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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 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 FIGURE 2. INCIDENTS BY FORCE LEVEL FOR THE PERIOD 1981 – 2012 April 2014
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 Only1981 to 2012 FIGURE 4. FORCE 3 INCIDENTS FOR THE PERIOD 1981 – 2012 April 2014
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 Level1981 to 2012 – Total 2974 FIGURE 6. INCIDENTS BY FORCE LEVEL FOR THE PERIOD 1981 – 2012 April 2014
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) FIGURE 8. INJURIES FROM INCIDENTS FOR THE PERIOD 1981 – 2012 April 2014
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
Fatalities from Explosions1981 to 2012 FIGURE 12: FATALITIES FROM EXPLOSIONS FOR THE PERIOD 1981 – 2012 April 2014
Force Level Incidents by Operation - 2012 FIGURE 13. FORCE LEVEL INCIDENTS BY OPERATION FOR THE PERIOD 2012 April 2014
Force Level Explosions by Operation1980 to 2012 FIGURE 14. FORCE LEVEL EXPLOSIONS BY OPERATION FOR 1980 – 2012 April 2014
13 Melting Explosions - 2012 Causes: Wet / Cold Charge, Tool or Salt FIGURE 15. MELTING EXPLOSIONS BY CAUSE FOR 2012 April 2014
Melting Explosions - Charge Material Involved1980 - 2012 FIGURE 16. MELTING EXPPOSIONS BY CHARGE MATERIAL FOR 1980 – 2012 April 2014
24 Casting Explosions - 2012 FIGURE 17. CASTING EXPLOSIONS FOR THE PERIOD 2012 April 2014
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 • 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 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
Transfer Explosions by Equipment – Total 6731980 to 2012 FIGURE 21: TRANSFER EXPLOSIONS by EQUIPMENT FOR 1980 - 2012 April 2014
23 Injuries by Operation - 2012 Note: All Injuries in ‘Other’ Category were in REDUCTION Process FIGURE 22. INJURIES BY OPERATION FOR 2012 April 2014
Injuries by Operation – 1980 - 2012 FIGURE 23. INJURIES BY OPERATION 1980 - 2012 April 2014
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 FIGURE 25. FORCE LEVEL BY PROCESS PLANT FOR 1980 – 2012 April 2014
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
Rolling Plant Injuries - 2012 FIGURE 27. ROLLING PLANT INJURIES BY OPERATION FOR 2012 April 2014
Extrusion Plant Injuries - 2012 FIGURE 28. EXTRUSIONS PLANT INJURIES BY OPERATION FOR 2012 April 2014
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 FIGURE 30. INJURIES BY PLANT REPORTED FOR 1980 – 2012 April 2014