The machinery industry is the pillar industry of the national economy
It is the "ballast stone" of the industrial economy
It is an important engine to stimulate domestic demand and promote internal circulation
In 2023, the main economic indicators of the machinery industry will achieve stable growth
But it may exist in production
Safety risks such as mechanical injury, object strike, explosion, etc
Be vigilant!
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Accident cases
At about 20:42 on July 31, 2023, an explosion accident occurred in Ningxia Zhongwei Xinshunfa Industry and Trade Co., Ltd., resulting in one death, one injury, and a direct economic loss of about 1.76 million yuan. After investigation, it was determined that the "7.31" accident of Zhongwei Xinshunfa Industry and Trade Co., Ltd. was a general other explosion production safety liability accident caused by illegal operations.
After investigation, it was determined that the direct cause of the accident was the leakage of molten iron caused by the burning of the furnace wall (about 26cm from the bottom of the furnace, and the hole was 10cm), which caused the leakage of molten iron to burn the circulating cooling water pipe of the furnace body, the leakage of circulating water, and the explosion of molten iron when it met water, resulting in casualties.
01. Characteristics of production safety accidents in the machinery industry in 2023
2023
Machinery industry co-occurrence
There were 310 production safety accidents and 294 deaths
(excluding fire, special equipment, and construction accidents)
Among them, there was 1 major accident and 3 deaths
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(1) Industry distribution
According to the "National Economic Industry Classification" (GB/T4754-2017), in 2023, among the nine sub-sectors of machinery, the top five production safety accidents are: metal products industry, special equipment manufacturing industry, general equipment manufacturing industry, machinery and equipment repair industry, and automobile manufacturing industry, and the number of accidents exceeds 80% of the total number of accidents in the machinery industry.
(2) The type of accident
According to the analysis of accident types, the top five accidents in the machinery industry in 2023 are mechanical injuries, object strikes, falls from heights, electric shock, poisoning and suffocation, and the number of accidents exceeds 90% of the total number of accidents in the machinery industry.
(3) Process distribution
The top three accidents in the main production processes are casting, pressure machining, and welding. Casting process accidents are mainly caused by high-temperature molten metal leakage, poor working environment and other reasons resulting in burning, explosion and mechanical injury, pressure processing technology accidents are mainly caused by the lack of equipment safety protection devices, etc., welding process accidents are mainly caused by electric welding equipment leakage, lack of oxygen suffocation in the operation area, illegal operation of operators, etc.
The number of accidents in the auxiliary production process ranks first is the equipment inspection and maintenance operation, mainly due to the fact that the equipment inspection and maintenance operation is mostly a temporary operation, the workplace, the operator, the construction process and the method are not fixed, the operation safety plan is not formulated in advance, the mechanical equipment dangerous energy control measures are insufficient, the safety technology disclosure before the operation is not sufficient, and the "three violations" phenomenon occurs repeatedly.
02. Security risk reminder
Overall, there are major safety risks in the machinery industry that cause mass deaths and injuries, larger accidents occur from time to time, the total number of general accidents is large, the stock risk and incremental risk are intertwined and superimposed, and the dangerous and harmful factors are complex. Combined with the risks and accident lessons existing in the industry, the typical safety risks of the machinery industry are summarized as follows:
No.1
Significant Risks
1. Aluminum, magnesium and other metal products machining, grinding and polishing process, dust removal system explosion-proof measures are not in place, on-site dust cleaning is not timely, ignition source may lead to dust explosion.
2. Ventilation and other measures to prevent hydrogen accumulation are not taken in the collection, stacking and storage places of high-magnesium alloy chips and waste chips, which may lead to explosion when encountering ignition sources.
3. The five types of personnel gathering places such as the conference room, activity room, rest room, dressing room, and handover room of the foundry workshop are set up in the floor area of the molten metal lifting span or pouring span.
4. The smelting furnace, refining furnace and holding furnace for casting are not equipped with emergency discharge and emergency storage facilities.
5. During the production period, there is water accumulation in the bottom of the furnace, furnace pit and accident pit of the smelting furnace, refining furnace and holding furnace for casting, as well as the platform in front of the furnace, the furnace foundation area, the modeling pit, the pouring pit and the molten metal transfer channel within the influence range of molten metal leakage and splashing.
6. The cooling water system of the casting melting furnace, refining furnace, die-casting machine and oxygen lance is not equipped with a monitoring and alarm device for the outlet water temperature and the difference in the flow rate of the inlet and outlet water, or the monitoring and alarm device is not interlocked with the molten metal heating and conveying control system.
7. When coal gas (natural gas) is used in casting, pressure processing, heat treatment and other processes, the explosion limit is reached after the local accumulation caused by natural gas leakage, and the explosion may occur when encountering an ignition source.
8. The paint mixing room and spray room of non-water-based paint are not equipped with exhaust facilities, resulting in the accumulation of combustible gas, which may lead to fire and explosion when encountering ignition sources.
9. Use flammable organic solvents to wipe the surface of parts, or clean equipment and facilities, tooling and appliances, ground and other auxiliary processes, and fail to take measures to prevent the accumulation of combustible gas in the surrounding closed or semi-confined space, which may lead to explosion in case of ignition source.
10. If the gas main pipe of the combustion device using gas (natural gas) is not equipped with a pipeline pressure monitoring and alarm device, or the monitoring and alarm device is not interlocked with the emergency automatic shut-off device, or the combustion device is not equipped with a flame monitoring and flame-out protection system, it may lead to a fire.
No.2
Greater risk
1. The welding process may lead to fire due to welding slag splashing, welding sparks encountering flammable and explosive gases or surrounding flammable substances, etc.
2. Leakage of liquid ammonia, methanol, etc. used in the heat treatment process may lead to poisoning or explosion.
3. There is no rapid circulation of the tank liquid of the automatic electroplating line, which causes hydrogen to accumulate, which may lead to explosion when encountering an ignition source.
4. Paint mixing room, painting room, paint spraying room paint and solvent encounter high temperature objects or sparks may lead to fire, carbon monoxide, toluene, xylene and other gases accumulation, may lead to suffocation or poisoning.
5. The accumulation of nitrogen, argon, hydrogen, fluoride and other gases used in special electronic processes may lead to poisoning, suffocation or explosion;
6. Stamping equipment (such as rigid clutch presses) lack safety devices, safety light curtains can not operate effectively, which may lead to mechanical injuries or object blows.
7. The failure of the anti-loosening measures of the fasteners connecting the large presses, or the failure of the overload protection device, may lead to mechanical injury or object strikes.
8. Non-metallic processing technology may lead to mechanical injury, object blow, and scald due to defects in injection molding equipment or inadequate protective devices.
9. The lifting equipment with multiple operations or large loads is not equipped with explosion-proof valves of the main hydraulic circuit, and the key safety function components such as column lifts and ceiling lifting equipment are faulty or missing, which may lead to mechanical injuries or object strikes.
No.3
New risks
The promotion and application of new processes, new technologies, new materials and new equipment in the machinery industry has not only promoted the rapid development of the machinery industry, but also brought some new risks.
1. Accidental drops and collisions, faulty (scrapped) battery mixing and poor ventilation in the handling, storage, and assembly of lithium batteries in the manufacturing of new energy vehicles and electric bicycles may lead to fire and electric shock.
2. The robot may start unexpectedly due to defects in safety control loops and safety software, resulting in casualties among surrounding personnel.
3.3D the field of printing and manufacturing, metal dust such as aluminum and magnesium is used as the base material, which is flammable and reacts with water to release flammable gas (hydrogen);
4. Risks posed by new chemical classes. If affected by the environmental protection policies of Europe and the United States, the overseas export of automotive air conditioning refrigerant is replaced with HFO-1234yf, which has a low specific gravity and low flash point, and is easy to form mixed explosive gases with air, which increases the risk of on-site filling and is prone to fire.
5. Air purification, sewage treatment and other environmental protection equipment are widely used in the machinery industry, which also brings new challenges to the safety production of the machinery industry.
6. There are functional safety risks due to design defects or poor manufacturing of industrial control systems for large-scale integrated manufacturing systems.
03. Suggestions for next steps
(1) Resolutely prevent major security risks. Implement the requirements of the "Three-year Action Plan for Tackling the Root Causes of Industry and Trade Safety in Production" issued by the Office of the State Council Safety Committee, focus on high-temperature molten metal, explosion-related dust, inspection and maintenance and other operational links that are easy to lead to mass deaths and injuries, continue to carry out precise law enforcement and departmental assistance, promote enterprises to establish a normalized mechanism for self-inspection and self-improvement of major accident hazards, carry out dynamic zero-clearance actions for major accident hazards, prevent major safety risks, and resolutely curb major accidents.
(2) Promote the standardization of production safety. Continue to promote enterprises to establish and effectively operate a standardized management system for safety production, realize the standardization of safety production site management, operation behavior, equipment and facilities, and operating environment, and promote the standardization of auxiliary processes such as equipment inspection and maintenance, warehousing operations, etc.
(3) Promote the digital transformation of the industry. Accelerate the digital transformation of safety supervision in key industries, comprehensively promote the application of safety risk monitoring and early warning systems in metal dust explosion-related enterprises, and promote all metal dust enterprises with more than 10 dust-related operators to access the system, so as to realize real-time monitoring, dynamic early warning, intelligent research and judgment, and timely disposal of safety production risks. Promote large-scale machinery manufacturing enterprises to actively explore the construction and application of "industrial Internet + safe production", and continuously improve the informatization and intelligence level of enterprise safety management.
(4) Promote the application of advanced technology and equipment. Implement the requirements of the "Action Plan for Promoting Large-scale Equipment Renewal and Trade-in of Consumer Goods", guide machinery enterprises to actively adopt advanced technology, study the promotion catalogue of advanced and applicable technology and equipment, and eliminate or restrict backward processes and technical equipment. Focus on major safety risks, increase the intensity of scientific and technological projects in safety production, vigorously promote "mechanized substitution, automation and reduction", and reduce the risk of high-risk places and on-site operations.
(5) Actively study new risk regulatory measures. In view of the new risks and new problems brought about by environmental protection facilities, photovoltaic power generation, lithium batteries, intelligent equipment, industrial control system design defects, etc., we will carry out in-depth research, carefully investigate the safety risk base, formulate and revise relevant safety standards in a timely manner, urge enterprises to strengthen the identification and control of new risks, improve the intrinsic safety level of relevant equipment and facilities, improve safety operation procedures, strengthen employee safety education and training, strengthen emergency response capabilities, and improve the prevention and response capabilities of new risks.
Source: Ministry of Emergency Management of the People's Republic of China
Editor/Reviewer: Xu Meihong
Review: Liu Chunxiang