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The article discusses how the neuroscience behind Critical Error Reduction Techniques aligns with safety practices. (Image source: Adobe Stock)

HSE

Larry Wilson, author and CEO, SafeStart, looks at how neuroscience aligns with critical error reduction techniques

As we continue our series on Paradigm Shifts in safety (if you haven’t yet, catch up at https://ae.safestart.com/paradigm-shifts/), we encourage you to dive into the seventh article of the twelve-part series.

In the last issue, we discussed the concept of self-triggering; the importance of learning how to self-trigger quickly, or at least quickly enough to prevent making a critical error, which means that we must train the sub-conscious mind. Now, to a certain extent, we have already discussed the importance of involving or using the sub-conscious mind to prevent injuries when we talked about developing good habits with eyes on task, so that if or when your mind goes off task, you’ll still, most likely, get the benefit of your reflexes.

Habits and reflexes are not things we are deciding to do in the moment with our conscious mind. They are both sub-conscious. All this is where the neuroscience comes in. Until recently (last 10 years or so) scientists and psychologists could speculate as to what part of the brain was being used. But it wasn’t until FMRI’s that they could prove it. And I think that it’s interesting how the neuroscience and the Critical Error Reduction Techniques (CERTs) are aligned or how the neuroscience supports or validates the CERTs. But my dad, who is an engineer, was unimpressed. When I explained it to him, he said that it was one of the best examples of, “Locking the door after the horse has got out” he’d ever heard.

So, he’s got a point. But it’s still pretty interesting. And it is science which always helps when dealing with sceptics. So, we’re going to get into at least a bit of it as we go through all four CERTs. Two of which we have discussed already: work on habits, or work on improving your safety-related habits and self-triggering on the states (rushing, frustration, fatigue) so you don’t make a critical error. And obviously, this has to happen quickly.

Even if it’s only a split-second too late, it’s still too late. And to get close to reflex speed, we need to use the sub-conscious mind. The conscious mind just isn’t quick enough. Ironically, training the sub-conscious mind—isn’t quick—and when you think about learning arithmetic, it wasn’t always exciting either. To give you an example of speed, repetition, and the power of the sub-conscious mind, just answer the following question as quickly as you can: What is 3 x 4? You probably already have the answer in your head before you read it here. It’s 12. That’s how quick your sub-conscious mind is. But how many repetitions did it take to get that quick—so you didn’t have to process anything? And very reliable: almost impossible to get it wrong… now try quickly 13 x 14.

To find out the answer to the last question (without checking your calculator) and explore how the neuroscience behind Critical Error Reduction Techniques aligns with safety practices, continue reading the full article clicking here. Stay with us as we delve deeper into the power of the subconscious mind and its role in preventing critical errors.

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As a result of the upgrade, production increased and performance was optimised. (Image source: CS Combustion)

Industrial

CS Combustion Solutions recently enhanced the capacity and efficiency of a sulfuric acid production plant located in Africa’s Copperbelt region, where demand for sulfuric acid is crucial in mining applications such as leaching copper and cobalt

Faced with growing demand, the plant needed to increase production while reducing operational costs and improving reliability. Through targeted improvements, CS increased daily production from 2,200 to 3,000 tons and optimised the plant’s overall performance.

Challenges before optimisation

Prior to the upgrade, the plant faced several challenges, including incomplete combustion, which led to sulfur droplets fouling downstream equipment like the waste heat boiler (WHB) and catalyst beds, increasing system pressure and requiring frequent shutdowns for maintenance. Clogging issues with conventional pressure atomisers resulted in frequent, costly nozzle replacements, while poor droplet atomisation caused hotspots in the refractory lining, increasing wear and reducing reliability.

Key measures implemented

CS Combustion Solutions tackled these issues with the following measures:
1. Ultrasonic atomisation: Replacing pressure atomisers with ultrasonic nozzles reduced droplet size from 400 to 110 µm, which minimised fouling, improved combustion, and protected the refractory lining from localised heat.
2. Swirl bodies: Introducing swirl bodies created rotational motion in the combustion air, enhancing flame formation and leading to more efficient sulfur combustion.
3. VectorWall installation: Replacing the plant’s original baffle walls with a VectorWall improved mixing within the combustion chamber, reduced hotspots, and prevented unreacted sulfur carryover to downstream components.
4. CFD analysis: A Computational Fluid Dynamics (CFD) study simulated and optimized the modifications prior to implementation, ensuring targeted performance improvements.

Results and benefits

With these enhancements, the plant boosted production capacity by 30%, enabling 40 tons of sulfur incineration per hour. The new configuration allows maintenance of sulfur guns without stopping operations, reducing downtime and saving US$160,000 annually by decreasing pressure drop. Additionally, precise ultrasonic atomisation prevented sulfur buildup on the refractory, extending its lifespan.

This case study highlights the importance of innovative combustion technologies and detailed pre-implementation analysis, offering valuable insights for facilities facing similar challenges in optimising sulfuric acid production.

The new uvex phynomic cut glove range is manufactured in Germany using 3D hand ‘formas’ to mimic the contours of the hand. (Image source: uvex)

PPE

uvex has announced the launch of new safety eyewear and safety gloves, which it will be showcasing at the Health and Safety Event in Birmingham, UK from 30 April-2 May

Dubai Electricity and Water Authority (DEWA) organised 61 training courses and awareness sessions on occupational health and safety during the first half of 2024, with the participation of 2,110 male and female employees from various divisions. (Image source: DEWA)

Training

Dubai Electricity and Water Authority (DEWA) conducted 61 training courses and awareness sessions on occupational health and safety in the first half of 2024.

These sessions saw the participation of 2,110 employees from various departments. This initiative is part of DEWA's ongoing efforts to enhance its employees' knowledge and skills in occupational health and safety.

Trainings throughout the year

“We are dedicated to effectively implementing quality, health, safety, and environmental management systems according to the highest international standards. We strive to cultivate a culture of occupational safety and health among all employees, enabling them to keep pace with the latest developments in this field. This is part of our responsibility towards our employees, customers, and the employees of suppliers and contractors who work on DEWA’s projects. Additionally, we are committed to providing our services according to the highest standards of quality, efficiency, availability, and reliability,” said HE Saeed Mohammed Al Tayer, CEO of DEWA.

“We offer the best training and awareness programmes to enhance the safe work environment and raise health and safety standards across all DEWA’s projects and operations. This contributes to achieving employees’ happiness and enhances productivity and quality,” said Dr. Yousef Al Akraf, executive vice president of business support and human resources at DEWA.

In addition to the training courses, DEWA organises many events and awareness activities throughout the year. These include Public Health and Safety Week, Internal Health and Safety Week, Contractor Health and Safety Awareness Day, and other activities and events aimed at improving the health and safety systems of human resources. Employees who complete the training provided by DEWA staff are awarded certificates in occupational health and safety.

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