The role of behavioral factors on safety management in underground mines

Traditional approaches on the prevention of accidents/injuries in mines reached its limit of effectiveness in improving safety performance and a fresh approach is utmost required. Behavioral safety analysis has been identified as an effective alternative in many industries. This paper is therefore sought to examine the role of behavioral factors on the occurrence of mine accidents and injuries through a case study. Data were collected from two neighboring underground coalmines operating under a large public sector organization of India. High–low plots and t-test were done to explore the differences between behavioral characteristics of accident involved (case) and non-involved (control) workers. How these differences could cause accidents/injuries in mines was estimated through structural equation modeling. The case study results show that accident group of workers (cases) are more job dissatisfied, negatively affected, and highly risk taking compared to the non-accident group of workers (controls). The accident model path analysis shows that negative affectivity, job dissatisfaction, and risk taking behaviors predict an increased number of injuries in mines. Apart from direct influences to work injuries, negative affectivity and job dissatisfaction make workers to take more risks and behave unsafely. These findings contribute to the design of safety programs including safety training, which should be behaviorally motivated. Mine safety management of the case study mines should outskirt their age old belief that accidents/injuries are due to hazardous nature of mining and only engineering control and regulatory monitoring are sufficient for improving safety of the mines. The multivariate analysis also shows that experience bears no relationships with work injury indicating that a less experienced worker is equally likely to be injured as an experienced worker. It implies that experience though helps workers in understanding the physical hazards, however, avoiding the imminent danger is much more behavioral. The variables negative affectivity, job dissatisfaction, and risk taking behaviors are therefore crucial in avoiding accident/injuries in mines.     

Study of chemical supply system of high-tech process using inherently safer design strategies in Taiwan

The photoelectric, semiconductor and other high-tech industries are Taiwan's most important economic activities. High-tech plant incidents are caused by hazardous energy, even when that energy is confined to the inside of the process machine. During daily maintenance procedures, overhauling or troubleshooting, engineers entering the interior of the machines are in direct contact with the source of the energy or hazardous substances, which can cause serious injury. The best method for preventing such incidents is to use inherently safer design strategies (ISDs); this approach can fully eliminate the dangers from the sources of hazardous energy at a facility.This study first conducts a lithography process hazard analysis and compiles a statistical analysis of the causes of the fires and losses at high-tech plants in Taiwan since 1996, the aim being to establish the necessary improvement measures by using the Fire Dynamics Simulation (FDS) to solve relevant problems. The researchers also investigate the lithography process machine in order to explore carriage improvement measures, and analyse the fires' causes and reactive materials hazardous properties, from 1996 to 2012. The effective improvement measures are established based on the accident statistics. The study site is a 300 mm wafer fabrication plant located in Hsinchu Science Park, Taiwan.After the completion of the annual maintenance jobs improvement from September 2011 to December 2012, the number of lithography process accidents was reduced from 6 to 1. The accident rate was significantly reduced and there were no staff time losses for a continuous 6882 h. It is confirmed that the plant safety level has been effectively enhanced. The researchers offer safety design recommendations regarding transport process appliances, chemical storage tanks, fume cupboard devices, chemical rooms, pumping equipment, transportation pipelines, valve manual box (VMB) process machines and liquid waste discharge lines. These recommendations can be applied in these industries to enhance the safety level of high-tech plants, facilities or process systems.     

Impact of improving vehicle front design on the burden of pedestrian injuries in Germany,the United States,and India

Objective: European car design regulations and New Car Assessment Program (NCAP) ratings have led to reductions in pedestrian injuries. The aim of this study was to evaluate the impact of improving vehicle front design on mortality and morbidity due to pedestrian injuries in a European country (Germany) and 2 countries (the United States and India) that do not have pedestrian-focused NCAP testing or design regulations.

Methods: We used data from the International Road Traffic and Accident Database and the Global Burden of Disease project to estimate baseline pedestrian deaths and nonfatal injuries in each country in 2013. The effect of improved passenger car star ratings on probability of pedestrian injury was based on recent evaluations of pedestrian crash data from Germany. The effect of improved heavy motor vehicle (HMV) front end design on pedestrian injuries was based on estimates reported by simulation studies. We used burden of disease methods to estimate population health loss by combining the burden of morbidity and mortality in disability-adjusted life years (DALYs) lost.

Results: Extrapolating from evaluations in Germany suggests that improving front end design of cars can potentially reduce the burden of pedestrian injuries due to cars by up to 24% in the United States and 41% in India. In Germany, where cars comply with the United Nations regulation on pedestrian safety, additional improvements would have led to a 1% reduction. Similarly, improved HMV design would reduce DALYs lost by pedestrian victims hit by HMVs by 20% in each country. Overall, improved vehicle design would reduce DALYs lost to road traffic injuries (RTIs) by 0.8% in Germany, 4.1% in the United States, and 6.7% in India.

Conclusions: Recent evaluations show a strong correlation between Euro NCAP pedestrian scores and real-life pedestrian injuries, suggesting that improved car front end design in Europe has led to substantial reductions in pedestrian injuries. Although the United States has fewer pedestrian crashes, it would nevertheless benefit substantially by adopting similar regulations and instituting pedestrian NCAP testing. The maximum benefit would be realized in low- and middle-income countries like India that have a high proportion of pedestrian crashes. Though crash avoidance technologies are being developed to protect pedestrians, supplemental protection through design regulations may significantly improve injury countermeasures for vulnerable road users.     

数控机床的人性化设计研究

人性化设计是工业设计研究中一个非常重要的课题,对人性的关怀是每个工业设计师不变的追求.在数控机床的设计中,设计师应以人机工程理论为指导,充分考虑如何让使用者掌握数控机床的操作,解决诸如程序设计、人机对话、心理负荷、故障诊断和处理、系统安全以及社会心理等问题.这是数控机床人性化设计的关键,也就是如何设计出和谐的人机系统,创造一种良好的人机互动.     

Gender aspects of work-related injuries in a Swedish municipality

The purpose of this study was to investigate gender aspects of work-related injuries in a Swedish municipality (population 41,000). All unintentional injuries treated at in- and out-patient facilities were recorded during a period of 1 year. The work-related injuries were mapped out in more detail with the help of standardized and structured surveys via telephone interviews and hospital records. The rate of work-related injuries among the gainfully employed was 33 per 1000. Males were observed to suffer more work-related injuries than females (46 compared to 12 per 1000 gainfully employed persons), and there were gender differences with regard to work-related injuries and injury event patterns. Young men showed the highest rate of injuries. Injuries caused during machine operation were the most common for both males and females, amounting to almost one quarter of all injuries. Injuries caused by falls were most common amongst females in the age groups 15–24 (25%) and 45–64 (28%). More attention should be given to gender aspects of work-related injuries and their prevention.     

Study of high-tech process furnace using inherently safer design strategies (II). Deposited film thickness model

In the low-pressure chemical vapor deposition (LPCVD) process, there are many factors that could affect the thin film thickness and homogeneity in the thin film deposition process. Besides temperature, the volume flow rate of the reactant gas, the Mole fraction, and pressure are all affecting factors. On the basis of the forecast mode result of the thermal model of wafer temperature distribution in the previously published article, this study used the optimal method to calculate the conversion rate of the surface of each wafer under simulated conditions of various furnace temperatures and Mole fractions, as well as silane flow rates and pressures, and finally calculated the thin film growth rate and homogeneity of the surface of each wafer.This study validated four types of process conditions, and found that the results were very close to the experimental values in the previous studies, when conditions such as temperature, Mole fraction of silane, flow rate and pressure in the process were changed. This study thus concluded that the proposed process film thickness mode could meet the requirement of the process capacity. This study found that adjusting the heating zone temperature to regulate the film thickness growth rate was able to control uniformity of the film thickness. These feasible adjustment measures could be very effective on the industry commercial processes.Furthermore, the film thickness mode established in this study was used to discuss the application level of the inherently safer design strategies. This study mode could be used to adjust the temperature, mole fraction (mf), flow rate (F) and pressure (P) in the process for a single machine. Under the condition of meeting the film thickness process recipes required by the process, the silane flow rate was lowered through the adjustment of the control system. The study took the silane supply system as the basis of the case study. Based on a daily required silane consumption of 64.4 L, the daily required amount was 1.5 cylinders in the case of using 40 L high-pressure cylinders. The total daily required amount would be three 40 L high-pressure cylinders, including one more reserve amount on top of the daily required amount, which could match the inherently safer design philosophy and the principles of intensification, attenuation and limitation of effects.In terms of the factory evaluation, among all of the 12-inch furnace machines in Taiwanese wafer factories, nine out of 47 sets use silane, and the total daily consumption reaches 579.6 L. The total required amount, including the reserve, is 27 cylinders for 40 L high-pressure cylinders. As for the setting of the gas cabinet, the required amount could be reduced, since the gas supply pipeline could be designed in a multiple circuit. The minimum reactant gas input amount could be obtained in combination with the proposed film thickness mode, and the safety could be improved greatly, in accordance with the inherently safer design philosophy and the principles of intensification, attenuation and limitation of effects. In addition to the process capacity, this study also took the elevation of the inherently safer level into consideration, which could be provided to the industry for more comprehensive design consideration.     

Inherently safer design of solvent processes at the conceptual stage: Practical application for substitution

The implementation of inherently safer design concepts is considered beneficial to avoid hazards during early stages of design. The application of existing process design and modeling techniques that aid ‘substitution’, ‘intensification’ and ‘attenuation’ has been shown in this work. The techniques have been applied to solvent processes because of the inherent hazards associated with them, such as large inventories, and presence of highly toxic and flammable materials. For ‘substitution’, computer aided molecular design technique has been applied to select inherently safer solvents for a solvent operation. For ‘intensification’ and ‘attenuation’, consequence models and regulatory guidance from EPA RMP have been integrated into process simulation. Combining existing techniques provides a design team with a higher level of information to make decisions based on process safety. A case study has been shown for liquid extraction of acetic acid–water mixture. Suitable solvents were identified using ICAS 11.0-ProCAMD, and consequence models were integrated into Aspen plus simulator using a calculator sheet. Solvents such as 5-nonanone, 2-nonanone and 5-methyl-2-hexanone provide inherently safer options, but conventionally-used solvent, ethyl acetate, provides higher degree of separation capability. A conclusive decision regarding feasible solvents and operating conditions would depend on design requirements, regulatory guidance, and safety criteria specified for the process. Inherent safety has always been an important consideration to be implemented during early design steps, and this paper presents a methodology to incorporate the principles and to obtain inherently safer alternatives.     

混合液体火灾爆炸危险性——闪点预测与实验研究

支持向量机应用核函数技术,已经成为当前国际上一个研究的热点,由于支持向量机具有良好的理论基础和泛化性能,可将其引入到混合液体闪点预测的研究之中,以期建立准确、高效的预测模型。本文建立了一个基于支持向量机的理论模型,用于预测二元互溶混合液体的闪点。根据所研究混合液体的物理性质,选择了纯物质的粘度、表面张力、配比、燃烧下限等物理参数来表征闪点,以这些参数作为输入参数,二元混合液体的闪点作为输出值,应用支持向量机方法对两者之间的内在定量关系进行模拟。结果表明,闪点预测值与实验值符合良好。本方法的提出为工程上提出了一种预测二元互溶液体闪点的有效方法,可应用于评估混合溶液的火灾爆炸危害性及本质较安全设计。     

The integration of Dow's fire and explosion index (F&EI) into process design and optimization to achieve inherently safer design

For the processing industries, it is critically to have an economically optimum and inherently safer design and operation. The basic concept is to achieve the best design based on technical and business performance criteria while performing within acceptable safety levels. Commonly, safety is examined and incorporated typically as an after-thought to design. Therefore, systematic and structured procedure for integrating safety into process design and optimization that is compatible with currently available optimization and safety analysis methodology must be available.The objective of this paper is to develop a systematic procedure for the incorporation of safety into the conceptual design and optimization stage. We propose the inclusion of the Dow fire and explosion index (F&EI) as the safety metric in the design and optimization framework by incorporating F&EI within the design and optimization framework. We first develop the F&EI computer program to calculate the F&EI value and to generate the mathematical expression of F&EI as a function of material inventory and operating pressure. The proposed procedure is applied to a case study involving reaction and separation. Then, the design and optimization of the system are compared for the cases with and without safety as the optimization constraint. The final result is the optimum economic and inherently safer design for the reactor and distillation column system.     

Simple graphical method for inherent occupational health assessment

The concept of inherently safer design was introduced to design a fundamentally safer process so that hazards can be avoided or minimized rather than controlled or managed. The ideology has later been extended to the environmental, but not health criteria due to its complicated underlying principles. Even though health risk methods are already established, majority are for existing plants assessment. Early consideration of health aspect starting from process design stage however, has received much less attention. This paper introduces a simple graphical method to evaluate the inherent occupational health hazards of chemical processes during the R&D stage. A survey was conducted to identify the important health parameters for the graphical method development, involving nine world inherent safety and health experts. Based on their input, process mode, material volatility, operating pressure and chemical health hazard (toxicity and adverse effect) are the significant factors affecting inherent health hazards of chemical processes. The choice of parameters was bounded by the information availability at this stage. The method was applied on six routes to methyl methacrylate and ten routes to acetic acid. The parameters were plotted for each subprocess of the alternative routes. The ‘healthiest’ route was selected based on thorough hazards assessment across all the subprocesses. The first case study reveals the tertiary butyl alcohol as the ‘healthiest’ one as it poses relatively lower, or at least comparable hazards to the other routes due to exposure and health impacts. Meanwhile the acetic acid case study indicates ethanol oxide and ethyl oxide based routes as the inherently healthier as they operate at lower operating pressure besides posing comparable hazards level for the other three parameters, compared to the other routes. The case studies show that the inherent occupational health of a chemical process can already be evaluated easily in the R&D stage with the simple graphical method proposed.     

The epidemiology of lawn trimmer injuries in the United States: 2000-2009

IntroductionYard maintenance equipment is potentially dangerous, and some of the more frequency used equipment (e.g., lawn mowers) has been extensively studied. However, the extent of lawn trimmers as a source of injury has not previously been explored.MethodsData from the Consumer Product Safety Commission's National Electronic Injury Surveillance System were used to estimate the number of patients treated in U.S. emergency departments for lawn trimmer-related injuries. Injury rates were calculated according to age, sex, and race, and characteristics of the injury event were determined.ResultsAn estimated 81,907 injuries involving a lawn trimmer occurred from 2000–2009. The incidence generally increased over time. Men, people aged 40–49, and Caucasians were the groups most likely to be injured. The most commonly injured body part was the head, specifically the eye, accounting for 42.5% of the injuries. Contusions and abrasions were the most common type of injury to the head, but lacerations were the most common injury to the extremities, and strains/sprains were the most common injury to the trunk.DiscussionAlthough previous research on lawn trimmers has focused exclusively on injuries to the eyes, the results of the current study show that such injuries are one component of the problem. Because most of the injuries were due to foreign objects, it is important that the use of adequate safety gear be emphasized when operating lawn trimmers.Impact on IndustryResults suggest that lawn trimmer design changes and better safety education for trimmer use can reduce the rate of injury and reverse the current trend.     

Fall from equipment injuries in U.S. mining: Identification of specific research areas for future investigation

Introduction

The objective of this study was to evaluate the circumstances leading to fall from equipment injuries in the mining industry.

Method

The 2006 and 2007 Mine Safety and Health Administration annual injury databases were utilized for this study whereby the injury narrative, nature of injury, body part injured, mine type, age at injury, and days lost were evaluated for each injury.

Results

The majority of injuries occurred at surface mining facilities (∼ 60%) with fractures and sprains/strains being the most common injuries occurring to the major joints of the body. Nearly 50% of injuries occurred during ingress/egress, predominately during egress, and approximately 25% of injuries occurred during maintenance tasks. The majority of injuries occurred in relation to large trucks, wheel loaders, dozers, and conveyors/belts. The severity of injury was independent of age and the median days lost was seven days; however, there was a large range in severity.

Impact on industry

From the data obtained in this study, several different research areas have been identified for future work, which include balance and stability control when descending ladders and equipment design for maintenance tasks.     

Impact resistance of guards on grinding machines

Guards on machine tools are meant to protect persons from injuries caused by parts ejected with high kinetic energy from the machine's working zone. With respect to stationary grinding machines, Standard No. EN 13218:2002, therefore, specifies minimum wall thicknesses for guards. These values are mainly based on estimations and experience instead of systematic experimental investigations. This paper shows to what extent simple impact tests with standardizable projectiles can be used as basis for the evaluation of the impact resistance of guards, provided that not only the kinetic energy of the projectiles used but also, among others, their geometry corresponds to the abrasive product fragments to be expected.     

设计初期化工过程本质安全化设计策略

该文提出了一种在设计初期进行化工过程本质安全化设计的策略。首先进行危险物质与危险能量两类共计11种危险类型的危险辨识。针对辨识出的危险类型,通过与相应的临界条件比较进行快速的危险评价,对于不可接受的危险必须采取本质安全化措施,可接受的危险可有选择性地进行本质安全化设计。在设计初期可以使用的本质安全化原则主要是消除、最小化、替代和缓和,针对11种危险类型可以应用不同的本质安全化设计模型,以使实际进行本质安全化设计时更加简单与快捷。该文把提出的本质安全化设计策略应用到一个甲苯硝化制硝基甲苯的工艺,形成了多种本质安全化措施,可以用来在设计初期消除或减少危险。     

武钢新一烧的环保设计及应用

根据武钢发展总体规划,武钢对一烧车间4台75 m2烧结机进行了易地改造,新建了1台450 m2烧结机.该改造工程淘汰老烧结机,推进设备大型化、自动化,采用先进的工艺技术和设备,从生产源头削减污染.对生产过程中产生的污染物积极治理,建立了相应的环保设施,最大限度地减少了污染物的外排及对环境的影响,实现了烧结的清洁生产.从清洁生产工艺和污染治理2个方面浅析了武钢新一烧环保设计的先进性、合理性.     

Safety of stationary grinding machines – impact resistance of work zone enclosures

Guards on machine tools are intended to protect persons from being injured by parts ejected with high kinetic energy from the work zone of the machine. Stationary grinding machines are a typical example. Generally such machines are provided with abrasive product guards closely enveloping the grinding wheel. However, many machining tasks do not allow the use of abrasive product guards. In such cases, the work zone enclosure has to be dimensioned so that, in case of failure, grinding wheel fragments remain inside the machine’s working zone. To obtain data for the dimensioning of work zone enclosures on stationary grinding machines, which must be operated without an abrasive product guard, burst tests were conducted with vitrified grinding wheels. The studies show that, contrary to widely held opinion, narrower grinding wheels can be more critical concerning the impact resistance than wider wheels although their fragment energy is smaller.     

Changes in logging injury rates associated with use of feller-bunchers in West Virginia

Problem: It is well documented that logging is one of the most dangerous occupations and industries in which to work, and trees fellers are at greatest risk of injury. The objective of this study was to determine whether West Virginia (WV) logging companies experienced a reduction in injuries after beginning to use feller-bunchers (tree cutting machines, which replace some of the work done with a chainsaw) during harvesting operations. Methods: WV workers compensation claims and employment data from 1995 to 2000 were used to calculate injury rates. Injury trends in the rest of the WV logging industry, not using feller-bunchers, were also assessed. Results: For 11 companies, the pre-feller-buncher injury claims rate was 19.4 per 100 workers and the post-feller-buncher rate was 5.2 per 100 workers. This was a significant difference, with an adjusted rate ratio of 2.8 (95% CI: 1.8–4.5) of pre to post claims. Struck by injuries also showed significant decline, with the pre-feller-buncher injury rate being 3.8 (95% CI: 1.8–8.2) times as great as post-feller-buncher rate. During the time of the study, the injury rate rose in the rest of the WV logging industry. The average cost of a workers compensation claim in the WV logging industry during the time of the study was approximately $10,400. Impact on industry: As mechanization of logging tasks becomes more widespread, the WV logging industry as a whole may see substantial injury declines and a reduction in the total cost of injury claims. Struck by injuries, the most common and potentially fatal of logging injury types, appear to be particularly affected. However, logging operations in areas of very steep terrain where it is not possible to use these machines may need to rely on strategies other than feller-bunchers to reduce injuries.     

Systematic inherent safety and its implementation in chlorine liquefaction process

As a proactive safeguard, inherent safety has been regarded as the top hierarchy for loss prevention and risk management due to its salient features in eliminating or significantly reducing risks at source rather than mitigating them by add-on protections. Simultaneously, various assessment tools have been developed for ranking and selecting inherently safer designs or modifications. However, there still lacks a metric that can systematically incorporate various hazardous factors, which may hinder most industries from utilizing it to a full extent. To address this limitation, this work developed a Systematic Inherent Safety Metric (SISM) for measuring the inherently safer modifications. Firstly, the conceptual framework of SIS was proposed based on 5M1E (man, machine, material, method, measurement, and environment). Subsequently, analytic hierarchy process and fuzzy comprehensive evaluation were adapted to conduct risk identification and assessment. Finally, taking chlorine liquefaction process as a case study, the applicability and efficacy of SIS were validated based on PDCA (plan-do-check-action) cycle. The results show that the SISM value has improved from the relatively dangerous (RD) to the relatively safe (RS) after implementing SIS, thus demonstrating that the revised design is inherently safer than the base design.     

Application of Prevention through Design for hearing loss in the mining industry

INTRODUCTION: Overexposure to noise remains a widespread and serious health hazard in the U.S. service providing and goods producing industries. Excessive noise can lead to poor verbal communication and reduce the ability to recognize warning signals. These dangerous work conditions can also cause stress and fatigue. Occupational hearing loss is a permanent illness, with no recovery currently possible. METHOD: National Institute for Occupational Safety and Health (NIOSH) has recognized Noise Induced Hearing Loss (NIHL) as one of the ten leading work-related diseases and injuries in the United States, and has emphasized its importance as one of the critical areas expressed in the National Occupational Research Agenda. RESULTS: One of the most serious noise problems in the goods producing industries is the operation of continuous mining machines during underground coal mining. In order to minimize occupational hearing loss, noise hazards are "designed out" early in the design process. NIOSH is leading a national initiative called Prevention through Design (PTD) to promote this concept. This paper describes the quiet-by-design approach of a noise control that reduced noise exposures of continuous mining machine operators by 3dB(A) using the four functional areas of PTD, namely Practice, Policy, Research, and Education.     

Design and operating practices for safe conveying of particulate solids

I am pleased to offer this treatise on the conveying of particulate solids. In doing so I wish to acknowledge the immense contributions of Trevor Kletz in providing guidance to the chemical process industries in many areas including inherently safer design principles and operating practices.