1. Introduction
In recent years, the issue of safety in environmental protection facilities has drawn increasing attention. With the growing emphasis on environmental protection, foundry enterprises have been continuously upgrading and expanding their environmental protection facilities. However, this has also brought about new safety challenges. The safety accidents related to environmental protection facilities in enterprises have been on the rise, making the safety of these facilities a key concern for enterprises.
This article focuses on foundry enterprises and conducts a comprehensive study on the safety risk assessment of their environmental protection facilities. By analyzing various aspects such as assessment purposes, principles, procedures, methods, hazard and harmful factor analysis, qualitative and quantitative evaluation, and risk identification and control, it aims to provide a practical and effective approach for ensuring the safety of environmental protection facilities in foundry enterprises. The research in this article is of great significance for promoting the coordinated development of enterprise production and environmental protection, and safeguarding the safety of personnel and property.
2. Assessment Purposes and Principles
2.1 Assessment Purposes
The fundamental purpose of safety risk assessment for environmental protection facilities in foundry enterprises is to ensure the safety of production activities. By implementing the safety production policy of “safety first, prevention first, and comprehensive management,” enterprises can enhance their management of environmental protection facilities and prevent potential safety accidents. This helps to create a safe working environment, protect the health and safety of employees, and avoid losses caused by accidents.
2.2 Assessment Principles
- Principle of Highlighting Key Points and Considering Others: In the assessment process, it is necessary to focus on the key components and potential high-risk areas of environmental protection facilities while also taking into account other relevant factors. This ensures a comprehensive and accurate assessment.
- Compliance with Laws and Policies: The assessment must adhere to national labor safety and health laws, regulations, and relevant policies. It should serve as a guide for safe production and follow the principles of policy orientation, scientificity, objectivity, and pertinence.
- Scientific and Rigorous Attitude: A serious and scientific approach is essential for conducting the assessment. This includes accurate data collection, in-depth analysis, and reliable evaluation to ensure the validity and credibility of the assessment results.
3. Assessment Procedures and Methods
3.1 Assessment Procedures
- Data Collection: The first step is to clearly define the assessment object and scope. Then, relevant laws, regulations, and industry standards are reviewed and sorted out. Information about accident cases, similar equipment and facilities, and production processes is gathered. Additionally, the natural and social environment of the enterprise’s location is thoroughly understood.
- Hazard and Harmful Factor Identification and Analysis: Based on the technical data and basic information provided by the assessed unit, on-site inspections are carried out. The main hazards and harmful factors are identified and analyzed, and the possible accident types, causes, and harm levels are determined.
- Assessment Process: The foundation of the assessment lies in hazard analysis and the division of assessment units. The safety checklist method is commonly used as the main assessment approach. Qualitative and quantitative evaluations are conducted to determine the severity and likelihood of accidents, and finally, the risk level and management priorities are established.
- Formulation of Safety Countermeasures: According to the assessment and classification results, different measures are taken for high-risk and low-risk factors. Engineering and management measures are used to reduce or control high-risk factors, while monitoring measures are established for low-risk factors. Emergency rescue plans are also formulated to deal with unavoidable risks.
3.2 Assessment Methods
Among the numerous evaluation methods available, the safety checklist method is often selected for the safety assessment of environmental protection facilities in foundry enterprises. This method is practical and effective in systematically checking and evaluating the safety status of facilities. It allows for a detailed examination of various aspects such as equipment, processes, and environmental conditions, ensuring that potential safety hazards are identified and addressed.
4. Hazard and Harmful Factor Analysis
The substances mainly involved in the exhaust gas environmental protection facilities of foundry enterprises are non-methane hydrocarbons and particulate matter. According to the “Catalogue of Hazardous Chemicals” (2015 edition), foundry enterprises generally do not deal with hazardous chemicals. The fire hazard rating and main hazardous substances of the environmental protection facilities are shown in the following table:
| Environmental Protection Facility Location | Fire Hazard | Main Hazardous Substances (Toxic, Explosive, Fire) |
|---|---|---|
| As per actual site situation (including latitude and longitude coordinates) | Class C | Non-methane hydrocarbons |
| As per actual site situation (including latitude and longitude coordinates) | Class C | Particulate matter |
5. Qualitative and Quantitative Evaluation
The safety checklist method is used to analyze the environmental protection equipment and facilities unit. The following is an example of a reference checklist:
| Serial Number | Inspection Items and Contents | Basis/Reference Standard | Inspection Results |
|---|---|---|---|
| 1 | The exposed conductive parts of the distribution device and electrical equipment that are normally not energized but may be energized in case of an accident shall be provided with a grounding device in accordance with the requirements of the current national standard “Code for Design of Grounding of AC Electrical Installations” GB/T 50065 | “Design Code for Safety and Health in Chemical Enterprises” HG 20571 – 2014 | Whether the motor housing of the environmental protection equipment is grounded |
| 2 | The sampling position shall avoid places that are dangerous for the testers to operate | “Technical Specification for Monitoring of Stationary Source Exhaust Gas” HJ/T 397 – 2007 | Whether the sampling position is dangerous for testers |
| 3 | If necessary, a sampling platform shall be set up. The sampling platform shall have a sufficient working area for the staff to operate safely and conveniently. The platform area shall not be less than 1.5m² and shall be equipped with a 1.1m high guardrail and a footrest not lower than 10cm. The bearing capacity of the sampling platform shall not be less than 200kg/m², and the sampling hole shall be about 1.2m – 1.3m from the platform surface | “Technical Specification for Monitoring of Stationary Source Exhaust Gas” HJ/T 397 – 2007 | Whether the exhaust stack is equipped with a sampling platform |
| 4 | The sampling position shall be preferably selected in the vertical pipe section and shall avoid the elbows of the flue and the parts with sharp changes in the cross-section | Article 5.1.2 of “Technical Specification for Monitoring of Stationary Source Exhaust Gas” HJ/T 397 – 2007 | Whether the sampling position is appropriate |
6. Environmental Protection Facility Safety Risk Identification and Control
6.1 Electrical Safety Measures
- Anti-electric Shock Measures: All power distribution cabinets are equipped with leakage protection, air switches, and emergency switches. Electrical joints and pipeline connections are provided with electrostatic grounding and electrostatic bridging, including flange bridging of pipelines, flange bridging of valve or equipment interfaces, and parallel pipeline bridging.
- Electrical System Conformance Analysis: The power supply of environmental protection facilities in foundry enterprises is usually designed as a three-level load. The power supply source and cable laying methods are briefly described. Special attention is paid to verifying whether the lightning protection and grounding system of the environmental protection facilities meets the requirements, especially considering the presence of exhaust stacks.
6.2 Fire Protection and Prevention Measures
- Environmental Protection Facility Location and Layout: Environmental protection facilities are considered as Class C production devices. According to the requirements of the “Code for Fire Protection Design of Buildings” (GB 50016 – 2014, 2018 edition), the distance between the environmental protection facilities and surrounding buildings and structures must comply with the relevant regulations to ensure fire safety.
- Fire Protection Equipment Conformance Analysis: The environmental protection facilities rely on the original fire hydrant system in the factory area. The key is to check whether the fire hydrants and fire extinguishers around the environmental protection facilities can meet the actual fire protection needs.
6.3 Process Safety and Protection Measures
- Anti-noise and Vibration Measures: Shock-absorbing pads are installed under the fans, and flexible connections are used at the joints to reduce noise and vibration.
- Individual Protection: Inspection operators are provided with personal protective equipment such as goggles and earplugs, and the distribution is strictly in accordance with the regulations to protect the operators from potential hazards.
- Anti-falling Measures: Operators working at heights must wear safety belts that meet the standards. Special personnel are assigned for supervision during high-altitude operations. Operators are not allowed to rest at the work site. In case of rain, snow, strong winds (above level 5), fog, and other severe weather conditions, high-altitude and outdoor climbing operations are prohibited. After snowstorms, typhoons, and heavy rains, the safety facilities should be inspected and any problems should be addressed immediately.
7. Conclusion
In conclusion, the safety risk assessment of environmental protection facilities in foundry enterprises is a complex and systematic task. Through a comprehensive analysis of assessment purposes, principles, procedures, methods, hazard and harmful factor analysis, qualitative and quantitative evaluation, and risk identification and control, foundry enterprises can effectively identify and manage potential safety risks. It is recommended that enterprises establish a risk identification and control ledger and a safety hazard inspection and rectification list for environmental protection facilities. This will help determine the safety hazards of the facilities and provide a strong guarantee for the coordinated development of enterprise safety production and environmental protection. By continuously improving the safety management of environmental protection facilities, foundry enterprises can not only protect the environment but also ensure the safety and well-being of employees and the sustainable development of the enterprise.
In the future, with the continuous development of technology and the strengthening of safety awareness, the safety risk assessment and management of environmental protection facilities in foundry enterprises will also be further improved and optimized. This will contribute to the healthy and stable development of the foundry industry and the entire industrial sector.
7. Recommendations for Improvement
7.1 Regular Training and Education
- Employee Training Programs: Foundry enterprises should establish comprehensive training programs for employees involved in the operation and maintenance of environmental protection facilities. The training should cover safety procedures, emergency response protocols, and proper use of personal protective equipment. Regular training sessions can help employees stay updated on the latest safety regulations and best practices, reducing the likelihood of human errors that could lead to accidents.
- Safety Awareness Campaigns: In addition to formal training, safety awareness campaigns can be launched within the enterprise. These campaigns can include safety posters, newsletters, and safety meetings to reinforce the importance of safety in daily operations. By creating a safety-conscious culture, employees are more likely to actively participate in maintaining a safe working environment.
7.2 Maintenance and Inspection Schedules
- Routine Maintenance Plans: Develop detailed maintenance plans for all environmental protection facilities. These plans should specify the frequency of inspections, cleaning, and replacement of parts. Regular maintenance can prevent equipment failures and ensure that the facilities operate at peak efficiency. For example, filters in air purification systems should be replaced regularly to maintain their effectiveness in removing pollutants.
- Inspection Checklists and Records: Create inspection checklists based on the safety requirements and equipment specifications. Inspectors should record the results of each inspection, noting any potential issues or deviations from the standard. These records can serve as a valuable reference for tracking the performance of the facilities over time and identifying trends that may require further attention.
7.3 Emergency Response Preparedness
- Emergency Response Plans: Update and improve emergency response plans specific to environmental protection facilities. The plans should include procedures for handling spills, fires, and other potential accidents. They should also identify the roles and responsibilities of each employee during an emergency and provide clear instructions on evacuation routes and assembly points.
- Drills and Exercises: Conduct regular emergency drills and exercises to test the effectiveness of the response plans. These drills can help employees familiarize themselves with the emergency procedures and improve their ability to respond quickly and effectively in a real emergency situation. After each drill, a debriefing should be held to identify areas for improvement and make necessary adjustments to the plans.
7.4 Technology Upgrades and Innovations
- Advanced Monitoring Systems: Consider investing in advanced monitoring systems that can provide real-time data on the performance and safety status of environmental protection facilities. These systems can detect potential problems early, allowing for proactive maintenance and reducing the risk of major failures. For example, sensors can be installed to monitor temperature, pressure, and gas concentrations in exhaust systems.
- Automation and Remote Control: Explore the possibility of automating certain processes and implementing remote control capabilities for environmental protection facilities. This can reduce the need for human intervention in potentially hazardous areas and improve operational efficiency. For instance, automated valve control systems can be used to regulate the flow of pollutants in treatment processes.
8. Case Studies
8.1 Case Study 1: Foundry A’s Successful Safety Improvement
- Initial Situation: Foundry A had an outdated environmental protection facility for treating exhaust gases. The facility had frequent breakdowns, and there were concerns about its safety performance. The company decided to conduct a comprehensive safety risk assessment.
- Assessment Findings: The assessment revealed several issues, including improper grounding of electrical equipment, insufficient fire protection measures, and a lack of regular maintenance. The sampling positions for exhaust gas monitoring were also not in compliance with the standards.
- Improvement Measures: Based on the assessment results, Foundry A implemented a series of improvement measures. They upgraded the electrical grounding system, installed additional fire extinguishing equipment, and established a strict maintenance schedule. The sampling platform was redesigned and relocated to meet the requirements.
- Results: After the improvements, the frequency of equipment breakdowns decreased significantly, and the safety performance of the environmental protection facility improved. The company also noticed a reduction in the emission levels of pollutants, which had a positive impact on the environment.
8.2 Case Study 2: Lessons Learned from an Accident at Foundry B
- Accident Description: Foundry B experienced a fire in its environmental protection facility due to a malfunction in the electrical system. The fire caused damage to the equipment and disrupted production for several days. Fortunately, there were no serious injuries to employees.
- Root Cause Analysis: The investigation found that the electrical wiring in the facility was old and had not been properly maintained. There was also a lack of effective fire detection and suppression systems. The safety procedures for operating the facility were not strictly followed by the employees.
- Corrective Actions: After the accident, Foundry B took immediate corrective actions. They replaced the entire electrical wiring system, installed advanced fire detection and suppression equipment, and provided additional safety training to employees. The company also revised its safety policies and procedures to ensure better compliance.
- Prevention for the Future: To prevent similar accidents in the future, Foundry B implemented a continuous monitoring system for the electrical and fire safety of the environmental protection facility. They also established a safety committee to oversee the implementation of safety measures and conduct regular safety audits.
9. Future Trends in Environmental Protection Facility Safety
9.1 Integration of Artificial Intelligence and Machine Learning
- Predictive Maintenance: AI and machine learning algorithms can be used to analyze data from environmental protection facilities and predict potential failures or safety risks. By continuously monitoring various parameters such as equipment vibration, temperature, and energy consumption, the system can identify patterns that indicate an impending problem. This allows for proactive maintenance, reducing unplanned downtime and improving overall safety.
- Intelligent Monitoring and Control: These technologies can enable real-time monitoring of the entire environmental protection process. For example, in air pollution control systems, AI can optimize the operation of fans and filters based on the pollutant levels and weather conditions. It can also detect abnormal emissions and automatically adjust the treatment process to ensure compliance with environmental regulations.
9.2 Green and Sustainable Safety Solutions
- Renewable Energy Integration: The use of renewable energy sources such as solar and wind power to operate environmental protection facilities can reduce the carbon footprint and enhance the overall sustainability of the enterprise. Additionally, it can provide a more stable power supply, reducing the risk of power outages that could affect the safety and performance of the facilities.
- Eco-friendly Materials and Processes: The development and application of eco-friendly materials in the construction and operation of environmental protection facilities can improve safety and reduce environmental impacts. For example, using non-toxic and fire-resistant materials for ductwork and equipment housings can enhance fire safety and minimize the release of harmful substances in case of an accident.
9.3 International Standards and Best Practices
- Harmonization of Standards: With the globalization of the foundry industry, there is a growing trend towards the harmonization of safety standards for environmental protection facilities. This allows for easier comparison and adoption of best practices across different countries and regions. Enterprises can benefit from international standards by improving the safety and competitiveness of their facilities.
- Knowledge Sharing and Collaboration: International collaboration and knowledge sharing platforms are emerging, enabling foundry enterprises to learn from each other’s experiences and adopt innovative safety solutions. This includes sharing information on accident prevention, emergency response, and technological advancements in environmental protection facility safety.
