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Reporter: What major safety incidents have occurred in the history of the petrochemical industry in Japan?
Yoshida: Yes. In 1964, an accident occurred in the propylene oxide manufacturing facility, where 15 people were killed and 103 were injured. In the 1968 high-pressure polyethylene manufacturing facility, 46 people were injured. In 1973, the acetylene-added water tower fire accident at the Ethylene Plant caused one death. Also in 1973, a polypropylene explosion caused a fire, resulting in four deaths and nine injuries. In 1982, an explosion occurred in the AS·ABS manufacturing facility, causing a fire and causing six deaths and 204 injuries.
Reporter: According to relevant data, there were more major accidents in petrochemical companies in Japan in 2003 than in previous years. Is this the case? why?
Yoshida: Yes. In 2003, more accidents occurred than in previous years. There was an earthquake here that caused a large area of ​​fire in the naphtha tank. In addition, 15 people’s casualties were caused by gas explosions at the tire plant. There were also oil tank tank explosions and explosions at the gunpowder plant that killed 6 and 9 people respectively.
Reporter: Are these accidents caused by mismanagement or misoperation?
Yoshida: The cause of the accident We have done analysis. From 1997 to 2005, the proportion of accidents was as follows: improper management accounted for 35% of accidents; human error was 11%; equipment corrosion and aging accounted for 13% of accidents; inspections accounted for 4% of accidents; Poor design and construction accounted for 15% of accidents, technically unpredictable accounts for 10% of accidents, and other unclear factors accounted for 2% of accidents. The root cause is still that our leaders and employees are not very aware of security and think that our security measures have been done well, so we have accidents.
Reporter: Does Japan have safety regulations for the petrochemical industry?
Yoshida: Yes. We rely entirely on laws and regulations to ensure safe production. Any person who violates any laws or regulations will be severely punished. Relevant laws and regulations include the "High-Pressure Gas Security Law," "Fire Protection Law," "Labor Safety and Health Law," and the "Law for Preventing Disasters Associated with Petroleum Enterprises." The four regulations are specifically designed to control accidents and regulations are very detailed. Our laws and regulations have played an important role in the accidents in our petrochemical industry, from the previous incidents to fewer incidents. At present, our laws and regulations are still improving and expanding. This law also needs to be synchronized with the world and introduce the most advanced concepts to improve and ensure that safety production is more standardized.
Reporter: How did your company do to prevent accidents?
Yoshida: First, we have a more thorough approach to the longevity of our equipment. For example, ethylene equipment, which was put into use in the 1960s, can be said to be a longevity equipment. 80% of the devices have been in operation for 30 to 40 years. To maintain, maintain, repair, and replace these longevity machines, you must not be sloppy at all. To maintain it on the go, let him maximize his potential without accidents. Second, our country’s measures in terms of security are very strict. For example, arbitrarily cutting down on security personnel and reducing security funds, security management fees and other acts are absolutely not allowed, and the government will deal with this seriously. And in the event of an accident, the company will be heavily punished. Any company will be terrified of this consequence. Therefore, companies prefer to invest more in advance and do not let accidents occur.
Reporter: What are your good methods for improving the security awareness of senior leaders and employees?
Yoshida: Let me explain first that security awareness includes two aspects: first, the security personnel's equipment and second, the security awareness. What I want to say now is the deployment of security personnel. Corporate security personnel in Japan are all tenured. As a profession, they have a strong professional ethics, and this professional ethics is passed down from generation to generation, just like a master with an apprentice. Another point, and most importantly, is that the company’s top leaders are critical to security awareness. They are the backbone of the enterprise. Only if they attach importance to it can the security of the company be guaranteed.
Reporter: What role does your Petroleum and Chemical Industry Association play here?
Yoshida: The Association is mainly responsible for exchanging security information, conducting various security activities, and providing enterprises with opportunities for exchanges and learning.
At the just-concluded Second China-Japan Petroleum and Chemical Industry Association meeting, the reporter interviewed Mr. Yoshida Shofu, the managing director of Japan’s Maruzen Petrochemical Co., Ltd., on issues such as how Japanese oil and chemical industry leaders and employees improved their security awareness.