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Sand casting safety assessment for foundry enterprises: fault tree analysis, Heinrich accident triangle, HAZOP-LOPA, bow tie model.

ABSTRACT: Sand casting operations, though commonplace, pose a significant threat of explosion accidents. This paper presents a novel sand casting safety assessment technique based on fault tree analysis, Heinrich accident triangle, hazard and operability-layer of protection analysis (HAZOP-LOPA) and bow tie model components. Minimal cut sets and minimal path sets are first determined based on fault tree analysis, then the frequency of sand casting explosion accidents is calculated based on the Heinrich accident triangle. Third, the risk level of venting quality can be reduced by adopting HAZOP-LOPA; the residual risk level of venting quality remains excessive even after adopting two independent protective layers. The bow tie model is then adopted to determine the causes and consequences of venting quality. Five preventative measures are imposed to enhance the venting quality of foundry sand accompanied by 16 mitigative safety measures. Our results indicate that the risk attributable to low foundry sand venting quality can be minimized via bow tie analysis.

SUBMITTER: Xu Q

PROVIDER: S-EPMC6227990 | biostudies-literature | 2018 Oct

REPOSITORIES: biostudies-literature

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Sand casting safety assessment for foundry enterprises: fault tree analysis, Heinrich accident triangle, HAZOP-LOPA, bow tie model.

Xu Qingwei Q Xu Kaili K Yao Xiwen X Zhang Jinjia J Wang Ben B

Royal Society open science 20181024 10

Sand casting operations, though commonplace, pose a significant threat of explosion accidents. This paper presents a novel sand casting safety assessment technique based on fault tree analysis, Heinrich accident triangle, hazard and operability-layer of protection analysis (HAZOP-LOPA) and bow tie model components. Minimal cut sets and minimal path sets are first determined based on fault tree analysis, then the frequency of sand casting explosion accidents is calculated based on the Heinrich ac ...[more]

PMID: 30473838

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Project description:BackgroundWith the rapid development of China's chemical industry, although researchers have developed many methods in the field of chemical safety, the situation of chemical safety in China is still not optimistic. How to prevent accidents has always been the focus of scholars' attention.MethodsBased on the characteristics of chemical enterprises and the Heinrich accident triangle, this paper developed the organizational-level accident triangle, which divides accidents into group-level, unit-level, and workshop-level accidents. Based on 484 accident records of a large chemical enterprise in China, the Spearman correlation coefficient was used to analyze the rationality of accident classification and the occurrence rules of accidents at different levels. In addition, this paper used TF-IDF and K-means algorithms to extract keywords and perform text clustering analysis for accidents at different levels based on accident classification. The risk factors of each accident cluster were further analyzed, and improvement measures were proposed for the sample enterprises.ResultsThe results show that reducing unit-level accidents can prevent group-level accidents. The accidents of the sample enterprises are mainly personal injury accidents, production accidents, environmental pollution accidents, and quality accidents. The leading causes of personal injury accidents are employees' unsafe behaviors, such as poor safety awareness, non-standard operation, illegal operation, untimely communication, etc. The leading causes of production accidents, environmental pollution accidents, and quality accidents include the unsafe state of materials, such as equipment damage, pipeline leakage, short-circuiting, excessive fluctuation of process parameters, etc. CONCLUSION: Compared with the traditional accident classification method, the accident triangle proposed in this paper based on the organizational level dramatically reduces the differences between accidents, helps enterprises quickly identify risk factors, and prevents accidents. This method can effectively prevent accidents and provide helpful guidance for the safety management of chemical enterprises.

Dataset Information

Sand casting safety assessment for foundry enterprises: fault tree analysis, Heinrich accident triangle, HAZOP-LOPA, bow tie model.

Publications

Sand casting safety assessment for foundry enterprises: fault tree analysis, Heinrich accident triangle, HAZOP-LOPA, bow tie model.

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