Human Factors Engineering in the Metallurgical Industry EAF Protection

Human Factors Engineering in the Metallurgical Industry EAF Protection
System of Individual Applications and Development *
XU Guoxiang
Department of Chemical Engineering Huaihai Institute of Technology
Lianyungang, China E-mail ˖xugx@
CHEN Wenbin
Department of Chemical Engineering Huaihai Institute of Technology
Lianyungang, China
E-mail ˖chenwenbin111@
Abstract -By human and machine and environment are the interactions among interdisciplinary, it is an important branch of industrial engineering. Based on the characteristics and development trend of subject proposed for metallurgy industry, the necessity of human engineering analysis on the possibility of behavior has errors, and good man-machine-environment system helps to reduce operator errors, and the objective factors conducive to prevent and reduce subjective factors or social factors. Study metallurgical industry, electric machine and environment steelmaking human interaction in order to achieve the purposes of safe, comfortable and efficient production
Keywords-human factors engineering; metallurgical industry; Interaction; production
1. INTRODUCTION
Large, modern man machine system has brought us great economic benefits, also profoundly changed the way people work. However, a number of such systems, once the accident, it may lead to social huge disaster, such as the Three Mile island nuclear accident, Indian chemical gas leak, the challenger shuttle accident etc. [1]. And the error caused by accidents accounted for large scale. At present, the psychological factors are gradually walking into our person in each part of the area, including the human psychological factors of the psychological structure, the relationship with the security, reliability, the psychological quality assessments etc. [1]. In this paper, on the basis of the previous studies are summarized in the safety of the person should be considered in the main psychological factors, and discusses the relationship between the psychological factors and behavior, psychology and the reliability of the people, and psychological factors in safety management system application. For engineering, who is the movement's industry ergonomy according to the physiological and psychological and physical structure factors, the relationship among human, machine, and environment should be reasonable to ensure people work in a safe, healthy and comfortable environment, and satisfactory effect of emerging disciplines. By absorbing the natural science and social science of extensive knowledge content, a door
involves psychology, physiology, diagnostics, human body measurements, artificial intelligence, automatic control and various professional edge disciplines [2] appears. It’s various mechanical design, engineering design and individual protective equipment design aspects have in-depth development and application, and it plays an important role in the process of product design in industrial production, and it attracts more humane care [3].
Steel production is in high temperature and high pressure, the mechanization of rolling, a high degree of automation, storage, transportation and use of gas, oil large amount of oxygen, hydraulic oil, crane transportation is busy, mechanical equipment [4], electrical equipment, various complex, it exists, fire, explosion, poisoning, machinery equipment, electric shock accidents, damage falling objects, high temperature burning hot, smoke and dust, noise, ray radiation, thermal and light should try to prevent such possibilities.1.1 Major Accident Statistics
ķThe metallurgical industry in fatal accidents in metallurgical industry, according to statistics of explosion is relatively serious, often causing casualties, facilities and of the damage, the impact the production or shut-down. For nearly 30 years, according to which the metallurgical industry explosion injuries statistical analysis: According to officials packed in the accident, the first one is 38.33% steelmaking, with the rest for mine (12%), coking (10.67%), iron, steel rolling (9.73%) , power supply (6.67% prior oriental-palaeaarctic), oxygen, gas and sintering (3.33% respectively each).By accident casualties, the arrangement of steelmaking (39.1%), and the rest (16.64% ), coking ironmaking (11.2%), mine (7.84%), steel rolling and oxygen supply, gas, and supply and sintering. The metallurgical industry, has ten types, mainly is the steel slag spray liquid, gas explosion, explosion, oxygen, explosion, explosive, inflammable, explosive gas pressure steam explosion and etc [5]. For metallurgical industry explosion types statistical analysis. The metallurgical industry mainly explosion accidents and management according to the statistical analysis of the defects in Tab.1-1 respectively list 1-2.
TABLE 1-1 METALLURGICAL INDUSTRY MAINLY EXPLOSION INJURIES REASON AND STATISTICAL ANALYSIS
The cause of the accident Officials
Total of accident
total 150
100 Operating defects 48
32 Management defects 3624 Behavior and people's unsafe
Small plan 84
56 Equipment defects 20
13.33 Safety device defects 1510 Design technology defects 12
8 Material defects 11
7.33
Installation and maintenance quality 5
3.33 Environmental defects 3
2 The unsafe state of the thing
Small plan 66
44
2010 International Conference of Information Science and Management Engineering
T ABLE 1-2 METALLURGICAL INDUSTRY MAINL Y EXPLOSION STA TISTICAL ANAL YSIS FOR MANAGEMENT DEFECTS
Management reason Officials packed Management of
Management confusion513.89
institution or lax management 1438.89
Poor management
Small plan1952.77
Blind command38.33
Poor decision-making1 2.7
Forcibly orders violations1 2.7
Blindness(repeated accident)2 5.5
Poor command
Small plan719.44
Lack of basic safety 38.33
Lack of exception handling2 5.5
Education poor
Small plan513.81
Differential protection513.81
total 36
100
Through the analysis of accident, long-term errors are found. Accidents People like to environment (including the production process of production and social environment, natural environment, environmental controls and avoid) will have an effect on production, such as: the gas and oxygen, lubricant, fire, gas leaks later, oxygen, and leakage reaches a certain concentration will explode, insufficient lighting can also cause accidents, lightning, storm, flood, typhoon, tornadoes later[6]. Safety management is an important factor of causing accidents. The direct cause of accidents is unsafe ACTS and the unsafe state of the thing, the error caused by "people" and "the fault is often defects in management, the unsafe behavior of the people can make the unsafe state of the thing, and the unsafe state of the thing which is caused by the material conditions of unsafe behavior, The unsafe behavior of the people and the unsafe state of the thing and management on the defect formation "hidden" coupling, will directly cause deaths of fire, explosion, even as malignant accidents[7]. Therefore, to realize safe production, machine, environment and management including five aspects.
1.2 Human Error Analysis
Human error is artificial fault or accident caused by the direct reason, need to prevent. About personal and collective caused by error and the reasons were shown in fig 1-1.
2. ELECTRIC FURNACE STEELMAKING SYSTEM 2.1 Main Security Hidden Danger Analysis
˄1˅Steel tank breakoutˈintermediate cans breakoutˈThe spill area with water or damp groundˈEasy to explode.
˄2˅The workshop accident breakout, such as water or pits is wet, easy explosion, slag is also dish damp explosion.
˄3˅Scrap must dry, charging scrap in airtight container even sometimes bring ammunition after charging explode, scrap contains lots of oil and water will explode.
˄4˅Oxygen pipe, valve materials and installation quality is bad, or leakage of fire, explosion occurred easily.
˄5˅The influx of electrical equipment, cable insulation material or damage, cable installation etc also can cause fire and explosion.
˄6˅Furnace of steel structure is more around the insulation measures, such as imperfect, burning scald.
˄7˅In the hot maintenance or clear, furnace slag around still has quite high temperature, burns.
˄8˅Steel during hot water to hurt.
˄9˅Fix open furnace and furnace, easy to someone lans burn or break.
˄10˅Smelting process of gas and CO, and stood with fluoride gas, and have a mote ferric oxide.
˄11˅Bulk materials and auxiliary materials of unloading systems transport links in the fall, materials, easy generation dust.
˄12˅Steel tank, tundish, build and repair double baking process produces baked in the flue gas and dust, contain a small amount of SO2[8].
2.2 Furnace Spitting Accident Tree Analysis
Steel, steel slag spillage is eaf adn and common phenomenon, easy cause accidents, therefore, is a electric accident tree analysis spillage.
˄1˅Electric furnace is mainly in spillage explosion YuGang residue, equipment, lining collapse or scrap reason 4 aspects. Therefore, the 4 factors in explosion accidents on electric spillage accident are analyzed in fig 2-1 furnace spitting accident tree.
FIGURE 2-1 FURNACE SPITTING ACCIDENT TREE
˄2˅The accident tree analysis
T=[X1+X2X3+X4X5+X6+X7X8+X9+X10+X11+X12+X 13+(X14+X1)X15+X16+X17X18+X19+X20
+X21+X22+A]S According to domestic Metallurgy system about the material and the experience of production, equipment, industrial injury accident judgment, the basic factors probability of electric spitting explosion was shown as table 2-1.
T ABLE 2-1 THE BASIC FACTORS PROBABILITY OF ELETRIC SPITTING EXPLOSION
This may occur probability for events T:
P(T)={1-(1-PX1)(1-PX2PX3)(1-PX4PX5)(1-PX6)(1-PX7P
X8)(1-PX9)(1-PX10)(1-PX11)(1-PX12)(1-PX13)[1-(1-PX14)(1
-PX1)(1-PX15)](1-PX17PX18)(1-PX19)(1-PX20)(1-PX21)(1-P
X22)[1-P(A)]}h1
=3.35h10-2
The blast furnace spillage probability from produces is 3.35h10-2 , belong to a probability of accidents[9].
2.3 Safety Operation Points and Basic Requirements
(1) The project design and layout of eaf steelmaking should comply with the design of metallurgical enterprises safety and health regulations (1996): 204 born smelting steel), and the safety rules "(AQ2001-2004) to the relevant requirements.
(2) Never put the containers sealed containers, it is elected in furnace were in when the melting, malignant accident explosion blew equipment and hurt.
(3) Scrap to dry, prevent moisture content and scrap, put scrap electric water expands explosion. Play speed,
(4) Furnace and peripheral insulation device structure should take security measures.
(5) Molten furnace, scrap confirmed, temperature measurement, the steel slag, repair the furnace operation, wave oven. In total wave furnace operations are also in the furnace, the furnace, the former wave between wave oven must strictly in accordance with the procedures, operating personnel shall wave oven operation leaves his post without permission.
(6) Repair tank and baking roasted brick facilities.
3.RESULTS AND DISCUSSION
Many domestic and foreign accident cases indicated that in production process of human error is often leads to the direct cause of accidents, operation, also have the management. Therefore, to "people-oriented", put forward to project measures to prevent the human error were shown as below [10]:
ķResearchers to choose from. Must have certain degree of selection, healthy body, skills and psychological quality good personnel engaged in the work, and the relevant investigation, evaluation, regularly.
ĸFor employees to strengthen vocational training and education. Make the worker has a high level of security responsibility, rigorous attitude, and must be familiar with the corresponding business, skilled operating skills, relevant materials, equipment, facilities and prevent leakage and technological parameters of danger, knowledge and emergency handling ability damage, prevention of fire, explosion, poisoning accidents and occupational hazards of knowledge and ability, in emergency situations can adopt the correct method, accident emergency has the ability of mutual rescue.
ĹTo strengthen the education of new employees, professional training and safety assessment, the new personnel must have the strict safety conception and ensure his education and professional training, and the examination before Posting. To transfer, resumption, type of transform personnel shall refer to the new employee training and test methods. The safety technical training and assessment must be taken at least twice a year. According to the special operation staff safety technical appraisal management rules (GB5306-1985) and the special operation staff safety assessment methods of management, technical training (SETC [1999] 13 order) in special operation staff training after the examination must be approved by the posts.
ĺThe worker should observe the rules and regulations, stop the "three violations" (illegal violation operation, and violates labor discipline), special attention should be paid to the production process, maintenance and repair, abnormal weather condition, emergency treatment etc, prior to complete assignments scheme, Homework to comply with regulations (such as climbing, hot and other provisions), the Gridhrakuta mountain.
ĻWearing PPE correctly, and keep good, maintain good and used correctly. Prohibit wearing belt running into inflammable, explosive dangerous area, producing area is strictly prohibited DuanYi wear shorts, kale, shoes and tint you hair.don etc.
ļAttention should be paid to the abnormal emotional, operators of abnormal behavior, found that the problem should be under timely and properly guidance.
References
[1]GUO Xiao-yan, ZHANG Ii. Psychology Factors in Safety
Elements Probability Elements Probability Elements Probability X1 1h10-5 X9 1h10-5 X17 1h10-4
X2 1h10-4 X10 1h10-3 X18 1h10-5
X3 1h10-6 X11 1h10-3 X19 1h10-6
X4 1h10-6 X12 1h10-3 X20 1h10-7
X5 1h10-6 X13 1h10-7 X21 1h10-5
X6 1h10-6 X14 1h10-5 X22 1h10-4
X7 1h10-1 X15 1h10-6 S 1 X8 1h10-4 X16 1h10-4 A1 0.00304
Human Factor Engineering[J], Industrial Safety and
Environmental Protectionˈ2007ˈ33(10)˖29-33.
[2]XIA Guang-jun, Human Factors Engineering in Process
Equipment[J]. Journal of OF DANDONG Teachers
College, 2002, 24(4): 56-57.
[3]CHAI Chun-feng. Study on the Improvement of the
Production Line Based on the Human Factors Engineering[J].Sci-TecH SCI—TECH Information Development˂Economy, 2006, 16(11): 148-149.
[4]WANG Qi-ming. Status of and Problems in Work Safety
of Chinese Metallurgical Industry and Research on the
Countermeasures[J]. Industrial Safety and Environmental
Protection, 2007, 9(2): 98-101.
[5]LI Jing-hua, XIAO Hui-yong. Safety management in
metallurgical enterprises[J]. Southern Iron and Steel, 2001,
5(7): 44-46.
[6]She Hong-yan. System safety analysis of typical accidents
for metallurgical enterprises[J]. Industrial Safety and Dust Control, 2001, 12(16): 55-58.
[7]Gu Qing-hong. A Discussion on Safety Management
Model of Metallurgical Trade[J]. Industrial Safety and Dust Control, 2003, 7(19): 40-44.
[8]Li Chi, Chen Hua-zhi. Statistics and Analyses on Industrial
Accidents in the Smelting System of Anyang Iron & Steel Group[J]. Industrial Safety and Dust Controlˈ2003ˈ9(12):
33-35.
[9]YANG Zhi-hua. Statistical Analysis and Countermeasures
steel plant accidents[J]. China Occupational Safety and Health Management System Certification, 2002, 4(13): 77-81.
[10]PAN Yi-fang, LING Zun-feng, LI Shu-qing, et al. Safety
of Oxygen Utilization for Steel-making and Experience[J].
Steelmaking, 2004, 4(9): 15-18
* Fund˖This project was supported by the natural science investigation program of Jiangsu province college committee (05KJB150003) and the Foundation of Science Committee of Jiangsu Institute of Marine Resources (Z2009).
Author introduction˖XU Guoxiang (1971ˉ) male, vice professor, docter, majors in research of chemical engineering.。