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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.

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incidents by year 1981 to 2012 total 2974

Incidents by Year1981 to 2012 – Total 2974

FIGURE 1. INCIDENTS REPORTED FOR THE PERIOD 1981 – 2012 April 2014

incidents by force level 1981 to 2012 total 2974

Incidents by Force Level 1981 to 2012 – Total 2974

FIGURE 2. INCIDENTS BY FORCE LEVEL FOR THE PERIOD 1981 – 2012 April 2014

incidents by force levels 2 3 1981 to 2012

Incidents by Force Levels 2 & 3 1981 to 2012

FIGURE 3. INCIDENTS BY FORCE LEVELS 2 & 3 FOR THE PERIOD 1981 – 2012 April 2014

force 3 incidents only 1981 to 2012

Force 3 Incidents Only1981 to 2012

FIGURE 4. FORCE 3 INCIDENTS FOR THE PERIOD 1981 – 2012 April 2014

force 2 3 incidents 1981 to 2012

Force 2 & 3 Incidents1981 to 2012

R² = 0.8132

Linear (Force 2: 2000 – 2012)Linear (Force 3: 2000 – 2012)

R² = 0.5453

FIGURE 5. FORCE 2 & 3 INCIDENTS FOR THE PERIOD 1981 – 2012 April 2014

incidents by force level 1981 to 2012 total 29741
Incidents by Force Level1981 to 2012 – Total 2974

FIGURE 6. INCIDENTS BY FORCE LEVEL FOR THE PERIOD 1981 – 2012 April 2014

slide8

All Force Levels by Percentage1981 - 2012

FIGURE 7. ALL FORCE LEVELS BY PERCENTAGE FOR THE PERIOD 1981 – 2012 April 2014

injuries from incidents 1981 to 2012 total 1422 injuries
Injuries from Incidents1981 to 2012 (Total 1422 Injuries)

FIGURE 8. INJURIES FROM INCIDENTS FOR THE PERIOD 1981 – 2012 April 2014

slide11

Injury Levels by Percentage1981 - 2012

FIGURE 10. INJURY LEVELS BY PERCENTAGE FOR THE PERIOD 1981 – 2012 April 2014

injury risk per 100 explosions 1980 2012
Injury Risk per 100 Explosions1980 - 2012

FIGURE 11. INJURY RISK PER 100 EXPLOSIONS FOR THE PERIOD 1981 – 2012 April 2014

fatalities from explosions 1981 to 2012
Fatalities from Explosions1981 to 2012

FIGURE 12: FATALITIES FROM EXPLOSIONS FOR THE PERIOD 1981 – 2012 April 2014

force level incidents by operation 2012
Force Level Incidents by Operation - 2012

FIGURE 13. FORCE LEVEL INCIDENTS BY OPERATION FOR THE PERIOD 2012 April 2014

force level explosions by operation 1980 to 2012
Force Level Explosions by Operation1980 to 2012

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

13 melting explosions 2012
13 Melting Explosions - 2012

Causes: Wet / Cold Charge, Tool or Salt

FIGURE 15. MELTING EXPLOSIONS BY CAUSE FOR 2012 April 2014

slide17

Melting Explosions - Charge Material Involved1980 - 2012

FIGURE 16. MELTING EXPPOSIONS BY CHARGE MATERIAL FOR 1980 – 2012 April 2014

24 casting explosions 2012
24 Casting Explosions - 2012

FIGURE 17. CASTING EXPLOSIONS FOR THE PERIOD 2012 April 2014

dc hdc emc explosions by cast segment 1980 to 2012
DC/HDC/EMC Explosions by Cast Segment 1980 to 2012

FIGURE 18. CASTING EXPLOSIONS by CAST SEGMENT FOR 1981 – 2012 April 2014

major causes of 24 casting incidents 2012
Major Causes of 24 Casting Incidents - 2012
  • 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

FIGURE 19: MAJOR CAUSES OF CASTING INCIDENTS FOR 2012 April 2014

causes of 3 transfer explosions 2012
Causes of 3 Transfer Explosions - 2012

1 - Wet Troughing (Force 2)

1 - Wet Spout (Force 1)

1 - Wet Pan (Force 1)

FIGURE 20. CAUSES OF TRANSFER EXPLOSIONS FOR 2012 April 2014

slide22

Transfer Explosions by Equipment – Total 6731980 to 2012

FIGURE 21: TRANSFER EXPLOSIONS by EQUIPMENT FOR 1980 - 2012 April 2014

slide23

23 Injuries by Operation - 2012

Note: All Injuries in ‘Other’ Category were in REDUCTION Process

FIGURE 22. INJURIES BY OPERATION FOR 2012 April 2014

slide24

Injuries by Operation – 1980 - 2012

FIGURE 23. INJURIES BY OPERATION 1980 - 2012 April 2014

force level by process plant 2012
Force Level by Process Plant - 2012

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

force level by process plant 1980 to 2012
Force Level by Process Plant 1980 to 2012

FIGURE 25. FORCE LEVEL BY PROCESS PLANT FOR 1980 – 2012 April 2014

slide27

Reduction Plant Injuries - 2012

Causes of Reduction Explosions:

Wet / Damp Tools & Samplers

Damp Wood Poles

Wet /Damp Metal Charged into Pot

FIGURE 26. REDUCTION PLANT INJURIES BY OPERATION FOR 2012 April 2014

slide28

Rolling Plant Injuries - 2012

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

slide29

Extrusion Plant Injuries - 2012

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

injury severity by process plant 2012
Injury Severity by Process Plant - 2012

FIGURE 29. INJURY SEVERITY BY PROCESS PLANT FOR 2012 April 2014

injury severity by process plant 1980 to 2012
Injury Severity by Process Plant 1980 to 2012

FIGURE 30. INJURIES BY PLANT REPORTED FOR 1980 – 2012 April 2014

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