View
221
Download
1
Category
Tags:
Preview:
Citation preview
ANNUAL SUMMARY MOLTEN METAL INCIDENTS
FOR 2012April 2014
Incidents by Year1981 to 2012 – Total 2974
1981
1983
1985
1987
1989
1991
1993
1995
1997
1999
2001
2003
2005
2007
2009
2011
0
20
40
60
80
100
120
140
160
180
200
FIGURE 1. INCIDENTS REPORTED FOR THE PERIOD 1981 – 2012 April 2014
Incidents by Force Level 1981 to 2012 – Total 2974
1981
1983
1985
1987
1989
1991
1993
1995
1997
1999
2001
2003
2005
2007
2009
2011
0
20
40
60
80
100
120
140
160
Force 1
Force 2
Force 3
FIGURE 2. INCIDENTS BY FORCE LEVEL FOR THE PERIOD 1981 – 2012 April 2014
Incidents by Force Levels 2 & 3 1981 to 2012
1981
1983
1985
1987
1989
1991
1993
1995
1997
1999
2001
2003
2005
2007
2009
2011
0
5
10
15
20
25
30
35
40
45Force 2
Force 3
Avg.# Force 2/yr - 24
FIGURE 3. INCIDENTS BY FORCE LEVELS 2 & 3 FOR THE PERIOD 1981 – 2012 April 2014
Force 3 Incidents Only1981 to 2012
1981
1983
1985
1987
1989
1991
1993
1995
1997
1999
2001
2003
2005
2007
2009
2011
0
1
2
3
4
5
6
7
8
9
Force 3
Avg # Force 3 Explosions/Yr
FIGURE 4. FORCE 3 INCIDENTS FOR THE PERIOD 1981 – 2012 April 2014
Force 2 & 3 Incidents1981 to 2012
1981
1983
1985
1987
1989
1991
1993
1995
1997
1999
2001
2003
2005
2007
2009
2011
0
5
10
15
20
25
30
35
40
45
Force 2
Force 3
FIGURE 5. FORCE 2 & 3 INCIDENTS FOR THE PERIOD 1981 – 2012 April 2014
Linear (Force 2: 2000 – 2012)Linear (Force 3: 2000 – 2012)
R² = 0.5453
R² = 0.8132
Incidents by Force Level1981 to 2012 – Total 2974
Force 1 Force 2 Force 3
Series1 2102 NaN 759 NaN 113
250
750
1250
1750
2250
Chart Title
FIGURE 6. INCIDENTS BY FORCE LEVEL FOR THE PERIOD 1981 – 2012 April 2014
70.7%
25.5%3.8%
Force 1
Force 2
Force 3
All Force Levels by Percentage1981 - 2012
FIGURE 7. ALL FORCE LEVELS BY PERCENTAGE FOR THE PERIOD 1981 – 2012 April 2014
Injuries from Incidents1981 to 2012 (Total 1422 Injuries)
0
10
20
30
40
50
60
70
80
90
100
Minor
Serious
Fatal
FIGURE 8. INJURIES FROM INCIDENTS FOR THE PERIOD 1981 – 2012 April 2014
Injuries by Severity – Total 14221981 to 2012
Minor Serious Fatal
Series1 964 NaN 368 NaN 90
50
150
250
350
450
550
650
750
850
950Chart Title
FIGURE 9. INJURIES BY SEVERITY FOR THE PERIOD 1981 – 2012 April 2014
68.0%
26.0%6.0%
Minor
Serious
Fatal
Injury Levels by Percentage1981 - 2012
FIGURE 10. INJURY LEVELS BY PERCENTAGE FOR THE PERIOD 1981 – 2012 April 2014
Injury Risk per 100 Explosions1980 - 2012
FIGURE 11. INJURY RISK PER 100 EXPLOSIONS FOR THE PERIOD 1981 – 2012 April 2014
Minor Serious Fatal
%Injury / 100 Explo-sions
0.32 0.12 0.03
3%
8%
13%
18%
23%
28%
33%
Fatalities from Explosions1981 to 2012
19821984
19861988
19901992
19941996
19982000
20022004
20062008
20102012
0
2
4
6
8
10
12
14
16
18
20
Fatals
Avg # of Fatalities - 2.8/yr
FIGURE 12: FATALITIES FROM EXPLOSIONS FOR THE PERIOD 1981 – 2012 April 2014
Force Level Incidents by Operation - 2012
Melting Casting Transfer Other
Force 1 11 22 2 17
Force 2 3 2 1 0
Force 3 0 0 0 0
2.5
7.5
12.5
17.5
22.5Note: All Explo-
sions in ‘OTHER’ Category were in
REDUCTION Process
FIGURE 13. FORCE LEVEL INCIDENTS BY OPERATION FOR THE PERIOD 2012 April 2014
Force Level Explosions by Operation1980 to 2012
Melting Casting Transfer Other
Force 1 641 725 514 232
Force 2 356 232 150 23
Force 3 79 17 9 8
50150250350450550650750
FIGURE 14. FORCE LEVEL EXPLOSIONS BY OPERATION FOR 1980 – 2012 April 2014
13 Melting Explosions - 2012
ScrapCharge
Sow Charge
RSI Charge
Alloying Mg Stirring Salt Charge
Force 1 6 1 1 1 0 1
Force 2 2 0 0 0 1 0
Force 3 0 0 0 0 0 0
0.5
1.5
2.5
3.5
4.5
5.5
FIGURE 15. MELTING EXPLOSIONS BY CAUSE FOR 2012 April 2014
Causes: Wet / Cold Charge, Tool or Salt
Scrap Sow Alloy Adds
Ingot /Tbar
Other Scrap / Sow
Force 1 279 77 107 52 26 12
Force 2 189 51 19 40 13 7
Force 3 52 9 4 0 3 2
25
75
125
175
225
275
FIGURE 16. MELTING EXPPOSIONS BY CHARGE MATERIAL FOR 1980 – 2012 April 2014
Melting Explosions - Charge Material Involved1980 - 2012
24 Casting Explosions - 2012
Start-up Steady State
Termina-tion
DC Slab / Bil-let
Rod Sow or Mold
Force 1 12 3 7 NaN 13 3 6
Force 2 1 1 0 NaN 2 0 0
Force 3 0 0 0 NaN 0 0 0
1
3
5
7
9
11
13
FIGURE 17. CASTING EXPLOSIONS FOR THE PERIOD 2012 April 2014
DC/HDC/EMC Explosions by Cast Segment 1980 to 2012
Start- up
SteadyState
Termina-tion
# of Explo-sions
553 107 73
50
150
250
350
450
550
FIGURE 18. CASTING EXPLOSIONS by CAST SEGMENT FOR 1981 – 2012 April 2014
Major Causes of 24 Casting Incidents - 2012
FIGURE 19: MAJOR CAUSES OF CASTING INCIDENTS FOR 2012 April 2014
DC Start-up Issues: Wet / Damp Starting Blocks, Water Control Problems, Equipment Malfunction, Metal Level Control, Recipe Problems, Metal Temperature Control
DC Steady-State Issues: Low Water Abort / Ingot Head Below Mold
DC Termination Issues: Wet / Damp Drain Pan
Rod Casting Issues: Broken Spout, Wet / Damp Degasser
Sow Casting Issues: Damp / Cold Molds & Tools, Delays, Equipment Malfunction
Causes of 3 Transfer Explosions - 2012
FIGURE 20. CAUSES OF TRANSFER EXPLOSIONS FOR 2012 April 2014
1 - Wet Troughing (Force 2)1 - Wet Spout (Force 1)1 - Wet Pan (Force 1)
FIGURE 21: TRANSFER EXPLOSIONS by EQUIPMENT FOR 1980 - 2012 April 2014
DrainPan
Trough Cruci-ble
Other
# of Explosions 286 185 109 93
25
75
125
175
225
275
Transfer Explosions by Equipment – Total 6731980 to 2012
Melting Casting Transfer Other
Minor 0 3 2 17
Serious 0 1 0 0
Fatals 0 0 0 0
13579
11131517
FIGURE 22. INJURIES BY OPERATION FOR 2012 April 2014
Note: All Injuries in ‘Other’ Category were
in REDUCTION Process
23 Injuries by Operation - 2012
Melting Casting Transfer Other
Minor 241 341 241 155
Serious 116 159 77 16
Fatals 59 21 7 3
25
75
125
175
225
275
325
FIGURE 23. INJURIES BY OPERATION 1980 - 2012 April 2014
Injuries by Operation – 1980 - 2012
Force Level by Process Plant - 2012
Reduction Extrusion Rolling Recycling
Force 1 39 2 6 5
Force 2 1 0 3 2
Force 3 0 0 0 0
2.57.5
12.517.522.527.532.537.5
FIGURE 24. FORCE LEVEL BY PROCESS PLANT REPORTED FOR 2012 April 2014
Force Level by Process Plant 1980 to 2012
Reduction
Extrusion
Rolling
Recycling
Foundry
Atomizing
Alloying
BRW Other R&D
Force 1 1182 230 646 183 28 11 9 12 2 34
Force 2 268 109 418 125 19 6 6 9 2 13
Force 3 25 17 210 36 9 0 0 2 0 0
100
300
500
700
900
1100
FIGURE 25. FORCE LEVEL BY PROCESS PLANT FOR 1980 – 2012 April 2014
Melting Casting Transfer Other
Minor 0 1 1 15
Serious 0 0 0 0
Fatals 0 0 0 0
1
3
5
7
9
11
13
15
FIGURE 26. REDUCTION PLANT INJURIES BY OPERATION FOR 2012 April 2014
Causes of Reduction Explosions:Wet / Damp Tools & Samplers
Damp Wood PolesWet /Damp Metal Charged into Pot
Reduction Plant Injuries - 2012
Melting Casting Transfer Other
Minor 0 2 0 0
Serious 0 1 0 0
Fatals 0 0 0 0
0.5
1.5
FIGURE 27. ROLLING PLANT INJURIES BY OPERATION FOR 2012 April 2014
Rolling Plant Injuries - 2012
Melting Casting Transfer Other
Minor 0 0 1 0
Serious 0 0 0 0
Fatals 0 0 0 0
0.5
FIGURE 28. EXTRUSIONS PLANT INJURIES BY OPERATION FOR 2012 April 2014
Extrusion Plant Injuries - 2012
Injury Severity by Process Plant - 2012
Reduction Extrusion Rolling Recycling
Minor 19 1 2 0
Serious 0 0 1 0
Fatals 0 0 0 0
2.5
7.5
12.5
17.5
FIGURE 29. INJURY SEVERITY BY PROCESS PLANT FOR 2012 April 2014
Injury Severity by Process Plant 1980 to 2012
Reduction
Extrusion
Rolling
Recycling
Foundry
Atomizing
Alloying
BRW Other R&D
Minor 471 121 175 100 82 0 2 9 6 12
Serious 110 65 83 71 34 2 1 1 0 1
Fatals 12 16 14 29 19 0 0 0 0 0
50
150
250
350
450
FIGURE 30. INJURIES BY PLANT REPORTED FOR 1980 – 2012 April 2014
Recommended