 10. The ropes used for lifting heavy objects do not meet safety requirements ； 11. Insufficient safety distance ； 12. The storage method is unsafe ； 13. Blasting operations during power and wind outages ； 14. Blasting operations carried out when gas emissions do not reach safe concentrations ； 15. Excessive gas level ； 16. No “safety path” was created during logging” ； 17. Others. (VI) Deficiencies in objective conditions 1. Working in dilapidated buildings ； 2. Conceal all defects during blasting operations ； 3. Narrow working space ； 4. The passage door blocks the view ； 5. Others. (7) Defects in the object itself: 1. Exposure of live parts of electrical installations ； 2. The workpiece has sharp burrs and rough edges ； 3. The equipment has sharp reverse shuttles ； 4. Insufficient mechanical strength ； 5. Insulation strength is insufficient ； 6. Others. The presence of these unsafe conditions can lead to accidents at any time, such as people being injured by rapidly moving machinery, by falling objects, by collapsing structures, by explosives, or by hitting equipment or objects; there are also injuries caused by chemical and physical factors. Such as explosions, fires, poisoning, burns, as well as injuries caused by chemical substances like dust, radiation, and electromagnetic waves. How to eliminate or control the unsafe conditions of objects? 1. Ensure the intrinsical safety of machinery and equipment. Maintain the machinery and equipment on site properly to keep them in good condition, ensuring that the production facilities can operate normally. There should also be reliable safety measures in place. Achieve the principle of \"six must-haves and six necessities\": ensure that there is a cover for every wheel, a sleeve for every shaft, a railing for every platform, a lid for every opening, a guard for every rolling point, and interlocks for situations involving extreme danger – thereby making the equipment intrinsically safe. 2. Implement organized management at the work site. Draw layout diagrams for the storage locations of various large tools, equipment, raw materials, finished products, semi-finished products, spare parts, etc., to ensure they are placed in designated areas. 3. Transform outdated and hazardous processes. Technical and process improvements are carried out on outdated processes, those with high risks, and unreasonable processes to enhance their safety. 4. Implement industrial hygiene measures that meet the standards. For hazardous work positions involving high temperatures, dust, noise, etc., measures such as ventilation, cooling, dust suppression, and isolation are taken to reduce and eliminate unsafe and unsanitary conditions. 5. Ensure that the production area is clean and orderly. The company’s access roads should be unobstructed; the production areas need to be well-organized with clear boundaries, and there should be no random placement of materials, spare parts, or waste items. There must be no garbage, standing water, oil stains, or accumulated debris. 6. Implement strict on-site fire safety measures. Production areas must be free of unnecessary sources of fire, and fire-fighting equipment must be placed in designated locations. Strengthening the management of production equipment (tools) plays an important role in eliminating or controlling unsafe conditions of objects. Production equipment (tools) are the material and technical foundation upon which enterprises create wealth. The quality of equipment plays an important role in enabling enterprises to achieve high quality, high productivity, and low consumption, thereby improving economic efficiency. With the advancement of technology and the growth of productivity, the level of mechanization, continuity, and automation of production equipment (tools) is constantly increasing, which in turn raises the demands for the management of such equipment (tools). If equipment (tools) are not managed properly, it not only has a direct impact on achieving high quality, high productivity, and low consumption, but it also inevitably leads to various equipment accidents as well as accidents involving personnel ； It can lead to production interruptions and disruptions in the production process. It may also result in resource waste, environmental pollution, and an increase in defective products due to leaks or other issues with the equipment. Furthermore, equipment (tools) can suffer from corrosion, fatigue, or creep, which can cause them to break or explode, leading to casualties and property losses. Therefore, the safety and reliability of equipment (tools) are the material guarantee for achieving safe production. To ensure the safe and reliable operation of production equipment (tools), it is necessary to carry out proper safety and technical management of such equipment. This safety and technical management includes safety oversight in all stages of the equipment’s life cycle, such as design, manufacturing, installation, use, maintenance, and repair. Equipment maintenance is essential for maintaining reproduction. The maintenance cycle for equipment is determined based on the feasibility of the equipment itself and the characteristics of the industry. Each cycle includes three processes: major, medium, and minor repairs. A major maintenance cycle can include varying numbers of medium and minor repairs. The length of the maintenance cycle and the quality of the maintenance not only directly affect the equipment’s operational time but can also lead to various types of accidents. The safety and technical management during major maintenance is generally divided into three phases: before maintenance, during maintenance, and after maintenance. (1) Safety management before maintenance: Before starting the maintenance work, a construction schedule, operation procedure sheet, accident prediction table, and control measure table (i.e., \"one chart and three tables\") should be prepared, so that the personnel involved in the maintenance work are aware of their tasks, the procedures to follow, as well as the safety measures to take, thereby enabling proper preventive actions. Steps for safety management prior to maintenance work: 1. Develop a construction plan and conduct safety training. For each maintenance task, it is necessary to prepare a construction plan and draw a construction network diagram. Especially in some industries, where the entire factory or a specific product production facility needs to be shut down for major repairs, it is necessary for the company’s maintenance command team or equipment department to prepare a comprehensive plan and schedule. This plan should outline the tasks involved in the repairs, their details, requirements, and responsibilities, as well as safety measures, construction methods, and timelines. The key points of each task should be made visible, so that every worker involved knows their duties and safety considerations. At the same time, mobile safety inspection officers and temporary publicity teams for major repairs should be established to carry out safety inspections during working hours. Before maintenance personnel enter the site, they must receive safety training for maintenance work. Before carrying out repairs, the maintenance personnel must, in accordance with the safety management regulations, obtain various work permits such as the “Repair Task Sheet,” “Hot Work Permit,” “Electrical Two Forms and One Certificate,” and “High-Altitude Work Permit.” Whenever maintenance work is carried out by two or more people, one person must be designated to be responsible for safety. After the maintenance personnel arrive at the site with the operation ticket, they must also conduct verification and hand over duties to the operator. At the same time, the operators must also proactively provide information, indicate the areas and requirements for construction, and carry out tasks such as cleaning, displacement, and neutralization in accordance with safety regulations for maintenance work. 2. Eliminate risk factors and implement safety measures. No maintenance can be carried out on any equipment that is in operation, especially those under pressure or containing materials. The operator must eliminate hazardous factors, such as releasing pressure to lower temperature and removing flammable or toxic materials, before the equipment can be handed over for maintenance. Especially for routine minor repairs or troubleshooting, appropriate safety precautions must be taken before proceeding with the work. 3. Carefully check and place maintenance tools in appropriate locations. Different types of maintenance work require their own specialized tools, which should be regularly inspected before use. “\"A craftsman must first sharpen his tools if he is to do his work well.\" If the tools are defective, it may lead to accidents. Therefore, construction machinery, welding equipment, lifting gear, electrical installations, climbing equipment, etc. Thorough inspection is required before use, and those that fail the inspection must not be used. Equipment, tools, materials, etc., for maintenance have been moved to the site. It should be properly arranged according to environmental conditions, without hindering safe passage and normal maintenance, to ensure civilized maintenance (construction).

1. Ensure that explosion-proof electrical instruments are safe and reliable； 2. Ensure that the safety accessories of the on-site equipment and pipelines are sensitive and accurate ； 3. Strengthen the inspection of stationary and moving equipment, address any abnormalities promptly and report them, to ensure the quality of these inspections ； 4. On-site maintenance must be carried out strictly in accordance with rules and regulations; inertial violation of rules is strictly prohibited ； 5. Strictly follow the ticketing procedures for starting up and shutting down operations, as well as the process specifications.

No matter how much is said about on-site safety precautions, the bottom line is to abide by the company’s safety regulations and procedures. What we lack is not the rules themselves, but their implementation. All safety accidents are caused by violations of these rules; therefore, all my advice regarding safety precautions is to strictly follow the regulations and avoid any violations.

1. Assume that all chemicals are toxic (I really hate it when people ask whether this or that is toxic; even eating too much sugar can be a problem, let alone these chemicals)； Therefore, one should be cautious about any chemical; before and after coming into contact with it, it is necessary to consult relevant technical personnel to understand its chemical and physical properties so as to have a clear understanding of them. 2. If working on-site or in the front line, it is even more necessary to have an understanding of the chemical toxicity of the products, and to follow the operating procedures strictly in order to achieve zero errors! Never assume anything you don’t understand; otherwise, it will harm both others and yourself ； Do not overlook small operational mistakes; you might think they shouldn’t be a problem, but keep in mind that just one mistake out of ten thousand operations can ruin everything for you. Anything you think might happen will happen! 3. In a chemical plant, never be curious! If you hear strange noises or see unusual phenomena, unless you are a professional, you should restrain your curiosity. First, inform the relevant management and technical staff, then stay as far away as possible; it’s never too late to find out more details later on. Be a hero according to your capabilities. 4. If you smell or come into contact with chemicals, there’s no need to panic. In general, when exposed to chemicals, it is advisable to first wash with plenty of water, then seek advice and go to a medical professional ； Upon smelling an unpleasant odor, move immediately to an upwind area to breathe fresh air; in severe cases, seek medical attention and receive oxygen therapy

Safety is actually a broad topic; there are countless aspects related to it. Things like rules and regulations, as well as various common issues, include the conflict between safety and production. Books say that safe production requires coordination, but in reality, there are often conflicts. I’d like to share my opinion based on my own experience: 1. Civilized construction – waste materials on site, boxes from disassembled equipment (especially those with nails), etc., can easily cause injuries, so special attention must be paid to this. 2. Crane operations: Swinging of lifting equipment, rope injuries, and situations where the person handling the load is not paying attention also occur from time to time; it is essential to adhere to the principle of preventing four types of harm at the work site. 3. Power supply issue. Especially during the rainy season, it is essential to carry out regular inspections. 4. Pits and protective signs. In places where there is danger, proper signage and protective measures must be put in place; warning lights should also be installed. Accidents occur frequently in such areas. 5. Labor protection. In fact, this is the least important aspect during construction, yet it plays a significant role; protective gloves are perhaps the easiest to overlook. 6. Guardian. When doing any work that is dangerous or could potentially be hazardous to others, it’s essential to have a supervisor present. Don’t rush. In safety work, one must be extremely careful, very careful indeed. No matter how hard and efficiently the work is done on a regular basis, one single security issue can ruin everything.

Regarding the safety precautions on site at my company in the oil and chemical industry: 1. Smoking is strictly prohibited on site. Any work involving open flames must be approved by the safety supervisor before it can be carried out, and thorough preparations must be made prior to such work； 2. The connection and disconnection of temporary power supplies on site are the responsibility of qualified electricians ； 3. Perform regular maintenance on the equipment, replace wear and tear parts, and reduce leaks at the site ； 4. New employees must complete three levels of safety training before they can start working ； 5. Install surveillance cameras and flammable gas detection and alarm devices on-site to prevent potential hazards ； 6. On-site employees must wear uniform anti-static clothing, and must wear safety helmets and safety shoes to enter the production area ； 7. Operators of special equipment on site must hold valid certificates to operate such equipment ； 8. For work in confined spaces on-site, it is necessary to replace the gases inside the equipment used for such work, cut off the power supply to any internal mechanical devices, block the material inlet, and have a dedicated person supervise the operation.

The conditions vary from factory to factory; here we only discuss the requirements for those responsible for safety production: 1. Managers should ideally be experienced and responsible frontline employees, either full-time or part-time, and they need to continuously update their knowledge of safety procedures in their roles. 2. Frontline workers must be obedient and have a strong sense of compliance, and they need to learn the safety knowledge necessary for their jobs.

Safety can be divided into inherent safety and occupational safety. In enterprises, emphasis is generally placed on occupational safety. Inherent safety measures and safety facilities are implemented during the design and construction phases. It is recommended that a comprehensive HAZOP analysis of the facility be conducted at least three years after it becomes operational. This solves the problems related to intrinsic safety. As for occupational safety, as a chemical manufacturing company, there are numerous things to keep in mind. The first step is to establish appropriate operating procedures, and employees must be required to follow these procedures strictly during operations. When new employees join the company, they should receive three levels of training to ensure that they prioritize safety in their thinking. As for fire prevention, working at heights, and similar matters, they are all details that require stricter supervision; reward and punishment systems should be established to ensure that everything is carried out in an orderly manner. Work must not be done blindly – safety is no trivial matter. Safety officers should pay close attention to safety issues and not dismiss them as unimportant.

On-site production management involves four main aspects: people, machinery, materials, and the environment. First and foremost, it is necessary to ensure that employees abide by the company’s various rules and procedures, and that operations are carried out strictly in accordance with these guidelines. Managers must be able to detect and prevent any instances where workers fail to follow the procedures for various reasons； Secondly, the equipment itself is important; efforts should be made to keep it in optimal operating condition. Everything possible should be done to ensure intrinsic safety, thereby preventing accidents caused by the equipment. Managers must also find ways to improve the equipment so that it is easier to operate ； Materials refer to physical items. The simplest approach is to implement fixed-position management, thereby preventing cross-contamination of materials and employees from using the wrong materials. Environment: pay attention to environmental hygiene. In fact, the most crucial aspect among these is the issue of people; there is never a lack of systems and procedures. The difficulty lies in getting the workers on site to follow them properly!