Chemical Engineering World

Last Friday, I was supposed to run my experiment. I had made the tedious preparation a day earlier so that the only think I need to do on Friday is to just start the experiment.

So, what happen on Friday?

I connected my online data logger to my laptop. I heat up the heating tape gradually. I switched on the online graph monitoring in the data logger software to monitor the temperature profile of each thermocouples fixed in several locations in my experimental rig. I saw the temperature increase for the heating tape thermocouple. However, the thermocouple temperature in the reactor did not raise (after I switched on my turbular furnace heating). This was strange. All this while, everything it's OK. So, it's trouble shooting time. I looked at the tubular furnace temperature display. To my surprise the temperature which I set to be 500oC is still maintained at 29oC. Oh my God... Is the tubular furnace spoil? I have just used it yesterday and it was just fine.


Troubleshooting the tubular furnace.

I turn off the helium gas from entering my reactor. I conditioned the GC. I then checked what's wrong with my tubular furnace. I attempted switching it on and off as well as changed the power supply socket. With the help of Mahadhir (my Ph.D colleague), we tried to play around with the temperature control display and investigated the setting and/or timer. Who knows this might be the reason the tubular furnace cannot heat up. Mahadhir also searched for the manual of this Carbolite tubular furnace and gave it to me. I spent quite some time digesting the information in the manual and try to relate it to the problem. By this time I already know that my Friday allocation for experiment is over. Worse case scenario is I have to spend another whole day to transfer my furnace (if it is spoil) with a spare furnace. That will definitely take one days work to do. We tried many things which also include the possibility of heater or filament spoil. However, deep in my heart, I believe that there must be a simple problem and a simple solution. But then, I cannot yet figure it out.

Accidental trouble shooting discovery

I almost get fed up and nearly decided to call for Carbolite engineer to come to see what is the problem. I sat on my tiny work station in the lab room. I look at my experimental rig from a distance (actually it is not that far - only about 1 meter). I wanted to see the overview of the problem and see if there is some possible solution. Then I noticed something!!!

I found that my tubular furnace was not closed and double clipped on. Oh my God... Maybe this was the culprit. I did not even close the furnace and decided to heat it up. Immediately I close the tubular furnace and clip them. I turned on the furnace heating and off it goes. The temperature increased. So, that was the thing. It was a silly mistake and a very simple solution. I just did not close the tubular reactor.

Morale of the story

I learn my lesson that day. I need to be more careful when running the experiment. It was my first silly mistake after many times running similar experiment. I also don't know why that happen. It must slipped my mind. In addition, I can also know another that the furnace heating would not turn on if it is not properly close. It took me 1 whole day to experience this... Haha..what a day...


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That is why every time before commencing a job/project or event a shift, it is important to conduct safety briefing. It doesn't matter if it is a short meeting or a casual one (normally in between shift in a plant). For huge project, a more intense meeting / documentation such as Job Safety Analysis (JSA), Method of Statement (MOS) plus filling up permit to work (PTW) and hot work /cold work permit is imperative. As an engineer, it is our duty to ensure the safety of the entire project or area under our responsibility. Safety involves our manpower, equipment and so on.

So, what and how do we create a safety working environment? To answer that question, I consulted with Mr. Mitchell, an experienced guy who specializes in workplace behavioral change through performance management.

According to him, a safe working environment is a condition or state, it is not necessarily an event like an incident of an accident. This means that the low number of incidents or accidents doesn't mean that the workplace is particularly safe. What really counts is the process of safety because it is an integral part of every day activities in the workplace. There are a number of activities which are clear indicators of a safe working environment and this article lists 10 of them.

1. Daily safety briefings. Every morning at the beginning of the work day or the shift, the leader holds an interactive safety briefing with his or her team. It lasts less than 10 minutes and has contributions from the team members.
2. Weekly inspections to identify unsafe conditions. Every staff member participates in turn and conducts a regular safety inspection where they look for hazards and unsafe conditions. This can occur weekly or twice a week.
3. Weekly inspections to identify unsafe behavior. Each week two staff members carry out a regular inspection where they are identifying unsafe behavior. The objective is to identify the unsafe behavior and mention it at the next daily safety briefing. Of course no names are mentioned.
4. Accident and incident investigation. Every accident or near accident is investigated with the sole objective of prevention in the future. The process of investigation is not a witch hunt to apportion blame
5. Constant improvement. During the daily safety briefings, the group members have an opportunity to recommend and discuss improvements to the workplace and the processes that are carried out within it
6. Reporting near hits. Every single near hit (this is an incident where no damage or injury occurs) is investigated and prevention measures are put in place so it will not happen again.
7. Positive reinforcement. Each day the leader goes into the workplace and gives positive reinforcement to those members of staff for working safely. This encouragement and enthusiasm for safety is a great motivator for safe working practices.
8. Blame. It is noticeable that all safe working environments do not use blame or punishment as tools for creating safe behavior. Instead, they use positive reinforcement, encouragement and recognition.
9. Practical on-the-job training. Group members are continually receiving on-the-job training from experts within the company and outside.
10. Effective leadership. Is no coincidence that all safe workplace environments have good leadership. This means that the leader is prepared to listen and has the skills to create followers. These leaders engender cooperation and most of all discretionary effort. They are the main reason why people are working safely. They are not invisible and spend between 30 and 50% of their time with their team members.