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ANNUAL SUMMARY MOLTEN METAL INCIDENTS FOR 2012

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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ANNUAL SUMMARY MOLTEN METAL INCIDENTS FOR 2012

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  1. ANNUAL SUMMARY MOLTEN METAL INCIDENTS FOR 2012 April 2014

  2. Incidents by Year1981 to 2012 – Total 2974 FIGURE 1. INCIDENTS REPORTED FOR THE PERIOD 1981 – 2012 April 2014

  3. Incidents by Force Level 1981 to 2012 – Total 2974 FIGURE 2. INCIDENTS BY FORCE LEVEL FOR THE PERIOD 1981 – 2012 April 2014

  4. Incidents by Force Levels 2 & 3 1981 to 2012 FIGURE 3. INCIDENTS BY FORCE LEVELS 2 & 3 FOR THE PERIOD 1981 – 2012 April 2014

  5. Force 3 Incidents Only1981 to 2012 FIGURE 4. FORCE 3 INCIDENTS FOR THE PERIOD 1981 – 2012 April 2014

  6. 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

  7. Incidents by Force Level1981 to 2012 – Total 2974 FIGURE 6. INCIDENTS BY FORCE LEVEL FOR THE PERIOD 1981 – 2012 April 2014

  8. All Force Levels by Percentage1981 - 2012 FIGURE 7. ALL FORCE LEVELS BY PERCENTAGE FOR THE PERIOD 1981 – 2012 April 2014

  9. Injuries from Incidents1981 to 2012 (Total 1422 Injuries) FIGURE 8. INJURIES FROM INCIDENTS FOR THE PERIOD 1981 – 2012 April 2014

  10. Injuries by Severity – Total 14221981 to 2012

  11. Injury Levels by Percentage1981 - 2012 FIGURE 10. INJURY LEVELS BY PERCENTAGE FOR THE PERIOD 1981 – 2012 April 2014

  12. Injury Risk per 100 Explosions1980 - 2012 FIGURE 11. INJURY RISK PER 100 EXPLOSIONS FOR THE PERIOD 1981 – 2012 April 2014

  13. Fatalities from Explosions1981 to 2012 FIGURE 12: FATALITIES FROM EXPLOSIONS FOR THE PERIOD 1981 – 2012 April 2014

  14. Force Level Incidents by Operation - 2012 FIGURE 13. FORCE LEVEL INCIDENTS BY OPERATION FOR THE PERIOD 2012 April 2014

  15. Force Level Explosions by Operation1980 to 2012 FIGURE 14. FORCE LEVEL EXPLOSIONS BY OPERATION FOR 1980 – 2012 April 2014

  16. 13 Melting Explosions - 2012 Causes: Wet / Cold Charge, Tool or Salt FIGURE 15. MELTING EXPLOSIONS BY CAUSE FOR 2012 April 2014

  17. Melting Explosions - Charge Material Involved1980 - 2012 FIGURE 16. MELTING EXPPOSIONS BY CHARGE MATERIAL FOR 1980 – 2012 April 2014

  18. 24 Casting Explosions - 2012 FIGURE 17. CASTING EXPLOSIONS FOR THE PERIOD 2012 April 2014

  19. DC/HDC/EMC Explosions by Cast Segment 1980 to 2012 FIGURE 18. CASTING EXPLOSIONS by CAST SEGMENT FOR 1981 – 2012 April 2014

  20. 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

  21. 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

  22. Transfer Explosions by Equipment – Total 6731980 to 2012 FIGURE 21: TRANSFER EXPLOSIONS by EQUIPMENT FOR 1980 - 2012 April 2014

  23. 23 Injuries by Operation - 2012 Note: All Injuries in ‘Other’ Category were in REDUCTION Process FIGURE 22. INJURIES BY OPERATION FOR 2012 April 2014

  24. Injuries by Operation – 1980 - 2012 FIGURE 23. INJURIES BY OPERATION 1980 - 2012 April 2014

  25. Force Level by Process Plant - 2012 FIGURE 24. FORCE LEVEL BY PROCESS PLANT REPORTED FOR 2012 April 2014

  26. Force Level by Process Plant 1980 to 2012 FIGURE 25. FORCE LEVEL BY PROCESS PLANT FOR 1980 – 2012 April 2014

  27. 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

  28. Rolling Plant Injuries - 2012 FIGURE 27. ROLLING PLANT INJURIES BY OPERATION FOR 2012 April 2014

  29. Extrusion Plant Injuries - 2012 FIGURE 28. EXTRUSIONS PLANT INJURIES BY OPERATION FOR 2012 April 2014

  30. Injury Severity by Process Plant - 2012 FIGURE 29. INJURY SEVERITY BY PROCESS PLANT FOR 2012 April 2014

  31. Injury Severity by Process Plant 1980 to 2012 FIGURE 30. INJURIES BY PLANT REPORTED FOR 1980 – 2012 April 2014

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