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ANNUAL SUMMARY MOLTEN METAL INCIDENTS FOR 2012 April 2014

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ANNUAL SUMMARY MOLTEN METAL INCIDENTS FOR 2012. April 2014. Incidents by Year 1981 to 2012 – Total 2974. FIGURE 1. INCIDENTS REPORTED FOR THE PERIOD 1981 – 2012 April 2014. Incidents by Force Level 1981 to 2012 – Total 2974. - PowerPoint PPT Presentation

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Page 1: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

ANNUAL SUMMARY MOLTEN METAL INCIDENTS

FOR 2012April 2014

Page 2: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

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

Page 3: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

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

Page 4: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

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

Page 5: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

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

Page 6: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

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

Page 7: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

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

Page 8: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

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

Page 9: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

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

Page 10: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

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

Page 11: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

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

Page 12: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

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%

Page 13: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

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

Page 14: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

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

Page 15: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

Force Level Explosions by Operation1980 to 2012

Melting Casting Transfer Other0

100200300400500600700800

FIGURE 14. FORCE LEVEL EXPLOSIONS BY OPERATION FOR 1980 – 2012 April 2014

Page 16: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

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

Page 17: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

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

Page 18: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  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

Page 19: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

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

Page 20: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

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

Page 21: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

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)

Page 22: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

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

Page 23: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  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

Page 24: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

Melting Casting Transfer Other0

50100150200250300350

FIGURE 23. INJURIES BY OPERATION 1980 - 2012 April 2014

Injuries by Operation – 1980 - 2012

Page 25: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

Force Level by Process Plant - 2012

Reduction

Extrusion

Rolling

Recycling05

10152025303540

FIGURE 24. FORCE LEVEL BY PROCESS PLANT REPORTED FOR 2012 April 2014

Page 26: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

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

Page 27: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

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

Page 28: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

Melting Casting Transfer Other0

1

2

FIGURE 27. ROLLING PLANT INJURIES BY OPERATION FOR 2012 April 2014

Rolling Plant Injuries - 2012

Page 29: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

Melting Casting Transfer Other0

1

FIGURE 28. EXTRUSIONS PLANT INJURIES BY OPERATION FOR 2012 April 2014

Extrusion Plant Injuries - 2012

Page 30: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  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

Page 31: ANNUAL  SUMMARY  MOLTEN  METAL INCIDENTS FOR  2012

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