annual summary molten metal incidents for 2012
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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
160Force 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 2Force 3Avg.# 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
9Force 3Avg # 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 30
500
1000
1500
2000
2500 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 Fatal0
100200300400500600700800900
1000 Chart 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
0%
5%
10%
15%
20%
25%
30%
35%
Fatalities from Explosions1981 to 2012
19821984
198619
8819
9019
921994
19961998
20002002
20042006
2008
2010
201202468
101214161820
FatalsAvg # 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 Other0
5
10
15
20
25 Note: 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 Other0
100200300400500600700800
FIGURE 14. FORCE LEVEL EXPLOSIONS BY OPERATION FOR 1980 – 2012 April 2014
13 Melting Explosions - 2012
ScrapC
harge
Sow
Charge
RSI
Charge
Alloying
Mg
Stirring
Salt C
harge
0
1
2
3
4
5
6
FIGURE 15. MELTING EXPLOSIONS BY CAUSE FOR 2012 April 2014
Causes: Wet / Cold Charge, Tool or Salt
ScrapSow
Alloy
Adds Ingot /
Tbar Other
Scrap /
Sow
0
50
100
150
200
250
300
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 0
2
4
6
8
10
12
14
FIGURE 17. CASTING EXPLOSIONS FOR THE PERIOD 2012 April 2014
DC/HDC/EMC Explosions by Cast Segment 1980 to 2012
Start- up
SteadyState
Termina-tion0
100
200
300
400
500
600
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
Drain
Pan TroughCruci-
ble Other0
50
100
150
200
250
300
Transfer Explosions by Equipment – Total 6731980 to 2012
Melting Casting Transfer Other02468
1012141618
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 Other0
50100150200250300350
FIGURE 23. INJURIES BY OPERATION 1980 - 2012 April 2014
Injuries by Operation – 1980 - 2012
Force Level by Process Plant - 2012
Reduction
Extrusion
Rolling
Recycling05
10152025303540
FIGURE 24. FORCE LEVEL BY PROCESS PLANT REPORTED FOR 2012 April 2014
Force Level by Process Plant 1980 to 2012
Reduc
tion Extru
sion Rolling Recy
cling Foundry Atom
izing Alloy
ing BRWOther
R&D0
200
400
600
800
1000
1200
FIGURE 25. FORCE LEVEL BY PROCESS PLANT FOR 1980 – 2012 April 2014
Melting Casting Transfer Other0
2
4
6
8
10
12
14
16
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 Other0
1
2
FIGURE 27. ROLLING PLANT INJURIES BY OPERATION FOR 2012 April 2014
Rolling Plant Injuries - 2012
Melting Casting Transfer Other0
1
FIGURE 28. EXTRUSIONS PLANT INJURIES BY OPERATION FOR 2012 April 2014
Extrusion Plant Injuries - 2012
Injury Severity by Process Plant - 2012
Reduction
Extrusion
Rolling
Recycling0
5
10
15
20
FIGURE 29. INJURY SEVERITY BY PROCESS PLANT FOR 2012 April 2014
Injury Severity by Process Plant 1980 to 2012
Reduc
tion Extru
sion Rolling Recycl
ing Foundry Atom
izing Alloy
ing BRWOther
R&D0
100
200
300
400
500
FIGURE 30. INJURIES BY PLANT REPORTED FOR 1980 – 2012 April 2014
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