Neelakanth Major Thesis

EVALUATION OF SAFETY PRACTICES
IN FOUNDRY INDUSTRIES USING

HAZOP ANALYSIS
Thesis
Submitted in partial fulfilment of the requirements for the degree
of
MASTER OF TECHNOLOGY
in
ENVIRONMENTAL SCIENCE AND TECHNOLOGY
by
NEELKANTHRADDI B PATIL
(2120024)
DEPARTMENT OF CHEMICAL ENGINEERING

NATIONAL INSTITUTE OF TECHNOLOGY
KARNATAKA MANGALORE, INDIA – 575025
JUNE 2023
DECLARATION
I hereby declare that the M.Tech Project Work entitled " Evaluation Of Safety Practices In
Foundry Industries Using HAZOP Analysis”, which is being submitted to the National
Institute of Technology Karnataka, Surathkal, in the fulfilment of the requirements for the award
of the degree of Master of Technology, in the Department of Chemical Engineering is a
Bonafide report of the project carried out by me. The material in this report has not been
submitted to any University for the award of any degree.
Place: NITK-Surathkal Mr. Neelakanthraddi B Patil

Date: June 2023 212ES024
Department of Chemical
Engineering NITK, Surathkal
i
CERTIFICATE
This is to certify that the project report entitled " EVALUATION OF SAFETY PRACTICES
IN FOUNDRY INDUSTRIES USING HAZOP ANALYSIS " submitted by
Neelakanthraddi B Patil (212ES024) as a record of the work carried out by him is accepted
by t h e National Institute of Technology Karnataka, Surathkal towards the fulfilment of
requirements for the award of the degree of Master of Technology in Environmental science
and Technology, Department of Chemical Engineering, National Institute of Technology
Karnataka, Surathkal during the academic year 2022-2023
Dr. Raj Mohan B. Dr. P E Jagadeeshbabu

Professor Head of the Department
Department of Chemical Engineering Department of Chemical Engineering
NITK, Surathkal NITK, Surathkal
ii
ACKNOWLEDGEMENT
I feel privileged to share my sincere gratitude to our guide Prof. Raj Mohan B., Department
of Chemical Engineering, under whose guidance I have done my project. I earnestly thank him
for constantly checking on my progress and providing much needed and helpful feedback.
I would like to thank Dr. P.E. Jagadeeshbabu, Head of the Department, Department of
Chemical Engineering, National Institute of Technology Karnataka, Surathkal for giving me
the opportunity to conduct the project work.
I, once again thank all the persons, directly or indirectly, involved in my project who were
cooperative and informative whenever required their assistance. Their intellectual support
throughout the project work is deeply appreciated.
Neelakanthraddi B Patil (212ES024)
iii
ABSTRACT
The foundry industry plays a crucial role in manufacturing processes by producing castings of
various metals and alloys. However, the casting methods employed in foundries can expose
workers to a range of occupational hazards, posing risks to their health and safety. This project
focuses on conducting a Hazards and Operability (HAZOP) analysis using the PHA
WORKLITE software to identify potential hazards and recommend measures for safeguarding
worker health in the foundry industry. The study involves an extensive review of existing
literature on the hazards associated with different casting methods and their impact on worker
health. The HAZOP analysis, a systematic and comprehensive methodology, is employed to
identify potential deviations from the normal operating conditions that could lead to hazards,
accidents, or adverse health effects. Based on the findings of the HAZOP analysis,
recommendations are formulated to mitigate the identified hazards and promote worker health
and safety. By addressing the identified hazards and adopting the recommended measures, it
is anticipated that worker health and safety in the foundry industry will be significantly
improved, fostering a safer and healthier working environment.
Keywords: Foundry industry, Hazard, HAZOP, Investment casting, Risk, Sand casting.
iv
CONTENTS
DECLARATION .............................................................................................................................. i
CERTIFICATE ................................................................................................................................ ii
ACKNOWLEDGEMENT .............................................................................................................. iii
ABSTRACT .................................................................................................................................... iv
LIST OF FIGURES........................................................................................................................ vii
LIST OF TABLES ........................................................................................................................ viii
CHAPTER 1 INTRODUCTION ....................................................................................................10
1.1 METHODS OF CASTING ...................................................................................................13
1.1.1 SAND CASTING...........................................................................................................13
1.1.2 INVESTMENT CASTING ............................................................................................13
1.1.3 PLASTER OF PARIS MOLDING ................................................................................14
1.1.4 CENTRIFUGAL CASTING ..........................................................................................14
1.1.5 DIE CASTING ...............................................................................................................15
1.1.5.1 GRAVITY DIE CASTING .........................................................................................15
1.1.5.2 PRESSURE DIE CASTING .......................................................................................15
1.1.6 SHELL MOLDING........................................................................................................16
1.2 RECOMMENDATIONS FOR WORKER’S SAFETY........................................................19
1.3 METHODS OF RISK ASSESSMENTS...............................................................................22
1.3.1 RISK MATRIX ..............................................................................................................22
1.3.2 DECISION TREE ANALYSIS .....................................................................................22
1.3.3 FAILURE MODE AND EFFECT ANALYSIS ............................................................22
1.3.4 BOWTIE ANALYSIS ...................................................................................................23
1.3.5 WHAT IF ANALYSIS ..................................................................................................23
1.3.6 FAULT TREE ANALYSIS ...........................................................................................23
1.3.7 HAZOP ..........................................................................................................................24
CHAPTER 2 LITERATURE REVIEW .........................................................................................25
2.1 MAJOR HAZARDS IN FOUNDRY INDUSTRIES AND THEIR EFFECT ON WORKERS
25
2.1.1 HEAT EXPOSURE: ......................................................................................................25
2.1.2 HAZARDOUS CHEMICALS .......................................................................................25
2.1.3 AIRBORNE CONTAMINANTS ..................................................................................25
2.1.4 MANUAL TASK ...........................................................................................................26
2.1.5 NOISE ............................................................................................................................26
2.1.6 VIBRATIONS................................................................................................................26
2.1.7 MOLTEN METAL ........................................................................................................26
2.1.8 PLANT AND MACHINERY ........................................................................................27
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2.1.9 ELECTRICITY .............................................................................................................. 27
2.2 HAZOP: ................................................................................................................................ 31
2.2.1 OBJECTIVES ................................................................................................................ 31
2.2.2 METHODOLOGY ........................................................................................................ 31
2.3. RISK ASSESSMENT IN THE FOUNDRY INDUSTRY................................................... 33
2.4 LITERATURE GAP ............................................................................................................. 33
AIM AND OBJECTIVES .............................................................................................................. 33
CHAPTER 3 METHODOLOGY ................................................................................................... 34
3.1 ANALYSING VARIOUS CASTING METHODS AND IDENTIFYING THE TWO MOST
HAZARDOUS METHODS: ...................................................................................................... 35
3.2 PERFORMING HAZOP STUDY ON SELECTED CASTING METHODS: ..................... 35
3.3 GENERATION OF WORKSHEET FOR HAZOP STUDIES............................................. 35
3.4 DRAWING CONCLUSIONS FROM THE WORKSHEETS ............................................. 39
CHAPTER 4 RESULTS AND DISCUSSION ............................................................................... 40
4.1 PRELIMINARY HAZOP ..................................................................................................... 40
4.2 HAZOP STUDY ON SAND AND INVESTMENT CASTING .......................................... 42
4.3 DESIGN INTENT AND NORMAL OPERATING CONDITIONS OF THE SECTION .. 45
4.4 GENERATION OF WORKSHEET FOR HAZOP STUDIES............................................. 47
4.5 CONCLUSIONS FROM WORKSHEETS .......................................................................... 48
CHAPTER 5 CONCLUSIONS ...................................................................................................... 50
APPENDIX .....................................................................................................................................51
REFERENCES ............................................................................................................................. 121
vi
LIST OF FIGURES
Figure 1.1 Foundry process ...............................................................................................................11
Figure 1.2 Green sand mold ..............................................................................................................13
Figure 1.3 Investment casting steps ..................................................................................................14
Figure 3.1 General Interface involving project information and intentions......................................38
Figure 3.2 Nodes considered for HAZOP........................................................................................ 39
Figure 3.3 Inbuilt lists of Guidewords, parameters, and deviation................................................... 38
Figure 3.4 Nodes involved ............................................................................................................... 38
Figure 3.5 Output interface ..............................................................................................................40
Figure 4.1 HAZOP flow summary for sand casting........................................................................ 44
Figure 4.2 HAZOP flow summary for investing casting…………………………………………..45
vii
LIST OF TABLES
Table 1.1 Application, Advantages, and Disadvantages of various molding process..................... 16
Table 2.2 Effect of foundry hazard on workers .............................................................................. 27
Table 2.3 Various Stages in foundry industries and related potential hazards................................ 29
Table 3.1 Risk Grid......................................................................................................................... 36
Table 3.2 Likelihood Ranking ........................................................................................................ 36
Table 3.3 Severity Ranking............................................................................................................ 36
Table 4.1 Node points for Shell Mold Casting ............................................................................... 40
Table 4.2 Node points for Investment Casting ............................................................................... 40
Table 4.3 Node points for Centrifugal Casting ............................................................................... 41
Table 4.4 Node points for Gravity Die Casting .............................................................................. 41
Table 4.5 Node points for Pressure Die Casting ............................................................................. 41
Table 4.6 Node points for Plaster Mold Casting ............................................................................. 42
Table 4.7 Node points for Sand Mold Casting................................................................................ 42
Table 4.8 Overview of worksheet for sand casting......................................................................... 46
Table 4.9 Overview of worksheet for Investment casting .............................................................. 46
Table 4.10 Risk Grid(Number of parameters associated) for Sand casting .................................... 47
Table 4.11 Risks for Sand casting................................................................................................... 47
Table 4.12 Risk Grid(Number of parameters associated) for Investment casting .......................... 48
Table 4.13 Risks Investment casting .............................................................................................. 48
viii
CHAPTER 1
INTRODUCTION
Foundries are important in human history, dating back thousands of years. The process
of founding, the simplest form of metallurgical process, is one of the oldest industries known
to humanity (Mgonja, 2017). In foundries, ferrous and non-ferrous metals and alloys are melted
and transformed into products by pouring and allowing the molten metal or alloy to solidify
within a mold, thus achieving their desired shape. The foundry industry is characterized by its
diversity and differentiation, encompassing a wide range of facilities varying in size from
small-scale to very large-scale operations. Each foundry adopts a combination of technologies
and unit operations tailored explicitly to the input materials, production volume, and types of
products manufactured in that particular facility. The sector's organizational structure is
primarily based on the type of metal used, with a primary distinction between ferrous and non-
ferrous foundries (Mgonja, 2017).
The steel industry plays a vital role in driving the industrialization and progress of a
country, as it provides the fundamental input for all manufacturing sectors (Salihoglu &
Pinarli, 2008). Ferrous metal foundries require precise control over the composition and
temperature of the metal, delivered at a rate that meets the fluctuating demands of the molding
line. The materials typically melted include foundry returns, iron scraps, steel scraps, and pig
iron, with the addition of alloying elements such as ferrosilicon (Brown, 2000). Non-ferrous
castings encompass metals and alloys like copper, zinc, tin, Aluminum, and lead. Notable
examples of alloy castings include Brass, Bronze, Aluminum Bronze, and Gun Metal. These
castings find application in various industries, such as bearings, bushes, automobile parts,
textile parts, corrosion-resistant components, marine parts, impellers, clamps, connectors,
overhead conductors, and more. Non-ferrous castings are in high demand due to their
advantageous mechanical and chemical properties, with their usage expanding across sectors
like the automobile, machinery, textile, and electrical industries (Mgonja, 2017). Figure 1
presents a general foundry process fluxogram (Institute for Prospective Technological Studies,
2004)
1
Figure 1.1 Foundry process
A hazard refers to anything that has the potential to cause harm, encompassing various factors
and associated events that can result in damage to human beings, property, or the environment.
2
Hazards include risks and dangers from unfavourable working conditions that do not meet
hygiene and environmental standards. These hazardous conditions increase the chances of
illnesses and diseases (Saravanakumar & Senthilkumar, 2014). The production of metal
castings involves a complex process that has historically been associated with worker injuries
and illnesses due to exposure to various chemical and physical agents generated or used during
casting. Foundry workers face numerous health hazards, including exposure to fumes, dust,
gases, heat, noise, vibration, and non-ionizing radiation. Prolonged exposure to these hazards
can lead to irreversible respiratory diseases such as silicosis, increasing the risk of lung cancer
and other illnesses. Additionally, foundry workers are susceptible to safety hazards that can
result in injuries such as strains, burns, eye damage, limb loss, and even fatalities. The adverse
health effects experienced by foundry workers can be categorized into respiratory diseases,
ergonomic injuries caused by falling or moving objects, lifting and carrying heavy loads, heat-
induced illnesses and injuries, vibration-induced disorders, noise-induced hearing loss, and
eye injuries (Midhun et al., 2019). To overcome hazards, proper risk identification and risk
assessment should be performed.
Hazard Identification and Risk Analysis (HIRA) focuses on identifying and assessing
the risks associated with accidents resulting from hazards present in the workplace or the
handling of hazardous substances. This process involves analyzing and quantifying various
dangers likely to occur in the industry and evaluating the consequences that may arise from a
specific hazard. Risk analysis involves estimating the probability and severity of a hazard's
impact on a group of exposed individuals, plant equipment, or both. HIRA plays a crucial role
in identifying the most significant hazards that can affect workplace safety in an industry. It
facilitates the development of effective management and engineering measures for prevention
and post-disaster management (Gobinath & Balan, 2014). Risk assessment is conducted
using various methods, tools, and assessment schemes. These methods offer different
strengths and weaknesses. Hammer(1993) present several techniques that can be categorized
into two main groups based on the approach and method of recording results: tree-based
analysis and spreadsheet-based analysis. Tree-based schemes focus on identifying a chain of
events to determine the risks involved. On the other hand, spreadsheet methods like Hazards
and Operability (HAZOP) and Preliminary Hazard Analysis (PHA) cover the entire scope of
risk assessment, including identification, analysis, and evaluation. The various software used
for HAZOP includes ProcessMAP, PHA worklite, safety culture, etc.
3
1.1 METHODS OF CASTING
1.1.1SAND CASTING
The process known as sand casting is referred to as "Green sand casting." In this
method, a mold made of green sand is created by combining silica sand (approximately 92%
by weight), a binder (7% by weight), and water (3% of weight), as illustrated in Figure
1.2. Adding water to the silica sand activates the binder, ensuring that the individual sand
particles form proper bonds with one another and the molding boxes (Ghubade & Kumar,
2019). Banchhor and Ganguly (2014) reported that more than 70% of metals are cast using the
green sand process.
Figure 1.2 Green sand mold (Ghubade & Kumar,

2019)
1.1.1 INVESTMENT CASTING

It is a casting process renowned for producing specific net-shaped components with
high dimensional accuracy and intricate designs (Ghubade & Kumar, 2019). It is particularly
suitable for manufacturing complex shapes such as modern weapons, turbine blades, and
aircraft parts, as highlighted by Davies and Jenkins (2016). Investment casting offers
numerous advantages, including achieving tight tolerances in cast parts, lower tooling costs,
the feasibility of intricate details, and a highly reliable process. The process initiates with the
creation of wax patterns using injection molding. These wax patterns are then attached to a
central wax sprue, forming a "tree" structure to enhance production efficiency. Next, the tree
is immersed in a refractory slurry, allowing a shell to form around the wax tree. The wax is
subsequently melted out by heating the wax tree, resulting in the formation of cavities. Finally,
the mold is filled with molten metal and left to solidify, as depicted in Figure 1.3 (Ghubade
& Kumar, 2019).
4
Figure 1.3 Investment casting steps (Ghubade & Kumar, 2019)
1.1.2 PLASTER OF PARIS MOLDING

Plaster of Paris casting is an expendable casting process that bears similarities to sand
casting, with the main difference being that the cavity or mold is formed using plaster of Paris,
also known as gypsum (CaSO4-2H2O). The plaster molding process involves pouring a
mixture of plaster and water over a plastic or metal pattern, which is then allowed to solidify.
During this process, the plaster mixture easily flows around the pattern, capturing its intricate
details and producing a smooth surface finish. Once the mold has been extracted from the
pattern, it is dried in an oven. Finally, the molten metal is poured into the molds (Ghubade &
Kumar, 2019).
1.1.2 CENTRIFUGAL CASTING
Centrifugal casting is a process in which mold is rotated about its central axis as the
metal is poured into it. Due to centrifugal force, a continuous pressure will be acting on the
metal, and the metal is get filled into the mold. According to the shape of the mold, the
centrifugal casting method can be classified as a)True centrifugal casting, b)Semi centrifugal
casting c) centrifuging (Ghubade & Kumar, 2019).
1.1.3 DIE CASTING:

Die casting is a manufacturing process that entails producing intricate products by
injecting molten metal into metal dies under high pressure. This metal dies can be reused once
the molten metal solidifies, typically through methods such as water spraying (it is important
5
to note that water is not directly sprayed onto the molten metal to prevent casting defects). Once
the casting process is complete, the finished product is ejected from the dies. In some cases,
minimal machining may be required, or no machining at all, as the casted product already
possesses excellent strength and enhanced mechanical properties (Sodhi, 2018). The mold,
crafted from metal, is designed to form a cavity filled with molten material through gravity,
pressure, or by utilizing the centrifugal force generated by rotating the mold (Ghubade &
Kumar, 2019).
1.1.3.1 GRAVITY DIE CASTING

Gravity die casting was one of the earliest processes invented for metal and light alloy
die casting. In this process which can be fully automated, the molten metal is poured directly
from a ladle into a semi-permanent or permanent die (Mishra, 2017).
1.1.3.2 PRESSURE DIE CASTING

The pressure casting process can be divided into two categories: high-pressure casting
and low-pressure casting (Ghubade & Kumar, 2019). High-pressure die casting involves
injecting molten metal under pressure into a securely locked metal die cavity. The metal is then
held in place by a powerful press until it solidifies. Once solidification is complete, the die is
unlocked, opened, and the casting is ejected (Bonollo et al., 2015). In contrast, low-pressure
die casting utilizes pressure, rather than gravity, to fill molds with molten metals like
aluminum and magnesium. In this method, the holding furnace is positioned below the cast,
and the liquid metal is forced upward through a riser tube and into the cavity. The low-pressure
die casting tends to be slower compared to high-pressure processes, and the size of the machine
can limit the size of castings produced (Nunes et al., 2023). High-pressure die casting is
commonly employed for soft alloys such as zinc and aluminum (Bonollo et al., 2015).
1.1.6 SHELL MOLDING:

Shell mold casting, also known as shell molding, is a metal casting process widely
used in manufacturing. In this process, the mold consists of a thin and hardened shell made
of sand and a thermosetting resin binder supported by another material. The internal surface
of the shell mold is exceptionally smooth and rigid, facilitating the smooth flow of liquid
metal through the mold cavity during the casting pour. As a result, castings produced through
shell mold casting exhibit a high-quality surface finish (Patel et al., 2014).
Table 1.1 Application, Advantages, and Disadvantages of various molding process
6
S. Type of casting Application Advantage Disadvantage
No.
1 Sand casting ➢Lead sheet for ➢ Good surface ➢Difficulty in
roofing ➢ texture achieving
➢Automobile homogeneity
➢ Fine microstructure
Engine Block ➢No flexibility
➢ High-strength
➢Cookware. as tooling is for
➢ components specific
➢ Low level of components
porosity ➢High cost due
to complex
tooling
2 Investment ➢ Turbine ➢ High precision is ➢Cast size
casting blades ➢ obtainable limitation
➢ Medical ➢High cost of
➢ Intricate and
Applications complex shapes are production
achievable
➢ Provides excellent
➢ surface finishing
➢ Little or no
machining is
required
3 Plaster of paris ➢Valves ➢High dimensional ➢Because of
casting ➢Decoration accuracy lower
items ➢Castings have fine thermal
➢Medical details & thin sections of conductivity,
purpose the mold. casting cools
➢Wall thickness as slowly
small as 0.6mm to 3mm ➢Low
can be cast. permeability
➢Smooth surface of plaster of
finishes paris.
➢Almost unlimited ➢POP destroys
intricacy and no porosity. at 1200˚C; the
process is only
suitable for
nonferrous
castings
4 Centrifugal ➢Water supply ➢Castings acquire ➢An inaccurate
casting and high density, high diameter of the
sewerage pipes mechanical strength, inner surface of
➢Steel gun affine- grained structure the casting.
barrels ➢Inclusions and ➢Not all
➢Chemical impurities are lighter alloys can be
reactor vessels ➢Gates and risers cast in this way.
➢Pressure vessel are not needed
bodies ➢High output Formation
7
➢Reactor tubes of hollow interiors
and pressure without cores
piping for nuclear
power plants
➢Paper mill rolls
➢Textile rolls
5 Gravity die ➢Automotive ➢Suitability for ➢High initial
casting parts high-volume, automated cost.
such as turbos, production ➢Very
brake calipers, ➢Minimum complex shapes
knuckles, engine investment required for cannot be
cylinder heads, small and medium- produced using
engine blocks, and volume production this technique.
pistons ➢Produces parts ➢The
➢Kitchen parts with excellent minimum
mechanical properties wall thickness
that are also suitable for that can be die-
heat treatment. cast ranges
between 3
and 5 mm.
6 Pressure die ➢Automotive ➢Good ➢Economical
casting housings dimensional tolerances only in Large
➢Appliance are possible quantities due
components ➢Excellent part- to high tool cost
➢Toys part dimensional ➢Not
consistency recommended
➢Parts require a for hydrostatic
minimal post machining pressure
applications
➢Difficult to
guarantee
minimum
mechanical
properties.
7 Shell ➢Gear housings ➢Good surface ➢High
➢Cylinder heads quality production
molding
and connecting ➢High rough casting costs and
rods dimensional accuracy casting prices
➢High-precision ➢Less manpower ➢High pattern
molding cores. and molding skill costs.
requirements ➢Size and
➢Thin wall weight
thickness and complex Limitation
castings
8
1.2 RECOMMENDATIONS FOR WORKER’S SAFETY
The general recommendation concluded from the HAZOP studies include:
1.2.1 Conduct thorough hazard assessment and monitoring programs
Conducting a comprehensive hazard assessment is crucial in order to identify potential

health and safety issues associated with casting processes. Although many foundries face
similar safety concerns during casting, each operation has its own distinct characteristics. By
performing this assessment, a facility can determine the specific risks that pose the greatest
threat to their organization.An established program addressing prevention and control
measures should encompass an evaluation of the workplace environment, focusing on gases,
vapours, fumes, and dusts. Regular environmental sampling and analysis should be conducted
by qualified occupational health and safety professionals, following the recommended
methods by the appropriate occupational health authority. Monitoring serves as a valuable
tool for evaluating hazards and gauging the efficacy of control measures. The design and
execution of a monitoring program should be conducted by a qualified individual or in
consultation with one.Records of the results of any monitoring should be maintained and
employees should be informed of these results.
1.2.2 Workers should wear proper safety equipment and clothing

Proper safety equipment is essential in mitigating the risks associated with various
health and safety issues during casting. Wearing the appropriate clothing and equipment can
significantly reduce the likelihood of burns, inhalation of dust, and eye damage for employees.
Personal protective equipment (PPE) should be utilized, including eye protection, hearing
protection, safety helmets, and skin protection such as gloves and barrier cream. It is crucial
to select the right PPE, ensuring that it fits each individual worker properly, and provide
training on its correct use and maintenance. Regular checks and maintenance should be
conducted on personal protective equipment to ensure ongoing worker protection.
1.2.3 Minimize the effect of heat :

Working in a high-heat environment, such as a foundry, can have a significant impact
on employees' well-being. Apart from burns, the primary heat-related risks that employees
face are heat stress, heat exhaustion, and heat stroke. To ensure the safety of employees, it is
important to provide them with adequate training to identify the signs of heat stress. This
knowledge enables them to watch out for each other, promptly inform management about any
concerns, and administer basic first aid when necessary. Eliminating unnecessary sources of
9
radiant heat and minimizing water vapor in the workplace (such as addressing steam valve
leaks and preventing water evaporation from wet floors) can help mitigate the effects of
heat.In cases where exposure to heat cannot be fully prevented or reduced through other
control measures, it becomes crucial to provide all exposed individuals with appropriate
personal protective equipment (PPE). Implementing planned job rotation can also assist in
reducing heat exposure. This may involve temporarily assigning workers to cooler
workstations or permanently transferring them to more moderate environments when
necessary.
1.2.4 Reduce the moisture content :
When moisture enters a foundry, it can create explosive bursts of steam that scald
employees. Therefore, facility managers must make every effort to minimize moisture on the
foundry floor. This minimization can be accomplished by warming metal ingots before
melting them and storing sand in moisture-tight areas.
1.2.5 Inspect Machinery Before Use and Be careful while using equipment:
Thorough equipment inspection is essential prior to use, ensuring proper functionality

and identifying any damage. Regular inspections enable facility managers to detect potential
issues early, prolong equipment lifespan, prevent casting defects, and minimize unexpected
production delays. Redesigning the workplace, equipment, or work process can also enhance
safety by modifying equipment, combining tasks, adjusting procedures, or altering task
sequences. Administrative measures include incorporating safety features in purchasing
specifications for new equipment, implementing routine and preventive maintenance
programs, and adhering to regular intervals.
1.2.6 Provide Adequate education and Training for workers

Employers can combat complacency in health and safety by providing regular training
to employees involved in casting. Annual safety training should be provided at a minimum.
This training should cover hazards, precautions, proper execution of tasks, use of engineering
controls, personal protective equipment, and maintaining cleanliness. Material safety data
sheets should be obtained for all substances, and a management representative should oversee
the supply, maintenance, and training of personal protective equipment.
1.2.7 Prevent and Minimize Harmful Vibration:

10
To minimize worker exposure to vibrations, prioritize engineering controls and
process substitution. Use tools with vibration dampers and design machinery to reduce
vibration risks. Implement administrative controls like labeling equipment and avoiding
prolonged use. Provide PPE such as protective gloves and vibration-absorbing materials when
other control measures are insufficient.
1.2.8 Monitor Noise Levels
Effective management of noise risks in a foundry involves implementing various

control measures in a specific order of effectiveness. The first priority is the elimination of
noise by replacing noisy machinery or operations with quieter alternatives that maintain or
improve efficiency. Upgrading equipment to newer models designed for lower noise levels
and making design changes, such as substituting metal components with plastic, can also help
reduce noise at its source. Engineering controls focus on treating the noise source, transmission
path, and receiver, utilizing techniques like noise insulation, enclosures, barriers, and vibration
isolation. Administrative controls include signposting noisy areas, providing quiet rest areas
for breaks, limiting workers' time in noisy environments, and considering work area rotations
to quieter sections. Lastly, personal protective equipment (PPE) such as earplugs, earmuffs, or
ear caps should be provided to workers. Regular monitoring of noise levels and investment in
noise-dampening equipment further contribute to maintaining a safe and conducive working
environment in the foundry.
1.2.9 Reduce the Risk of air borne contaminants Exposure
To mitigate health risks from dust inhalation in foundries, proactive steps should be
taken to minimize dust production and improve ventilation. Employees should be provided
with personal protective equipment (PPE) like respirators. Control options include
substituting hazardous processes or materials, using engineering controls to minimize
contamination generation and spread, and implementing administrative controls such as
training in safe work practices. PPE like face and eye protection, as well as appropriate
respiratory protection, should be utilized. By combining these measures, foundries can
effectively reduce the risks associated with airborne contaminants.
1.2.10 Perform health assessment for workers
Health assessment plays a crucial role in the occupational health and safety strategy
of foundries. However, before implementing such programs, it is essential to engage in
11
thorough consultation with employees. The confidentiality and privacy of medical records
must be strictly upheld. Establishing a link between employee health and illness data and
workplace exposure levels can yield valuable information for ensuring a safe working
environment. By conducting health assessments and analyzing the correlation, foundries can
take proactive measures to safeguard the well-being of their employees.
1.3 METHODS OF RISK ASSESSMENTS

1.3.1 Risk Matrix
A risk assessment matrix, also known as a risk control matrix, is an essential tool
utilized during the risk assessment phase of project planning. Its purpose is to identify and
assess the likelihood of potential risks in a project, as well as evaluate the potential impact or
consequences that may arise from those risks. The risk assessment matrix provides a visual
representation of the risk analysis, allowing for the categorization of risks based on their
probability level and severity or impact. This matrix is a straightforward and effective means
of understanding project risks comprehensively for all team members and relevant
stakeholders. Project planners can use the risk assessment matrix to prioritize risks and
develop appropriate risk mitigation strategies to ensure a successful project outcome (Thomas
et al., 2013).
1.3.2 Decision Tree Analysis
Decision tree analysis involves creating a decision tree, a visual depiction of different
alternative solutions for solving a specific problem. It is a systematic process to determine the
most effective courses of action. A decision tree consists of nodes and branches. Nodes
represent tests on specific attributes or variables, while branches represent potential outcomes
or decisions resulting from those tests. The decision tree branches out as different choices or
paths are evaluated, ultimately leading to potential solutions or actions (Zaku & Uysal, 2022).
1.3.3 Failure Mode And Effect Analysis
Failure Mode and Effects Analysis (FMEA) is a systematic approach developed by the
U.S. military in the 1940s to identify potential failures in processes, products, or services. It
involves analyzing all components, assemblies, and subsystems to identify possible failure
modes and their effects on the system. The analysis considers the likelihood of occurrence and
severity of each failure mode. FMEA allows organizations to anticipate problems before they
happen and take preventive measures to reduce risks and enhance quality. By proactively
identifying potential issues, appropriate corrective actions can be implemented to minimize
defects and ensure the delivery of high-quality products or services to customers. FMEA is an
12
effective tool for improving overall performance and customer satisfaction (Mascia et al.,
2020).
1.3.4 Bowtie Analysis

A bowtie diagram visually represents a risk, presented in a clear and easy-to-
understand format. Shaped like a bowtie, it distinguishes between proactive and reactive risk
management. The diagram effectively presents multiple plausible scenarios in a single picture,
offering an overview of the risk. In summary, a bowtie diagram provides a simple and visual
explanation of a risk, making it much easier to comprehend than other forms of explanation
(McLeod & Bowie, 2018).
1.3.5 What If Analysis
The "What-if" approach is a simple yet effective method for understanding and
assessing risk. By using the question "what-if" prior to incidents, organizations can potentially
prevent or minimize the impact of fatalities and serious incidents. Safety professionals utilize
the "What-if" tool to analyze risk sources, causes, conditions, consequences, and controls. It
involves a team-based, qualitative approach where brainstorming "what-if" questions are used
to identify potential hazards and their effects on systems. Techniques such as What-if analysis
and Structured What-if Risk Assessment serve as valuable tools for identifying, assessing, and
communicating risk within an organization (Golfarelli et al., 2006).
1.3.6 Fault Tree Analysis

Fault Tree Analysis (FTA) is a failure analysis technique that focuses on examining the
undesired states of a system. It is commonly applied in safety engineering and reliability
engineering to gain insights into system failures and estimate event rates for safety accidents
or functional failures at various system levels. FTA finds applications in aerospace, nuclear
power, chemical and process, pharmaceutical, petrochemical, and other high-hazard sectors.
It is also utilized in diverse fields, like identifying risk factors associated with failures in social
service systems. FTA is a valuable tool for understanding system failures and improving safety
and reliability (N. O. Health et al., 2021).
13
1.3.7 HAZOP Analysis
HAZOP is a recognized Process Hazard Analysis (PHA) method outlined in OSHA's
Process Safety Management (PSM) standard. It is a risk management approach used to
identify, assess, and control hazards and risks associated with complex processes. HAZOP is
particularly applicable to processes involving highly hazardous chemicals, as mishandling or
improper processing can lead to severe injuries to workers and substantial damage to property
and a company's reputation. By conducting HAZOP studies, organizations can proactively
mitigate risks and ensure the safe and efficient operation of their processes.
In this project, a HAZOP study was conducted using PHAWorks Lite software to
assess the safety risks in two casting industries known for their high potential for worker
injuries. The study aimed to identify potential hazards, and based on the findings, practical
recommendations were proposed to improve safety measures and reduce hazards in the
workplace.
14
CHAPTER 2
LITERATURE
REVIEW
2.1 MAJOR HAZARDS IN FOUNDRY INDUSTRIES AND THEIR EFFECT ON
WORKERS
The main hazards in the foundry industry include heat, hazardous chemicals, airborne
contaminants, manual tasks, noise, vibration, molten metal, plant and machinery, and
electricity (N. O. Health et al., 1989).
2.1.1 Heat Exposure:

The furnaces and molten metal generate an intensely hot working environment in
foundries. The heat is further amplified by activities such as mold and core heating, ladle
preheating, and metal casting heat treatment. Workers involved in tasks like a furnace or ladle
slagging, as well as those near molten metal, face the highest levels of heat exposure. High
temperatures and direct infrared (IR) radiation are common hazards in foundries (IFC, 2007).
2.1.2 Hazardous Chemicals:

The foundry industry extensively employs hazardous chemicals, encompassing
hazardous substances, dangerous goods, and combustible liquids. Some common hazardous
chemicals found in the foundry industry include amines, benzene, hexachloroethane, ammonia,
epoxy resins, formaldehyde, furfuryl alcohol, isocyanates, mold release paints, protective
coatings, phenol, crystalline silica, and more (Mgonja, 2017; Safety, 1997).
2.1.3 Airborne Contaminants:

Airborne contaminants, including fumes, mists, gases, vapors, dust, and
microorganisms, are prevalent throughout all foundry operations. Foundries encounter
significant concentrations of airborne contaminants due to various activities, including
handling scrap materials, scrap preparation using heat and solvent degreasers (which can
release carbon monoxide), the melting process (resulting in carbon monoxide, sulfur dioxide,
nitrogen oxides, chloride, and fluoride compounds), treatment and inoculation of molten
metal, core and mold making processes (including sand reclamation, preparation, and mixing),
mold and core forming processes (such as core baking and mold drying with additives,
binders, and catalysts), cooling of casts leading to organic binder decomposition, casting
knockout and shake-out, and fettling (Weber, 1961; Tossavainen,1976).
15
2.1.4 Manual Task
Manual work involving physical movements like lifting, carrying, pushing, and pulling
presents significant hazards for industrial workers worldwide. These tasks contribute to
musculoskeletal disorders (MSDs) due to unassisted object movement and awkward postures.
They are prevalent in various industries, especially in developing regions. Workers in foundry
settings and other areas frequently perform manual tasks, increasing the risk of MSDs.
Recognizing and addressing these risks is vital to ensure worker safety and prevent MSDs
(Mgonja, 2017; Mohammadi et al., 2013).
2.1.5 Noise
The foundry industry is known for generating hazardous noise levels in its operations.
The noise produced by foundry machinery is diverse and can vary in intensity and consistency.
Various machinery used throughout the foundry process contributes to the overall noise,
including equipment involved in pattern making, molding, core-making, furnaces, shake-out
and knockout of castings, tumbling, grinding and cleaning of castings, as well as fettling and
dressing of castings. The complex nature of these noise sources poses a challenge in managing
and mitigating the associated risks. Recognizing the potential harm caused by excessive noise,
appropriate measures should be taken to control and reduce noise levels to safeguard workers’
hearing health and well-being in the foundry industry (Nsw, 2011).
2.1.6 Vibrations
Exposure to vibration often accompanies noise in industrial settings. Vibration can be
classified as whole-body vibration (1 to 80 Hz) or hand-arm vibration (8 Hz to 1 kHz).
Foundry workers are at risk of whole-body vibration during processes like shake-out, sand-
slinging, and operating machinery such as forklift trucks and jolt-squeeze machines. Hand- arm
vibrations can occur when using tools like power grinders and chippers. These vibrations can
lead to various health issues. It is essential to assess and manage the risks by using measures
such as vibration-damping materials, ergonomic tool design, maintenance, and providing
appropriate personal protective equipment to protect the well-being of foundry workers (W.
Health & Queensland, 2004; Rytkönen et al.,2008).
2.1.7 Molten Metal

Molten metal in foundry melting and pouring areas presents significant hazards to
workers. Contact with metal splashes and exposure to electromagnetic radiation are major
concerns. Extreme caution must be exercised to prevent contact between molten metal and
16
water, which can cause explosive reactions. Elctromagnetic radiation, including infrared and
ultraviolet (UV) radiation, is emitted in these areas. Workers should be protected through
safety measures such as appropriate personal protective equipment and safety protocols to
minimize the risks of molten metal and electromagnetic radiation (W. Health & Queensland,
2004).
2.1.8 Plant And Machinery

In foundry environments, giving special attention to the maintenance and operation of
plants and machinery is essential. The elevated temperatures and continuous vibrations can
cause stress on crane components and other equipment, leading to shorter working life and
potential failures. This can result in serious incidents such as explosions, fires, spills, and
burns. Contamination from atmospheric particulate matter can also accelerate wear and
damage to lubricants and bearings. Regular maintenance, proper lubrication, and cleaning
procedures are essential to mitigate these risks and ensure safe and efficient operations in
foundry environments (N. O. Health et al., 1989; Mgonja, 2017).
2.1.9 Electricity
Electrical risks in foundry environments pose a threat of death, electric shock, or injury
due to direct or indirect contact with electricity. Foundry workers who work with or near
electrical equipment, such as in the pattern shop, fettling shop, and furnace section, are
particularly vulnerable to these hazards. The leading causes of electrical injuries can be
categorized into three broad categories, with electric shock being a significant concern that can
result in severe injury or even death (Safe work australia, 2018).
Table 2.1 Effect of foundry hazard on workers (N. O. Health et al., 2021; W.
Health & Queensland, 2004; IFC, 2007; Safety, 1997)
S.no. Hazard Effect on workers

1 Heat exposure Discomfort, heat fainting, heat stroke, prickly heat irritability,
dehydration, reduced concentration or attention, heat rash,
reduced tolerance to chemicals and noise exposure, heat cramps,
heat exhaustion
2 Hazardous Headaches, nausea, fatigue, irritant or allergic dermatitis,
chemicals asthma bronchitis, chemical burns, irritation of the nose, eyes,
and respiratory tract adverse effects on the central nervous
system and other bodily systems, including the lungs, kidneys,
17
and liver.
3 Airborne Respiratory irritation, coughing, asthma, acidic taste, eye
contaminants irritation, cancer of the nasal cavity, sinuses, siderosis, chronic
non-specific lung disease
4 Manual task Damage to the low back, upper back, or shoulder can gradually
build up through frequent lifting with the back bent or twisted, or
pushing/pulling loads; working in a fixed position with the back
bent, continuous sitting or
standing or driving vehicles for extended periods; repetitive
work with the hand or arm and having to grip tools or loads
tightly; working with the neck, shoulders, and arms in a fixed
position
5 Noise Temporary threshold shift, noise-induced hearing loss, tinnitus -
ringing in the ears, acoustic trauma - results from explosions or
deafening impulsive noise
6 Vibrations Blood pressure and heart problems, nervous disorders, stomach
problems, joint and spine damage
7 Molten metal Severe burns may result from splashes of molten metal and
radiant heat at any time in the melting and pouring areas. Sparks
from molten metal may also damage the eyes. Exposure to
infrared and ultraviolet radiation may result in eye damage,
including cataracts
8 Plant and Cuts and lacerations, Amputations, foreign bodies in eyes, crush
machinery injuries
Fractures, burns, manual handling injuries
9 Electricity Electric shock causing death, Arcing, explosion or fire causing
burns.
18
Table 2:Various Stages in foundry industries and related potential hazards
(Safety, 1997)
S.no Name Description Potential Hazards
1 Pattern/to Manufacturing the Woodworking machinery, Metal working

ol making tooling for machinery, Noise, Dust, Chemicals and
producing the final
solvents, Hand tools, Material and manual
component from
the metal casting handling, Fumes.
process.
2 Mold Mold is formed
preparatio by manual Molding machines, Dust, Noise/vibration,
n Chemicals /solvents, Fumes, Manual
handling, Heat/flames.
or
3 Metal Segregation and Sharp edges, Hot material, Dust/sparks,
mechanical means.
Preparation preparation of Material/manual handling, Toxic waste,
alloys and scrap Heavy metal contamination, Housekeeping.
prior to the
melting process
4 Metal melting Metals are Moisture, Extreme heat/temperature,
melted to a Fumes, Explosions, Equipment failure,
controlled Materials/manual handling
temperature and
composition.
5 Casting Transferring the Molten metal, Latent heat, Fumes, Dust,
molten metal into Materials/manual handling, Equipment
failure, Moisture, Explosions.
the prepared mold
for solidification.
6 Removal Removing the Noise, Dust, Fumes, Heat, Sharp edges,

casting from the Waste, Mechanical/ manual handling
molding medium
of castings in preparation
for fettling
and finishing.
19
7 Fettling Removing the Mechanical/manual handling, Equipment
an excess material failure, Stress/ mental fatigue, Cutting oils, X-
from the casting
d finishing to meet specified rays, Ultraviolet light.
dimensions.
8 Heat Enhancing the Radiant heat, Steam,
treatme metallic structure Mechanical/manual handling,
and physical Chemicals, Fire, Explosions (gas
nt properties of the mixtures), Dusts, Waste, Fume,
Equipment failure
component by
the use of
controlled
9 Plant temperatures.
Maintaining all Electricity, Dust, Gas, Noise/vibration,
maintenanc plant and Compressed air, Chemical/solvents,
machinery used Heights/ confined space,
e for metal casting Mechanical/manual handling
so as Housekeeping, Hazardous waste.
to keep it in a
safe, operable
condition.
10 Waste Removal, Dust, Hazardous/toxic waste,
dispos segregation. and Manual/mechanical handling, waste
safe storage and storage, Sharp edges, Heavy objects.
al disposal of
unusable
materials and
by- products
11 Material Handling Manual/mechanical handling, Sharp edges,

handling and materials Lack of traceability, Incorrect storage, and
throughout the staking
packaging casting process
and the
presentation of
components for
dispatch to meet
the customer’s
specifications
22
2.2 HAZOP:
Hazard and Operability Analysis (HAZOP) is a methodical and structured approach
for examining systems and managing risks. Its primary purpose is to identify potential hazards
within a system and highlight operational issues that may result in nonconforming products.
HAZOP operates on the principle that risk events stem from deviations in design or
operational intentions. To facilitate the identification of such deviations, HAZOP employs
sets of "guidewords" that provide a systematic framework for exploring different perspectives
and stimulating the creativity of the team members involved in the analysis process. This
unique aspect of HAZOP enables a comprehensive exploration of potential deviations and
their associated risks (Galante et al., 2014).
2.2.1 OBJECTIVES
To assess:
➢ Possibility of degradation/decomposition of raw materials,
➢ Possibility of a failure of the human factors,
➢ Possibility of an exothermic runaway of reaction, decomposition hazard from the raw

materials, reaction mixture, intermediates, and final products,
➢ Possibility of undesirable side reactions,
➢ Possibility of a utility failure (Kotek & Tabas, 2012).
2.2.2 METHODOLOGY
The HAZOP analysis process is executed in four phases :
1. Definition Phase:
In the Definition Phase, the risk assessment team selects members and emphasizes
the importance of cross-functional collaboration. Subject Matter Experts (SMEs) from
various disciplines, possessing relevant skills, experience, intuition, and sound judgment,
participate in the HAZOP process. The team should be comprised of individuals
knowledgeable about system deviations. Maintaining an atmosphere of positive thinking and
open discussion during HAZOP is crucial. Additionally, the team must carefully determine
the assessment scope by defining study boundaries, key interfaces, and underlying
assumptions(PQRI, 2014).
23
2. Preparation phase:
The Preparation Phase of a study typically involves the following activities:
1. Identifying and gathering supporting data and information.
2. Identifying the audience and users of the study outputs.
3. Making project management preparations, such as scheduling meetings and transcribing

proceedings.
4. Reaching a consensus on the template format for recording study outputs.
5. Reaching a consensus on the HAZOP guide words for the study.
Risk assessment teams use predetermined guide words to identify deviations from the
design intent. These guidewords stimulate creative thinking, focus the study, and promote
productive discussions. The teams are responsible for selecting the guide words that are most
suitable for their analysis based on the scope and problem statement. The guide words used
are Less, More, Part of, Earlier, later, reversed, etc. (PQRI, 2014).
3.Examination Phase
In the Examination Phase, all elements of the system or process are identified for
examination. The HAZOP guidewords are systematically applied to each element to search
for deviations. It is important to note that not all combinations of guide words and elements
may yield sensible or credible deviations. However, it is necessary to identify and challenge all
reasonable use and misuse conditions the user expects to determine their credibility and assess
them further. Instances where combinations do not produce credible deviations, do not need
to be explicitly documented (PQRI, 2014).
4. Documentation & Follow-up Phase

A template recording form specified in IEC Standard 61882 is commonly used to
facilitate the documentation of HAZOP analyses. However, risk assessment teams can modify
the template to meet specific needs. Factors influencing template modifications include
regulatory requirements, more detailed risk rating or prioritization (e.g., rating deviation
probabilities, severities, and detection), company documentation policies, traceability or audit
readiness requirements, and other relevant considerations (PQRI, 2014).
24
2.3. RISK ASSESSMENT IN THE FOUNDRY INDUSTRY
Gopinath and Balan (2014) presented a comprehensive approach for identifying and
mitigating significant health and safety risks associated with the manufacturing and supplying
castings and related support activities. Their work outlined a step-by-step process for
prioritizing identified risks and provided recommendations to prevent the occurrence of such
hazards.
In their case investigation, Rajkumar et al. (2021) focused on implementing effective

safety management using management approaches. Their study aimed to identify potential
hazards arising from automation and recommend effective workplace implementation. The
researchers utilized the Job Safety Hazard Identification and Risk Assessment (JSHIRA)
analysis methodology to identify different types of incidents to enhance safety measures.
In their study, Saravanakumar & Senthilkumar (2014) employed Hazard Identification

and Risk Assessment (HIRA) methodology to identify and assess hazards. They analyzed
each hazard by estimating the potential damages it could cause. The risk associated with each
hazard was then calculated, taking into account factors such as probability, severity, and the
potential number of individuals affected by accidents or incidents.
2.4 Research GAP

This study aimed to fill the gap in HAZOP assessments within the foundry industry. It
involved conducting a HAZOP study specifically focused on assessing workers' safety. By
identifying potential hazards and risks, the study aimed to enhance safety measures and ensure
the well-being of workers in foundry industries.
25
AIM AND OBJECTIVE
AIM
To evaluate the safety practices in foundries using HAZOP study
OBJECTIVES
1. Identify the types of foundries in India and understand the operational risks faced by the
employees/labors
2. Analyze and choose two distinct types of foundry industries that are more hazardous for
labor.
3. Identifying the operations that are associated with risks
4. Understanding HAZOP Analysis for the types of risks associated in foundry industries
5. Define nodes, parameters, and conditions for HAZOP analysis and
6. Identify a suitable software available in public domain for HAZOP analysis.
7. Perform HAZOP Analysis for various parameters and conditions in foundries
8.Evaluate the results obtained from the analysis and draw conclusions and recommendations
for ensuring safe operations.
26
CHAPTER 3
METHODOLOGY
A detailed review of various foundries and their operations dealing with a specific
casting method, each from manual and semi-automated casting procedures, was performed, and
an extensive HAZOP report was generated using an application tool. Using a risk ranking tool
allows the ranking of the hazards according to their specific risks. The Hazard Register, which
includes information on the guideword, deviation, parameter, causes, consequences,
safeguards, and recommendations, was generated.
The step-by-step procedure is as follows:
3.1 ANALYSING VARIOUS CASTING METHODS AND IDENTIFYING THE

TWO MOST HAZARDOUS METHODS:
For this purpose, a detailed study was conducted on 7 casting methods. A rough
estimation of the magnitude of risk involved in different casting methods was done. Based on
the higher risk involved, one from completely manually performed and one semi- automated
pouring method were selected for extensive HAZOP analysis were selected.
3.2 PERFORMING HAZOP STUDY ON SELECTED CASTING METHODS:

A HAZOP study is a formal systematic procedure used to review the design and
operation of a potentially hazardous process facility. Here HAZOP study was conducted to
assess worker’s safety.
The various step involved are:
1. Identify various processes on selected casting methods.
2. Define the design intent and normal operating conditions of the section.
3. Identify a deviation from design intent or operating conditions by applying a system of
guidewords.
4. Identify possible causes for, and consequences of, the deviation. A deviation can be
considered meaningful if it has reasonable cause and can result in harmful effects.
5. Decide what action, if any, is necessary for a meaningful deviation.
6. Record the discussion and action.
3.3 GENERATION OF WORKSHEET FOR HAZOP STUDIES:

The above-obtained data were entered into the HAZOP software PHAWORKS LITE for
27
the above process, and a worksheet was generated. The high-risk involved areas were
highlighted through risk matrix ranking. The HAZOP risk matrix prioritizes resources for risk
mitigation by visually representing the risk profile, identifying critical areas, and aiding
decision-making. It should be regularly updated to maintain relevance and accuracy. The risk
assessment matrix in the figure portrays risk based on occurrence likelihood and consequence
severity. A likelihood of occurrence was assigned to each identified hazardous event. The contribution
of the preventative and protective features to the occurrence of hazardous events was considered when
assessing the likelihood of the occurrence of each hazardous event. The frequency of occurrence for
this risk assessment is listed in Table 3.2. The potential consequences and outcomes were
assessed for each potential incident. These consequences are considered threats to health and
safety.
Table 3.1 Risk Grid
Likelihood Risk Ranking

of Severity
occurrence Very high(1) High(2) Medium(3) Low(4) Very low(5)
Very high Extremely Very high High Moderately Moderate
(1) high (1) (2) (3) high (4) (5)
High Very high High Moderately Moderate Moderately
(2) (2) (3) high (4) (5) low (6)
Medium high Moderately Moderate Moderately Low
(3) (3) high (4) (5) low (6) (7)
Low Moderately Moderate Moderately Low Very low
(4) high (4) (5) low (6) (7) (8)
Very low Moderate Moderately Low Very low Extremely
(5) (5) low (6) (7) (8) low (9)
Table 3.2 Likelihood Ranking
Likelihood of occurrence Description

Very high (1) Expected to occur frequently
High (2) Expected to occur several times
Medium (3) Expected to occur once in the while
Low (4) Expected o occur very unlikely
Very low (5) Expected not to occur, but it happened in the past
Table 3.3 Severity Ranking

Severity Description
Very high (1) Fatality
High (2) Loss of body parts (limbs, hands, eyes)
Medium (3) Severe injuries
Low (4) Mild injuries
Very low (5) No injuries
28
PHA WORKS LITE is Primatech’s entry-level software that provides Intuitive
Design Philosophy Clean and intuitive user interface. It is a cost-effective Solution
Alternative option at a lower price point for conducting PHA and LOPA studies. Easily
Perform Common PHA Studies Select from the most commonly used PHA methods,
including HAZOP, What If, FMEA, HAZID, DHA, and Job Safety / Hazard Analysis.
WORKS LITE is a streamlined PHA tool for performing hazard analysis studies using PHA
methods, such as HAZOP and What-If analysis. PHA Works Lite enables studies to be
performed quickly and efficiently. All essential elements of a study are integrated from start
to finish. An intuitive flow for entering project information provides all the necessary
information to support the study’s pre-defined reports and provides a means of quickly
generating study documentation.
Figure 3.1 General Interface involving project information and intentions
29
Figure 3.2 Nodes considered for HAZOP
Figure 3.3 Inbuilt lists of Guidewords, parameters, and

deviation
Figure 3.4 Nodes involved
30
Figure 3.5 Output interface
3.4 DRAWING CONCLUSIONS FROM THE WORKSHEETS
The various risk associated with the processes for workers were identified from the
worksheet generated, and possible solutions and recommendation were listed to ensure
worker’s safety.
31
32
CHAPTER 4
RESULTS AND DISCUSSION
4.1 PRELIMINARY HAZOP
A Preliminary HAZOP was carried out on all 7 casting methods of the foundry
industry to conduct extensive HAZOP on each of the manual and semi-automated methods
which have more hazardous to labor safety from the preliminary survey. A flow list of crucial
node points is prepared for all methods by going through their flow charts to compare the
more hazard-prone method
Table 4.1 Node points for Shell Mold Casting
S. NO. NODE
1 Insertion of pattern and frame into shell machine and securing with ejection
pins
2 Invest cycle-covering pattern with sand in the shell machine
3 Heat treatment from the oven on top and burner at the bottom
4 Joining of cope and drag mold cases and inserting core
5 Compression of assembly in squeeze station
6 pouring of molten metal through the gate system
7 Shake out of the sand
8 Cleaning and processing of sand
Table 4.2 Node points for Investment Casting
SL NO NODE
1 Preparation of replica (wax into dye)
2 Assembling of wax patterns in the wax feeder system
3 Coating of ceramic slurry on wax assembly by dipping several times to achieve
the required thickness
4 Melting out of wax in a steam autoclave
5 Pouring of molten metal into molds
6 breaking of the ceramic shell mold
7 Fettling, blasting, and heat treatment
8 Xray and die treatment
33
Table 4.3 Node points for Centrifugal Casting
S.NO. NODE
1 Preparation of mold cavity(ceramic slurry)
2 Proper assembling of spinning die, pouring basin, motor, and rollers
3 Pouring of metal from oven to pouring basin
4 Pouring of molten metal to mold cavity through ladle
5 Removal of casted metal
Table 4.4 Node points for Gravity Die Casting
S. NO. NODE
1 Preparation of die(refractory coating, heating, and pins)
2 Pouring of molten metal into die through ladle
3 Removal of cast parts and pins
4 Removal of Scrap(runners, spruces, and flash)
5 Blast cleaning
Table 4.5 Node points for Pressure Die Casting
S. NO. NODE
1 Preparation of Die casting mold(pins and lubrication)
2 Transportation of Ingots
3 Pouring molten metal into the injection barrel
4 Forcing metal from barrel to mold through plunger
5 Removal of pins
6 Removal of sprue and other parts
34
Table 4.6 Node points for Plaster Mold Casting
S. NO. NODE
1 Preparation of Flask and board arrangement using clamps(lubrication)
2 Filling of POP with Model in-between the board
3 Tapping for removal of air bubbles
4 Opening of assembly and extraction of POP mold
5 Shaping for uniform spruce
6 Pouring of molten metal in a mold
7 Extraction of metal casted
Table 4.7:Node points for Sand Mold Casting
S.NO. NODE
1 Preparation of sand mold
2 Transportation of raw materials to oven
3 Transportation from oven to ladle
4 Ladle to the casting line
5 Extracting mold materials
6 Cleaning of casted materials
7 Heat treatment
From the above methods Sand Casting(manual) and Investment Casting(Semi-automated) has
been selected such that it acts as the superset for rest of the processes and extensive HAZOP
has been conducted
4.2 HAZOP STUDY ON SAND AND INVESTMENT CASTING

• HAZOP study was conducted to assess workers’ safety.
• Identified various processes on selected casting methods.
35
Figure 4.1 HAZOP flow summary for sand casting
36
Figure 4.2 HAZOP flow summary for investment casting
37
4.3 DESIGN INTENT AND NORMAL OPERATING CONDITIONS
OF THE SECTION
➢ Identified a deviation from design intent or operating conditions by applying a
system of guidewords.
➢ Identified possible causes for, and consequences of, the deviation.
➢ Listed out the action, if any, that is necessary for a meaningful deviation.
Table 4.8 Overview of worksheet for sand casting
Parameter Deviations Consequences Mitigati

on
Addition, More and Confusion leads parts and apparatus
strategie
Instrumentation, repetitive work, to errors, fatigue maintained
s and
Concentration, Improper pouring Damage to the serviced, Threads
Flow, setup, High emission vicinity, Nausea, revived, safety shoes
Reaction, of metal fumes CO, headache, dry throat, Continuous
Maintenance, SO2, Pouring higher chest pain, Tinnitus, supervision,
Composition, than ladle capacity, Splashing Sound enclosures,
Level, The reaction of Respiratory elastic surface
Services/Utilitie additives with irritation, Asthma, coating,
s, Safety, molten metal, eye irritation Metal audiometric testing,
Less effective fume fever aluminum liners,
ventilation and Disfiguring, fatal control at source,
collection burns, incapacitating noise map, padded
system, Bp, heart gloves, anti-
Improper surface problems Skin vibration mounts,
finishing, rash, ergonomics, PPE,
Overflow from inflammation, pH balanced soap,
the casting line, Siderosis wet scrubbers,
Moisture Explosion, short remove oxides,
content, circuit Making the scarfing, surface
High vibration oven unusable, grinding,
emission, Improper Lower back and degreasing,
markings, Careless stomach pain pickling, piping for
handling of Vibration of surface gas
instruments, machines Falling cleaning, radiation
No proper into or entering the barriers, work
warning signs, danger zone rotation, water with
No obstruction and Disturbing electrolytes,
protection against communication portable reflective
flying objects, Loss of life, shielding, local
High noise emission Affects sleep, serious exhaust, proper
injuries from flying warning signal
objects, system, air testing,
safety inspection
for ladles, proper
layout map, aspirin,
38 air inlet,
Table 4.9 Overview of worksheet for Investment casting
Parameter Deviation Consequences Mitigatio

n
Temperature, Over or Property damage, Strategies
Strict material
Pressure, uncontrolled severe burns, scalding inspection,
Composition, heating, higher injuries, explosions, calibrated
Level, pressure on wax in loss of life, hearing temperature control
Addition, die, unwanted impairment, system, safe storage
Reaction, contaminant, high interference with of flammable
Maintenance, noise emission, communication, materials, inspection
Instrumentatio repetitive work, nervous fatigue, wax injection
n, adhesive reaction, affecting sleep, system, fire safety
Services/utilitie less effective excessive fatigue, protocols, proper
s, ventilation, errors from training to workers,
Concentration, collection system, confusion, errors suppression system,
Safety, equipment failure, from boredom, low Sound enclosures,
improper warning bp, sore lumps, damp proof coat,
signs, high asthma, alteration to PPE kit, moisturize
emission of wax the structure of the the skin, pH
vapors, improper mucous membrane, balanced soap, wet
storage of risk of cancer, scrubbers, pits, and
flammable siderosis, short floor openings
materials, non- circuit, getting should be covered,
maintenance of crushed in between ventilation and air
electrical parts, machinery, entering purification system,
sharp edges and the danger zone, electrical safety
protrusions, no inhalation of toxic measures, chemical
proper warning wax vapors, electrical resistant gloves,
signs, exposure to shocks, thermal ergonomic study,
hazardous burns, disfigurement, preheating of tools,
chemicals, control skin irritation, anti-splash
system failures, incapacitating, measures, PPE fit
moisture content, neurological test and training,
high vibration disorders, lower back, audiometric testing,
level, high heat and stomach pain, shift rotation for
stress emission, heat stroke, workers, radiation
additives react dehydration, mental barriers, water with
with molten metal, disorders, splashing, proper electrolytes,
improper surface lung disease, tripping, scarfing, degreasing,
finishing, high making oven air inlet, pressure
emission of metal unusable, metal fume control devices,
fumes, excessive fever, loose focus, proper storage and
air pressure, serious injury from labeling, pickling,
careless handling flying padded gloves, local
of exhaust, surface
39
instruments, no objects, spill out grinding,
obstruction while transportation, protective barrier
from flying
objects,
4.4 GENERATION OF WORKSHEET FOR HAZOP STUDIES:

The above-obtained data were entered into the HAZOP software PHAWORKS
LITE for the above process, and a worksheet was generated. The high-risk involved
areas were highlighted through risk matrix ranking.
Table 4.10 Risk Grid(Number of parameters associated) for Sand casting
Likelihood Number of parameters in respective risk Ranking

of Severity
occurrence Very high High Medium Low Very low
high (0) (17) (1) high (0) (0)
(9) (19) high (4) (0) low (0)
(16) high (8) (2) low (0) (1)
high (4) (5) low (1) (2) (0)
(0) low (1) (0) (0) low (0)
Table 4.11 Risks for Sand casting
Level Description Number of parameters

1 Extremely high 0
2 Very high 26
3 High 36
4 Moderately high 16
5 Moderate 7
6 Moderately low 2
7 Low 3
8 Very low 0
9 Extremely low 0
40
Table 4.12 Risk Grid(Number of parameters associated) for Investment casting
Likelihood Number of parameters in respective risk Ranking

of Severity
occurrence Very high High Medium Low Very low
high (0) (9) (4) high (0) (0)
(11) (40) high (4) (0) low (0)
(1) high (14) (1) low (0) (0)
high (0) (0) low (1) (1) (0)
(0) low (0) (0) (0) low (0)
Table 4.13 Risks Investment casting
Level Description Number of parameters

1 Extremely high 0
2 Very high 20
3 High 45
4 Moderately high 18
5 Moderate 1
6 Moderately low 1
7 Low 1
8 Very low 0
9 Extremely low 0
4.5 CONCLUSIONS FROM WORKSHEETS

The various risk associated with the processes for workers were identified from the
worksheet generated, and possible solutions and recondition were listed to ensure workers’
safety.
In conclusion, this HAZOP report emphasizes the utmost importance of labor safety in the
foundry industry. Through identifying potential risks and offering proactive
recommendations, we strive to safeguard the well-being of workers.
41
It is imperative for the foundry industry to acknowledge the human aspect within its operations
and make a resolute commitment to establishing a safe environment. Industry leaders,
policymakers, and regulatory bodies must unite in enforcing comprehensive safety protocols
that go beyond mere compliance.
Our vision entails a future where workers can perform their tasks without fear of harm or
enduring long-term health implications. Achieving this necessitates substantial investments in
robust safety measures and cultivating a pervasive culture of safety across the industry.
May this thesis serve as a catalyst for action, urging all stakeholders to prioritize the
preservation of workers' lives. Together, let us forge a path towards a safer future, ensuring the
well-being of those dedicated to the foundry industry's prosperity.
The detailed HAZOP report containing all essential data had been generated which covers all
minute deviations that can go wrong in the casting process which in turn results in hazards for
labor safety respective safeguards and recommendations have been provided to overcome the
injuries and fatalities and if taken care as mentioned will make the workplace nearly risk free
Extensive HAZOP Report with Risk ranking generated using PHA works lite is given in
APPENDIX
42
CHAPTER 5
CONCLUSIONS
The foundry industry is a significant global industry, but it poses numerous hazards to
workers, including fine dust, toxic gases, noise, temperature extremes, and molten metal
splashes. Failing to control or prevent these hazards can seriously jeopardize worker health and
overall effectiveness. It is crucial for the foundry industry to prioritize the well-being of its
workforce and commit to creating a safe working environment.
In this projrct for enhancing safety in the foundry industry, a detailed HAZOP (Hazard
and Operability) study was conducted specifically for sand casting and investment casting
processes. The objective was to evaluate the safety of workers and provide recommendations
for their protection. Through the HAZOP study, various risks associated with these processes
were identified, and potential solutions and precautions were outlined to ensure the safety of
the workers.
The HAZOP report underscores the paramount importance of labor safety in the
foundry industry. By identifying potential risks and offering proactive recommendations, the
aim is to safeguard the well-being of the workers. The comprehensive HAZOP report contains
all the necessary data, covering even the smallest deviations that could lead to hazards in the
casting process. It provides safeguards and recommendations to mitigate the risks and
potential injuries or fatalities. By implementing these measures as outlined in the report, the
workplace can become significantly safer, reducing risks to a minimum
43
43
WORKSHEET
Study Type: HAZOP (Parameter-Based, Traditional)
Project Name: EVALUATION OF SAFETY PRACTICES IN FOUNDRY INDUSTRY
Company: NITKC
Location: SURATHKAL
Facility: MANUFACTURING
Plant: FOUNDRY
Process: METAL CASTING
Description: to protect workers in the Foundry industry from workplace hazards and to preventing or reducing work-related injuries and diseases, ill health and
incidents;
Scope: to amend or add-in to the elements of rules that has been framed for safety of labourers
Purpose: to evaluate safety practices in foundry industry
Objectives: To identify the areas in foundry industries that are associated with hazards which are “inherent in the job”.
44
Node: 1. Preparation of sand mold using pattern

Parameter: Pressure
Intention: Pressure on flask and board
Raw Risk
Guidewords Deviations Causes Consequences Safeguards Recommendations
S L R
high/more over 1. tapping more than required 1.1.1. damages to joints and bolts 5 3 7 1.1.1.1. making sure the parts and 1.1.1.1. continous supervision and
compression that holding flask and board ,may apparatus used are properly check the apparatus before using
result in the sudden break open of maintained and serviced
the mold material and harm labour
1.1.1.2. threads on bolts and joints
are properly maintained
1.1.1.3. safety shoes are wore all
the time during the process

Parameter: Level
Intention: more than normal noise and vibration
Raw Risk
S L R
high/more high noise 1. repeated tapping and adjusting 1.1.1. hearing impairment 3 3 5 1.1.1.1. using sound enclosures. 1.1.1.1. quantify the level and
emission the board and flask setup duration of exposure of workers and
compare it with exposure limits
1.1.2. interference to 2 3 4 1.1.2.1. elastic surface coatings 1.1.2.1. necessity ,elimination
communications essential for safety such as damping and deadening on ,replacing
purposes the impacted structure causing
noise.
1.1.3. nervous fatigue 2 2 3 1.1.3.1. Install sound-absorbing 1.1.3.1. first step in the noise-control
materials for walls and roofs process should be to attempt to
control it at source.
1.1.4. affecting sleep and relaxation 3 2 4 1.1.4.1. provide hearing protection 1.1.4.1. minimize by appropriate
and offer audiometric testing. organizational measures the time
workers spend in the noisy
environment;
1.1.4.2. Install sound deadening 1.1.4.2. create a noise map for the
troughs such as aluminum liners, or determination of risk areas and
external spray-on sound absorber quantify the level and duration of
exposure of workers and compare it
45
Raw Risk
S L R
with exposure limits
high 2. repeated tapping and adjusting 2.1.1. raises blood pressure, leading 3 3 5 2.1.1.1. use of tools can be 2.1.1.1. if possible, determine the
vibration the board and flask setup to heart problems improved by supports. resonance frequencies and avoid
emission resonance frequencies of the
component parts of machinery and
equipment
2.1.2. Neurological disorders 2 4 5 2.1.2.1. Wear padded gloves when 2.1.2.1. Process improvements to
using hand tools with vibration and reduce the use of hand tools with
full equipt with foundry ppe. vibration
2.1.3. Lower back pain. 3 2 4 2.1.3.1. vibration-damping 2.1.3.1. should permit an
techniques and anti -vibration ergonomically good working position.
mounts
2.1.4. Stomach pain 4 4 7 2.1.4.1. Allow workers to rest 2.1.4.1. as far as practicable, anti-
alternately, avoid working in contact vibration handles.
with continuous vibration.
2.1.5. body or limb vibration which 2 4 5 2.1.5.1. quantify the level and
can affect the manipulation of duration of exposure of workers and
controls. compare it with exposure limits

Parameter: Reaction
Intention: chemicals with skin
Raw Risk
S L R
high/more adhesive 1. while preparing molds excessive 1.1.1. topical skin adhesives can also 3 4 6 1.1.1.1. Use a skin preparation 1.1.1.1. Assess the skin for visual
reaction with exposure to adhesives cause wound dehiscence (reopening barrier film signs of flaky, cracking or dryness
skin of a previously closed wound)
1.1.2. Shortness of breath, low 3 3 5 1.1.2.1. moisturise the skin 1.1.2.1. Advocate washing with
blood pressure, and chest pain. emollient wash products and apply
an emollient
1.1.3. Urticaria (hives) 3 2 4 1.1.3.1. Avoid washing the skin too 1.1.3.1. Avoid clothing that
much and Use a pH-balanced soap scratches the skin, causes itching, or
substitute to avoid drying the skin puts pressure on the skin
1.1.4. Red, itchy or sore lumps at 3 2 4 1.1.4.1. Alcohol-free products are
injection sites. recommended because alcohol can
46
Raw Risk
S L R
cause pain when applied to sore,
broken, irritated skin, such as
peristomal or periwound skin.
1.1.5. suspected human carcinogen 2 5 6
1.1.6. Skin is pulled away and the 2 4 5
layers of the skin separate

Parameter: Maintenance
Intention: improper collection and ventilaton system and surface polishing
Raw Risk
S L R
low/less less 1. not properly planned ventilation 1.1.1. various irritating effects 1 4 4 1.1.1.1. Fabric filters andInertial 1.1.1.1. Add personal respiratory
effective system for escape of contaminated such as respiratory irritation, separators,Wet protection equipment such as
ventilation air and collection of contaminants for coughing, asthma, acidic taste scrubbers,Electrostatic precipitators respirators, specialized masks in
and proper disposal and eye irritation case the ventilation system in the
collection foundry is not enough to remove
system dust in those areas.
1.1.2. alteration to the structure of 1 4 4 1.1.2.1. Install local exhaust 1.1.2.1. Avoid using sand with
the mucous membrane lining of the ventilation system moisture below 2%, should use
nasal cavity more binder to reduce the amount
of loose sand
1.1.3. risk of cancer of the nasal 1 4 4 1.1.3.1. Use an efficient dust
cavity and sinuses collection system (eg CMAXX)
1.1.4. manifest itself as a skin rash, 2 3 4
inflammation or as an
asthmatic condition
1.1.5. may accumulate in the lungs 1 4 4
and cause siderosis
1.1.6. lung disease; 1 4 4
tracheobronchitis, pneumonitis
and beryllosis
1.1.7. Metal dust can cling to 1 3 3
electrical equipment and catch fire
causing problems with fire, explosion
47
Raw Risk
S L R
or short circuit.
improper 2. improper cleaning and not 2.1.1. tripping and falling 2 3 4 2.1.1.1. remove defects, scale, 2.1.1.1. Scarfing and surface
surface removing the roughness and oxides, and other impurities from the grinding should be done in
finishing contaminants properly from surface surface of steel at different points in enclosures, with good exhaust
the process. ventilation
2.1.2. sometimes the residues will 2 3 4 2.1.2.1. scarfing, which uses fixed or 2.1.2.1. chemical-resistant clothing,
react with the atmosphere and hand-held torches or lances to burn goggles and face shields, footwear
cause harm away the impurities and leggings, and respiratory
protection where necessary.
2.1.3. vibration of machines for 2 4 5 2.1.3.1. surface grinding 2.1.3.1. To the extent practicable,
transport acid pickling tanks and solvent
degreasing tanks should be covered,
and provided with exhaust ventilation
to control the vapours.
2.1.4. disturbance and molten metal 1 4 4 2.1.4.1. degreasing, which uses 2.1.4.1. minimize exposure to dust.
may spill out while transportation detergents or solvents to remove
grease
2.1.5. the residue may react due to 1 4 4 2.1.5.1. pickling, which uses acids or
heat and explode hydrogen peroxide to dissolve scale
and oxides

Parameter: Instrumentation
Intention: Fitting the joints is improper
Raw Risk
S L R
low/less improper 1. manual error while tightening and 1.1.1. the setup may break open 1 4 4 1.1.1.1. proper checking after fitting 1.1.1.1. Constant supervision and
apparatus worn out equipments after pouring molten metal and awareness should be provided about
setup cause unbearable harm to worker safety and accurste work
1.1.2. risk of damaging the 1 3 3 1.1.2.1. providing protection cloth
instruments and fatal blow to worker and accessories to worker involved in
this process
Node: 2. transportation of raw materials to oven

Parameter: Composition
48
Intention: content other than required,

Raw Risk
S L R
other than moisture 1. water is poured into molten metal 1.1.1. disfiguring, incapacitating or 1 3 3 1.1.1.1. Equipment and piping for 1.1.1.1. The greatest splashing
content or molten metal is poured into damp fatal burns. furnace gas cleaning, and piping hazards, therefore, are likely to
containers carrying gas in the air preheating occur at the beginning of the work
system of the dry dust catchers, week or workday or after a
should be built in such a way that shutdown
they can be ventilated and cleaned.
2. ignition of volatile materials and 2.1.1. wearing off appropriate 1 4 4 2.1.1.1. The fuel supply to gas- or 2.1.1.1. Allowing more time for the
fuels. Personal Protective Equipment (PPE) oil-fired furnaces should be fitted with initial melt during these start-up
an automatic shut-off mechanism. periods can help reduce the potential
for splashing hazards
3. Liquid metal spilled out in contact 3.1.1. 2 4 5 3.1.1.1. tools should be preheated
with water.Charging furnace with wet and dried before use to minimize the
ingots or crumbs risk of explosion
4. When wet tools, molds and 4.1.1. 2 4 5 4.1.1.1. Refractory linings should be
materials are in contact with liquid regularly inspected for wear.
metal.

Parameter: Level
Intention: more than normal noise,vibration
Raw Risk
S L R
high/level high noise 1. continous exposure to higher level 1.1.1. hearing impairment 2 4 5 1.1.1.1. using sound enclosures. 1.1.1.1. quantify the level and
emission of sound involving duration of exposure of workers and
cranes,collection,pouring and compare it with exposure limits
conveyance of raw materials
noise.
49
Raw Risk
S L R
environment;
high 2. continous exposure to higher level 2.1.1. raises blood pressure, leading 2 4 5 2.1.1.1. use of tools can be 2.1.1.1. if possible, determine the
vibration of sound involving to heart problems improved by supports. resonance frequencies and avoid
emission cranes,collection,pouring and resonance frequencies of the
conveyance of raw materials component parts of machinery and
equipment
mounts
high heat 3. temperature and/or humidity are 3.1.1. Heat rash causes itching 1 3 3 3.1.1.1. increase the distance 3.1.1.1. minimizing exposure to the
stress unusually high; between the equipment and hazardous substances so that there
emission exposed workers is less need for protective clothing
4. workers are exposed to high 4.1.1. Muscle cramps leads to pain 1 3 3 4.1.1.1. reduce the temperature of 4.1.1.1. Measure the temperatures
radiant heat the surface by changing plant- in the work areas as well as monitor
operating temperatures, insulating workers’ heat stroke regularly.
the surfaces or reducing the
emissivity of the surface.
5. high temperatures and/or 5.1.1. Heat stroke leads to 1 4 4 5.1.1.1. the use of radiation barriers 5.1.1.1. work rotation between
humidity occur in combination with exhaustion and nausea (of low conductivity and high workers to minimize time exposure
heavy protective clothing or a high emissivity) to hot temperatures.
work rate;
5.1.2. Sweating can lead to 2 3 4 5.1.2.1. sufficient quantities of 5.1.2.1. Provide personal cooling or
dehydration drinking water, with the proper heat reflective clothing for workers
50
Raw Risk
S L R
electrolytes, who are frequently exposed to heat
radiation.
5.1.2.2. rescue and first-aid
measures;
5.1.3. Stroke 2 4 5 5.1.3.1. The core body temperature
should not be allowed to fall below
36°C
5.1.4. Mental disorders, affecting 2 5 6 5.1.4.1. the use of portable
behavior and perception. reflective shielding
5.1.5. causes skin burns and 1 3 3
blistering

Parameter: Addition
Intention: workload and inefficient ergonomics analysis
Raw Risk
S L R
high/more more and 1. The risk of musculoskeletal 1.1.1. Too high a physical load may 2 2 3 1.1.1.1. ensure the appropriate 1.1.1.1. ergonomic study should be
repetitive injuries is common . Manual carrying cause excessive fatigue, especially in selection and design of tools, undertaken
work and lifting of large, bulky and/or a hot environment machines, equipment and work
heavy objects is common stations
2. Long-lasting repetitive work 2.1.1. Confusing and/or missing 1 2 2 2.1.1.1. workers get all the 2.1.1.1. The workload be brought to
movements and awkward postures . information may lead to errors being necessary information about the a tolerable level
Maintaining the same posture for made. process, machinery and their co-
extended periods workers in correct form and in due
time.
3. Repetitive work and tasks with 3.1.1. Repetitive work and tasks with 2 2 3 3.1.1.1. Temporary work phases
little variety little variety and/or few events may should be checked and temporary
lead to boredom and errors being workers informed.
made.
4. Confusing and/or missing 4.1.1. 2 2 3
information
5. Too high a physical load 5.1.1. 2 4 5
51

Intention: improper surface polish,slippery,improper collection and ventilaton system
Raw Risk
S L R
low/less improper 1. improper cleaning and not 1.1.1. tripping and falling 1 3 3 1.1.1.1. remove defects, scale, 1.1.1.1. Scarfing and surface
polish contaminants properly from surface surface of steel at different points in enclosures, with good exhaust
grease
1.1.5. the residue may react due to 1 3 3 1.1.5.1. pickling, which uses acids or 1.1.5.1. floor surface around the kiln
heat and explode hydrogen peroxide to dissolve scale must be made of anti-slip and
and oxides fireproof materials.
less 2. not properly planned ventilation 2.1.1. various irritating effects 2 3 4 2.1.1.1. Fabric filters andInertial 2.1.1.1. Add personal respiratory
of loose sand
52
Raw Risk
S L R
asthmatic condition
and cause siderosis
and beryllosis
or short circuit.

Parameter: Testing
Intention: low importance on analyzing capacity of cranes and machines
Raw Risk
S L R
low/less putting more 1. over-loading of the machine used 1.1.1. Falling of load 1 4 4 1.1.1.1. The rated capacity and/or 1.1.1.1. alternative safe means
load an for transport legible load chart,permanently should be provided to get from the
crane and marked on the structure and clearly operating position to a safe area .
its visible.
accessories
2. non-maintenance of the 2.1.1. Hitting & crushing of a load to 1 3 3 2.1.1.1. Platforms and walkways 2.1.1.1. The crane or hoist operator
can take
transporting instruments existing facilities should be accessible via permanent, should sound a warning signal when
fire-resistant elevators, stairways or it is necessary to alert workers.
ladders
3. no periodic checking of the 3.1.1. Damage to underground 2 3 4 3.1.1.1. indicate the boom angle, if 3.1.1.1. The hooks, cables and
accessories utilities of earth the rated capacity is affected. other equipment should be designed
for use under conditions of high
thermal load
4. over estimation of the capacity it 4.1.1. Toppling of Crane 1 4 4 4.1.1.1. ransport routes be clear of 4.1.1.1. maintenance, to verify that
can hold obstructions, and in the case of it can continue to operate at its
molten metal, free of water. original safe working load.
Transport route should be level.
5. insufficient strength of materials 5.1.1. 2 3 4 5.1.1.1. The load should be lowered
and inappropriate design of slowly and smoothly
machines
53

Intention: improper setup for pouring,improper marking of sharp edges
Raw Risk
S L R
less/low improper 1. Load was not lowered slowly and 1.1.1. Spilling of molten metal and 1 2 2 1.1.1.1. Indicate the boom angle, if 1.1.1.1. alternative safe means
pouring smoothly damage the vicinity the rated capacity is affected. should be provided to get from the
setup operating position to a safe area
2. Height of railing of the furnace , 2.1.1. Splashing 1 3 3 2.1.1.1. Proper maintenance and 2.1.1.1. The hooks, cables and
height of door to pour raw material cleaning of the oven other equipment should be designed
into oven was not properly provided for use under conditions of high
thermal load
2.1.2. Making the oven unusable 2 2 3 2.1.2.1. controlling the process from
a distance
3. In-sufficient safe clearance to 3.1.1. Causing serious burns to the 2 2 3 3.1.1.1. pathway near oven should
allow for aisles and turns, or other workers around be smooth and even without any
types of control area uneveness
improper 4. Lack of means of shielding, 4.1.1. Falling into or entering the 1 3 3 4.1.1.1. platforms and walkways 4.1.1.1. sufficient safe clearance to
markings worker safety equipment from danger zone. should be clearly marked. allow for aisles and turns, or other
that cause moving parts, dangerous areas such types of control area.
skin as high voltage, heat radiation,
scratches
5. The unreasonable layout of 5.1.1. Severe scratches that may 2 2 3 5.1.1.1. maps showing the proposed 5.1.1.1. danger zone should be
equipment and workplace, making prove to be fatal route should be provided. equipped with devices which prevent
operations difficult and easy to workers from falling into or entering
cause collisions. the danger zone.
6. Cleaning the gating system and 6.1.1. getting crushed in between 1 4 4 6.1.1.1. The safe operating speed 6.1.1.1. Safety harnesses should be
machining the casting leads to skin machinery for vehicles should be posted and worn where required and the lifeline
scratches due to contact with the enforced. should be attached to an adequate
sharp surface of the casting. anchor point.
7. Interaction between vehicles, 7.1.1. unintentional interference with 1 3 3 7.1.1.1. timely rescue should be
vehicles and other objects and the process that may cause death provided when using fall-arrest
personnel, or by loads falling off or equipment to prevent suspension
from the vehicle. trauma.
8. No proper safety or danger 8.1.1. 2 2 3
markings to make workers alert

54
Parameter: Services / Utilities

Intention: not sufficient boards potraying warning signs
Raw Risk
S L R
low/less no proper 1. The unreasonable layout of 1.1.1. unintentional interference with 1 3 3 1.1.1.1. keep areas clean, in good 1.1.1.1. prevent access to areas
warning equipment and workplace, making the process that may cause death working order and well maintained where there is a risk of falling
signs and operations difficult and easy to objects, except in an emergency.
cleanliness cause collisions.
1.1.1.2. ensure the use of covered 1.1.1.2. Floor surfaces should be
walkways or alternative safeguards maintained regularly, and kept clean
such as safety nets and free of oil spills
2. No proper safety or danger 2.1.1. getting crushed in between 1 4 4 2.1.1.1. Furnaces with elevated 2.1.1.1. Floors adjoining tracks in the
markings to make workers alert machinery points of access . The platforms and foundry should be level with the tops
walkways should be clearly marked. of the track rails.
3. Interaction between vehicles, 3.1.1. Falling into or entering the 1 3 3 3.1.1.1. Pits and other floor 3.1.1.1. Platforms and walkways
vehicles and other objects and danger zone. openings should be covered ,should should be accessible via permanent,
personnel, or by loads falling off or always be well lit. fire-resistant elevators, stairways or
from the vehicle. ladders.

Parameter: Concentration
Intention: higher than safe limit
Raw Risk
S L R
high/more high 1. casting or melting process will lead 1.1.1. metal fume fever and eye 2 2 3 1.1.1.1. lie down and drink enough 1.1.1.1. Metal fume fever usually
emission of to generate large amounts of lead irrigation water clears up after 24-48 hours of
metal fumes fume emissions known as dangers expose treatment.
of melting lead.
1.1.2. Symptoms that appear 2-10 2 1 2 1.1.2.1. use symptomatic therapies 1.1.2.1. Carry out air testing where
hours later are nausea, headache, such as aspirin to relieve headache necessary to ensure the pollution
dry throat, wheezing, chills, chest symptoms concentrations do not exceed
pain, and often mistaken for Workplace exposure standards for
bronchitis or pneumonia. airborne contaminants
1.1.3. increased skin metal 1 3 3 1.1.3.1. Install the air inlet above 1.1.3.1. Consider alternatives to less
concentration and blood count the metal furnace to suck the fumes toxic substances, or modify
and lead them to the exhaust gas procedures to minimize the
control system. generation of toxic fumes and
vapors
1.1.4. cause asthma and allergies 2 2 3
55
Raw Risk
S L R
high 2. gas produced from metal 2.1.1. blood being prevented from 1 3 3 2.1.1.1. nstall exhaust ventilation to 2.1.1.1. t is recommend to check
emission of furnaces and during metal pouring supplying oxygen and causing control CO emissions. CO levels in blood or breathing of
CO,SO2 into mold process suffocation. workers regularly at the end of
working shifts
2.1.2. If exposed to CO 1 2 2 2.1.2.1. Install the air inlet above 2.1.2.1. Carry out air testing where
500-1000ppm for about 30 minutes, the metal furnace to suck the fumes necessary to ensure the pollution
it can cause headaches, tinnitus, and lead them to the exhaust gas concentrations do not exceed
dizziness, nausea, and mental control system. Workplace exposure standards for
confusion. airborne contaminants
2.1.3. Exposure above 1000ppm 1 3 3
can cause fainting, and even more
severe it can lead to death.
Node: 3. transporting from oven to ladle

Parameter: Flow
Intention: pouring more than required quantity
Raw Risk
S L R
high/more pouring 1. Uncontrolled over filling of ladle 1.1.1. Causing serious burns to the 1 3 3 1.1.1.1. Do not pour metal into 1.1.1.1. integral locking device to
more than workers around ladles or barrels exceeding 80% of prevent accidental tipping. Large
ladle their volume transport ladles (>500kg) should
capacity have a self-restraining anti-tipping
device.
1.1.1.2. Locking devices on casting 1.1.1.2. not be suspended from a
and transport ladles crane or other lifting device during
filling
1.1.1.3. Safety inspection of ladles
1.1.2. Spilling of molten metal and 1 3 3 1.1.2.1. properly clean and service
damage the vicinity after certain amount of usage
1.1.3. Splashing 1 2 2
2. reduction in capacity of ladle due 2.1.1. Making the oven unusable 2 3 4
to poor maintenance

56
Raw Risk
S L R
2. ignition of volatile materials and 2.1.1. Damage to Personal 1 3 3 2.1.1.1. The fuel supply to gas- or 2.1.1.1. Allowing more time for the
fuels. Protective Equipment (PPE) oil-fired furnaces should be fitted with initial melt during these start-up
3. Liquid metal spilled out in contact 3.1.1. Damaging the apparatus and 2 2 3 3.1.1.1. tools should be preheated 3.1.1.1. gas produced from metal
with water.Charging furnace with wet vicinity and dried before use to minimize the furnaces and during metal pouring
ingots or crumbs risk of explosion into mold process so careful handling
is important
metal.

Parameter: Reaction
Intention: adding additives in ladle for improved qualities
Raw Risk
S L R
high/more additives 1. addition of additives to improve 1.1.1. splashing 1 2 2 1.1.1.1. tools should be preheated 1.1.1.1. proper sign board should be
reacts with properties sometimes reacts with and dried before use to minimize the installed such that no one other than
molten molten metal or atmosphere risk of explosion intended enter the vicinity of the
metal process
1.1.2. explosion that may cause 2 2 3 1.1.2.1. Refractory linings should be 1.1.2.1. gas produced from metal
severe injuries to worker regularly inspected for wear. furnaces and during metal pouring
into mold process so careful handling
is important
2. uncleaned residue reacts with the 2.1.1. disfiguring, incapacitating or 2 2 3 2.1.1.1. the process should be
additives fatal burns. controlled from the safe distance
57
Raw Risk
S L R
2.1.2. Damage to Personal 1 3 3
Protective Equipment (PPE)
2.1.3. Damaging the apparatus and 1 2 2
vicinity

Raw Risk
S L R
of loose sand
asthmatic condition
and cause siderosis
and beryllosis
or short circuit.
58
Raw Risk
S L R
grease

Raw Risk
S L R
thermal load
a distance
59
Raw Risk
S L R
scratches

Raw Risk
S L R
of melting lead.
60
Raw Risk
S L R
vapors
metal fumes into mold process suffocation. workers regularly at the end of
working shifts
Node: 4. treatment ladle to casting line

Parameter: Flow
Intention: pouring more than required quantity
Raw Risk
S L R
high/more pouring 1. Overflow of the molten metal 1.1.1. disfiguring, incapacitating or 1 2 2 1.1.1.1. Equipment and piping for 1.1.1.1. The greatest splashing
more than fatal burns. furnace gas cleaning, and piping hazards, therefore, are likely to
required carrying gas in the air preheating occur at the beginning of the work
quantity into system of the dry dust catchers, week or workday or after a
casting line should be built in such a way that shutdown
1.1.1.2. The fuel supply to gas- or
oil-fired furnaces should be fitted with
an automatic shut-off mechanism.
2. improper setup for pouring into 2.1.1. wearing off appropriate 1 3 3 2.1.1.1. Refractory linings should be 2.1.1.1. Allowing more time for the
the casting line Personal Protective Equipment (PPE) regularly inspected for wear. initial melt during these start-up
periods can help reduce the potential
2.1.1.2. tools should be preheated
and dried before use to minimize the
61
Raw Risk
S L R
risk of explosion

Raw Risk
S L R
3. Liquid metal spilled out in contact 3.1.1. 2 2 3 3.1.1.1. tools should be preheated 3.1.1.1. gas produced from metal
with water.Charging furnace with wet and dried before use to minimize the furnaces and during metal pouring
ingots or crumbs risk of explosion into mold process
metal.

Parameter: Level
Raw Risk
S L R
emission of sound involving collection and duration of exposure of workers and
pouring compare it with exposure limits
62
Raw Risk
S L R
noise.
environment;
vibration of vibration involving collection and to heart problems improved by supports. resonance frequencies and avoid
emission pouring resonance frequencies of the
equipment
mounts
63
Raw Risk
S L R
work rate;
radiation.
5.1.2.2. rescue and first-aid
measures;
36°C
blistering

Raw Risk
S L R
of loose sand
64
Raw Risk
S L R
asthmatic condition
and cause siderosis
and beryllosis
or short circuit.
grease

65
Raw Risk
S L R
thermal load
a distance
scratches

66
Raw Risk
S L R
of melting lead.
vapors
working shifts
Node: 5. Extracting mold materials

Parameter: Level
Raw Risk
S L R
emission of sound involving blasting,crushing duration of exposure of workers and
and abrasion compare it with exposure limits
67
Raw Risk
S L R
noise.
environment;
vibration of vibration involving to heart problems improved by supports. resonance frequencies and avoid
emission blasting,crushing and abrasion resonance frequencies of the
equipment
mounts

68

Raw Risk
S L R
of loose sand
asthmatic condition
and cause siderosis
and beryllosis
or short circuit.
69
Raw Risk
S L R
grease

Intention: improper marking of sharp edges,improper handling of instruments
Raw Risk
S L R
less/low improper 1. Lack of means of shielding, 1.1.1. Falling into or entering the 1 2 2 1.1.1.1. platforms and walkways 1.1.1.1. sufficient safe clearance to
scratches
less 6. ill trained workers in handling 6.1.1. serious injury from flying 2 2 3 6.1.1.1. ensure the use of covered 6.1.1.1. rotation of work at regular
carefulness vibrators,blasting instruments objects walkways or alternative safeguards intervals
in handling such as safety nets
of
7. fatigue and nervousness while 7.1.1. repeated vibration and sound 2 1 2 7.1.1.1. ergonomic study should be 7.1.1.1. focus should be given in
70
Raw Risk
S L R
instruments handling can make worker fatigue easily undertaken creating awareness about threats
while handling
8. get disturbed by the flying objects 8.1.1. little negligence while handling 1 3 3 8.1.1.1. The workload be brought to 8.1.1.1. Temporary work phases
which further causes danger to life can cause serious injury which may a tolerable level should be checked and temporary
of worker result in loss of life workers informed.
8.1.1.2. Safety harnesses should be 8.1.1.2. workers get all the
worn where required and the lifeline necessary information about the
should be attached to an adequate process, machinery and their co-
anchor point. workers in correct form and in due
time.
8.1.1.3. timely rescue should be
provided when using fall-arrest
equipmen

Raw Risk
S L R
signs operations difficult and easy to objects, except in an emergency.
cause collisions.

Parameter: Safety
71
Intention: ineffective protective layer for safeguarding against flying objects from breaking,shaking and conveyance
Raw Risk
S L R
low/less improper 1. breaking down the mold can 1.1.1. injury to workers 2 1 2 1.1.1.1. control the process from 1.1.1.1. make sure workers other
obstruction make sharp material to fly around distance than involved should not enter
and strictly
protection
1.1.2. damaging apparatus in vicinity 2 1 2 1.1.2.1. create the protective barrier 1.1.2.1. properly training workers in
against
the risk involved
flying
objects 1.1.3. can make worker to loose 2 2 3 1.1.3.1. provide appropriate safety 1.1.3.1. proper supervision and
focus and get hurt by instruments clothing controlling multiple procedures such
handling that no one comes under danger
Node: 6. Cleaning of casted metal

Parameter: Level
Raw Risk
S L R
emission of sound involving abrasion,water jet duration of exposure of workers and
and polishing compare it with exposure limits
noise.
environment;
72
Raw Risk
S L R
vibration of vibration involving abrasion,water to heart problems improved by supports. resonance frequencies and avoid
emission jet and polishing resonance frequencies of the
equipment
mounts

Raw Risk
S L R
of loose sand
73
Raw Risk
S L R
asthmatic condition
and cause siderosis
and beryllosis
or short circuit.
grease

74
Raw Risk
S L R
scratches
of
instruments
handling can make worker fatigue easily undertaken creating awareness about threats
while handling
time.
equipmen

75

Raw Risk
S L R
cause collisions.

Parameter: Safety
Intention: ineffective protective layer for safeguarding against flying objects from breaking,shaking and conveyance
Raw Risk
S L R
and strictly
protection
against
the risk involved
flying
objects 1.1.3. can make worker to loose 2 2 3 1.1.3.1. provide appropriate safety 1.1.3.1. proper supervision and
Node: 7. heat treatment to improve mechanical properties

Parameter: Level
76
Raw Risk
S L R
emission of sound involving annealing, case duration of exposure of workers and
hardening, precipitation compare it with exposure limits
strengthening, tempering,
carburizing, normalizing and
quenching.
noise.
environment;
vibration of vibration involving annealing, case to heart problems improved by supports. resonance frequencies and avoid
emission hardening, precipitation resonance frequencies of the
strengthening, tempering, component parts of machinery and
carburizing, normalizing and equipment
quenching.
mounts
77

Raw Risk
S L R
scratches
of
instruments
while handling
time.
78
Raw Risk
S L R
equipmen

Parameter: Safety
Intention: ineffective protective layer for safeguarding against hot water and flying objects
Raw Risk
S L R
and strictly
protection
against
the risk involved
flying
objects and 1.1.3. can make worker to loose 2 2 3 1.1.3.1. provide appropriate safety 1.1.3.1. proper supervision and
hot water focus and get hurt by instruments clothing controlling multiple procedures such
Node: 8. wax pattern creation

Parameter: Temperature
Intention: high temperature due to uncontrolled heating
Raw Risk
S L R
high/more over or 1. Wax temperature exceeds safe 1.1.1. leading to property damage 1 2 2 1.1.1.1. Strict material selection and 1.1.1.1. Establish a comprehensive
uncontrolled limits due to a malfunctioning and potential harm to personnel. inspection procedures to ensure the material testing and verification
heating temperature control system. quality and purity of pattern process to ensure the quality and
materials. purity of pattern materials
1.1.1.2. - Installation of reliable and
properly calibrated temperature
control systems with alarms for
temperature deviations
2. Wax injection system failure leads 2.1.1. Severe burns and scalding 1 2 2 2.1.1.1. proper storage of 2.1.1.1. Provide training to pattern
to an uncontrolled release of molten injuries to workers due to exposure flammable materials and availability makers on the safe use of tools and
wax. to high-temperature wax. of fire extinguishers. equipment
3. Introduction of foreign particles or 3.1.1. - Fires and explosions 2 2 3 3.1.1.1. Regular maintenance and 3.1.1.1. Conduct regular fire safety
79
Raw Risk
S L R
contaminants into the pattern inspection of wax injection systems drills and inspections, ensuring the
material. availability and proper functioning of
fire prevention and suppression
systems
4. inefficient fire suppression 4.1.1. severe burns may result in 1 3 3 4.1.1.1. fire safety protocols, 4.1.1.1. Establish a routine
systems. loss of life including proper storage and fire maintenance schedule for
suppression systems. temperature control systems,
including sensor calibration and
replacement

Parameter: Pressure
Intention: higher pressure than required
Raw Risk
S L R
high/more higher 1. Wax injection system failure leads 1.1.1. Severe burns and scalding 1 2 2 1.1.1.1. Regular maintenance and 1.1.1.1. safety features in wax
pressure on to an uncontrolled release of molten injuries to workers due to exposure inspection of wax injection systems, injection systems, such as pressure
wax in die wax. to high-temperature wax. including periodic testing and relief valves and automatic shutdown
preventive maintenance. mechanisms

Intention: material contamination
Raw Risk
S L R
other than unwanted 1. Use of contaminated or incorrect 1.1.1. Casting defects due to 3 2 4 1.1.1.1. Strict material selection and 1.1.1.1. Establish a comprehensive
contaminant pattern materials. material contamination in the inspection procedures to ensure the material testing and verification
pattern. quality and purity of pattern process to ensure the quality and
materials. purity of pattern materials.
1.1.2. non uniform melting and 2 2 3
splashing
1.1.3. may cause serious burns 1 3 3
when erupts
80

Parameter: Level
Intention: more than normal sound
Raw Risk
S L R
emission of sound involving operation of duration of exposure of workers and
certain machinery and tools compare it with exposure limits
noise.
environment;

Parameter: Addition
Raw Risk
S L R
high/more more and 1. The risk of muscuskeletal injuries 1.1.1. Too high a physical load may 3 1 3 1.1.1.1. ensure the appropriate 1.1.1.1. ergonomic study should be
repetitive is common . Manual carrying and cause excessive fatigue, especially in selection and design of tools, undertaken
work lifting of large, bulky and/or heavy a hot environment machines, equipment and work
objects is common stations
81
Raw Risk
S L R
time.
3. Repetitive work and tasks with 3.1.1. Repetitive work and tasks with 3 1 3 3.1.1.1. Temporary work phases
little variety little variety and/or few events may should be checked and temporary
lead to boredom and errors being workers informed.
made.
4. Confusing and/or missing
information
5. Too high a physical load

Parameter: Reaction
Intention: chemical exposure
Raw Risk
S L R
high/more adhesive 1. while preparing molds excessive 1.1.1. topical skin adhesives can also 3 2 4 1.1.1.1. Use a skin preparation 1.1.1.1. Assess the skin for visual
reaction with exposure to adhesives cause wound dehiscence (reopening barrier film signs of flaky, cracking or dryness
skin of a previously closed wound)
1.1.2. Shortness of breath, low 3 2 4 1.1.2.1. moisturise the skin 1.1.2.1. Advocate washing with
blood pressure, and chest pain. emollient wash products and apply
an emollient
1.1.3. Urticaria (hives) 3 1 3 1.1.3.1. Avoid washing the skin too 1.1.3.1. Avoid clothing that
much and Use a pH-balanced soap scratches the skin, causes itching, or
substitute to avoid drying the skin puts pressure on the skin
1.1.4. Red, itchy or sore lumps at 2 2 3 1.1.4.1. Alcohol-free products are
injection sites. recommended because alcohol can
cause pain when applied to sore,
broken, irritated skin, such as
peristomal or periwound skin.
1.1.5. suspected human carcinogen 1 3 3
1.1.6. Skin is pulled away and the 2 2 3
layers of the skin separate

82
Intention: improper ventilation
Raw Risk
S L R
1.1.2. alteration to the structure of 2 3 4 1.1.2.1. Install local exhaust
the mucous membrane lining of the ventilation system
nasal cavity
asthmatic condition
and cause siderosis
and beryllosis
or short circuit.

Intention: equipment failure,improper use of tools,malfunctioning of temperature control system
Raw Risk
S L R
less/low 1.Hazards 1. Wax temperature exceeds safe 1.1.1. Injuries from improper use of 2 2 3 1.1.1.1. Implementation of safe 1.1.1.1. - Provide training to pattern
associated limits due to a malfunctioning pattern making tools and equipment operating procedures for pattern makers on the safe use of tools and
with pattern temperature control system. making tools, including proper equipment, emphasizing proper
making tools training and maintenance handling and maintenance practices
83
Raw Risk
S L R
and
equipment
2.Equipment 2. Wax injection system failure leads 2.1.1. Severe burns and scalding 2 2 3 2.1.1.1. Installation of reliable and 2.1.1.1. - Conduct regular fire safety
failure to an uncontrolled release of molten injuries to workers due to exposure properly calibrated temperature drills and inspections, ensuring the
wax. to high-temperature wax control systems with alarms for availability and proper functioning of
temperature deviations fire prevention and suppression
systems.
2.1.2. Fires and explosions resulting 2 2 3 2.1.2.1. Establish a routine
from uncontrolled wax injection and maintenance schedule for
ignition sources temperature control systems,
replacement.

Intention: no adequate warning system
Raw Risk
S L R
cause collisions.
2. No proper safety or danger 2.1.1. getting crushed in between 1 3 3 2.1.1.1. Pits and other floor 2.1.1.1. Floors adjoining tracks in the
markings to make workers alert machinery openings should be covered ,should foundry should be level with the tops
always be well lit. of the track rails.
3. unguarded machinery 3.1.1. Falling into or entering the 2 2 3 3.1.1.1. Platforms and walkways
danger zone. should be accessible via permanent,
fire-resistant elevators, stairways or
ladders.

Intention: higher than safer limit
84
Raw Risk
S L R
high/more high 1. Inadequate ventilation system 1.1.1. Inhalation of toxic wax vapors 1 2 2 1.1.1.1. Implementation of efficient 1.1.1.1. Conduct regular air quality
emission of causes the accumulation of toxic leading to respiratory distress and ventilation systems with air testing to identify potential
wax vapours wax vapors. chemical toxicity purification measures, including hazardous emissions and ensure
monitoring for volatile organic adequate ventilation and air
compounds (VOCs) and hazardous purification systems.
gases.

Parameter: Safety
Intention: improper storage of flammable materials,negligence of electrical system
Raw Risk
S L R
low/less improper 1. flammable pattern materials 1.1.1. Fire incidents leading to 2 3 4 1.1.1.1. Installation of reliable and 1.1.1.1. Establish a routine
storage of property damage and potential harm properly calibrated temperature maintenance schedule for
flammable to personnel. control systems with alarms for temperature control systems,
materials temperature deviations. including sensor calibration and
and non replacement.
maintenance
2. electrical equipment malfunctions 2.1.1. electrical shocks 2 2 3 2.1.1.1. electrical safety measures 2.1.1.1. ensure proper storage and
of electrical
handling of flammable materials,
parts
inspect and maintain electrical
equipment regularly
Node: 9. wax pattern assembly

Intention: high temperature of wax
Raw Risk
S L R
high/more over or 1. working with hot plates and wax 1.1.1. leading to property damage 2 2 3 1.1.1.1. Strict material selection and 1.1.1.1. Conduct regular
uncontrolled and potential harm to personnel. inspection procedures to ensure the maintenance and calibration of
heating quality and purity of pattern assembly equipment to ensure safe
materials. operating temperatures.
1.1.1.2. - Installation of reliable and
properly calibrated temperature
control systems with alarms for
temperature deviations
85
Raw Risk
S L R
2. improper monitoring of assembly 2.1.1. Severe burns and scalding 2 2 3 2.1.1.1. proper storage of 2.1.1.1. Provide training to pattern
equipment injuries to workers due to exposure flammable materials and availability makers on the safe use of tools and
to high-temperature wax. of fire extinguishers. equipment
3. Introduction of foreign particles or 3.1.1. - Thermal burns from contact 2 2 3 3.1.1.1. Implementation of safe 3.1.1.1. Conduct regular fire safety
contaminants into the pattern with hot assembly equipment or operating procedures for assembly drills and inspections, ensuring the
material. molten wax equipment availability and proper functioning of
fire prevention and suppression
systems
4. inefficient fire suppression 4.1.1. severe burns may result in 2 3 4 4.1.1.1. Establish a routine
systems. loss of life maintenance schedule for
temperature control systems,
replacement

Intention: material contamination
Raw Risk
S L R
other than unwanted 1. Use of contaminated or incorrect 1.1.1. Casting defects due to 5 3 7 1.1.1.1. Strict material selection and 1.1.1.1. Establish a comprehensive
contaminant pattern materials. material contamination in the inspection procedures to ensure the material testing and verification
pattern. quality and purity of pattern process to ensure the quality and
materials. purity of pattern materials.
1.1.2. non uniform melting and 2 2 3 1.1.2.1. Provide cut-resistant gloves, 1.1.2.1. Enforce the use of
splashing heat-resistant gloves, safety appropriate PPE, provide training on
goggles, chemical-resistant gloves/ safe tool handling, establish safe
aprons, fire prevention measures work procedures, conduct chemical
risk assessments, implement fire
safety protocols, eliminate ignition
sources in the assembly area
1.1.3. may cause serious burns 2 2 3
when erupts

Parameter: Addition
86
Raw Risk
S L R
time.
3. Repetitive work and tasks with 3.1.1. Repetitive work and tasks with 2 2 3 3.1.1.1. Temporary work phases 3.1.1.1. Provide workers with
little variety little variety and/or few events may should be checked and temporary ergonomic tools and adjustable
lead to boredom and errors being workers informed. workstations to minimize physical
made. strain and fatigue.
4. Confusing and/or missing 4.1.1. 2 2 3 4.1.1.1. Ergonomically designed 4.1.1.1. Implement regular training
information workstations and tools, including sessions on proper lifting techniques,
adjustable tables, ergonomic grips, body mechanics, and awareness of
and anti-vibration gloves. RSIs

Parameter: Maintenance Intention:
improper ventilation
Raw Risk
S L R
1.1.2. alteration to the structure of 2 2 3 1.1.2.1. Install local exhaust
the mucous membrane lining of the ventilation system
nasal cavity
87
Raw Risk
S L R
asthmatic condition
and cause siderosis
and beryllosis
or short circuit.

Intention: incorrect assembly ,equipment failure,improper use of tools,malfunctioning of temperature control system
Raw Risk
S L R
less/low 1.Wax 1. poor mold design. 1.1.1. Injuries from improper use of 2 1 2 1.1.1.1. Implementation of safe 1.1.1.1. - Provide training to pattern
patterns pattern making tools and equipment operating procedures for pattern makers on the safe use of tools and
with sharp making tools, including proper equipment, emphasizing proper
edges and training and maintenance handling and maintenance practices
protrusions
2.improper 2. contact with hot wax,spilling and 2.1.1. Severe burns and scalding 2 2 3 2.1.1.1. Installation of reliable and 2.1.1.1. - Conduct regular fire safety
handling splashing injuries to workers due to exposure properly calibrated temperature drills and inspections, ensuring the
to high-temperature wax control systems with alarms for availability and proper functioning of
temperature deviations fire prevention and suppression
systems.
2.1.2. Fires and explosions resulting 2 2 3 2.1.2.1. optimize wax pattern 2.1.2.1. Conduct thorough design
from uncontrolled wax injection and designs and minimize sharp edges. reviews and analysis to ensure
ignition sources smooth and rounded edges on wax
patterns, eliminating sharp corners.
2.1.3. Cuts, lacerations, and 2 1 2
puncture wounds from contact with
sharp edges.
88

Raw Risk
S L R
cause collisions.
ladders.

Parameter: Safety
Intention: improper wax storage and handling,ignition source and negligence of electrical system
Raw Risk
S L R
maintenance
of electrical
parts
equipment regularly
Node: 10. shell making

89
Intention: high temperature

Raw Risk
S L R
high/more High- 1. Lack of proper training and 1.1.1. Burns or injuries from contact 2 1 2 1.1.1.1. Establish proper training and 1.1.1.1. Conduct regular training
temperature handling procedures for high- with high-temperature materials. handling procedures for high- sessions on the safe handling of
temperature materials. temperature materials. high-temperature materials.
2. improperTemperature control and 2.1.1. 2 2 3 2.1.1.1. Ensure safe working
equipment maintenance temperatures and equipment
functionality.

Parameter: Level
Intention: more than normal sound
Raw Risk
S L R
high/more high noise 1. continous exposure to higher level 1.1.1. hearing impairment 2 2 3 1.1.1.1. using sound enclosures. 1.1.1.1. quantify the level and
emission of sound involving operation of duration of exposure of workers and
certain machinery and tools compare it with exposure limits
noise.
environment;

Parameter: Reaction
90

Raw Risk
S L R
high/more Exposure to 1. Exposure to hazardous chemicals 1.1.1. Chemical exposure leading to 2 2 3 1.1.1.1. Proper ventilation and 1.1.1.1. Implement a
hazardous (e.g., binders, refractories, skin irritation, respiratory issues, or personal protective equipment (PPE) comprehensive chemical
chemicals solvents). allergic reactions to minimize chemical exposure risks. management program, including
proper handling, storage, and
disposal procedures.
2. exposure to toxic or corrosive 2.1.1. Health hazards 2 2 3 2.1.1.1. Ensure workers are trained 2.1.1.1. enforce chemical safety
chemicals. on proper handling and use of protocols
chemicals
3. Improper handling or insufficient 3.1.1. Respiratory issues and health 2 2 3
use of personal protective problems caused by dust inhalation.
equipment during chemical
operations.

Raw Risk
S L R
low/less improper 1. Dust generation during the shell 1.1.1. asphyxiation or physical 2 2 3 1.1.1.1. Implementation of confined 1.1.1.1. Develop and enforce
ventilation making process. entrapment. space entry procedures, including confined space entry protocols,
system proper training and availability of ensuring proper training, permits,
safety equipment and rescue plans
2. Inadequate control of dust control 2.1.1. Inhalation of dust particles 2 2 3 2.1.1.1. Implement dust collection 2.1.1.1. Regularly inspect and
systems and improper cleaning leading to respiratory issues and systems and local exhaust maintain dust control systems and
procedures. long-term health problems. ventilation to minimize dust ventilation equipment.
generation
3. Insufficient ventilation 3.1.1. risk of cancer of the nasal 2 2 3 3.1.1.1. Fabric filters andInertial
cavity and sinuses separators,Wet
scrubbers,Electrostatic precipitators
3.1.1.2. Install local exhaust
ventilation system
3.1.1.3. Use an efficient dust
collection system (eg CMAXX)
3.1.2. alteration to the structure of 2 3 4
91
Raw Risk
S L R
the mucous membrane lining of the
nasal cavity
asthmatic condition
and cause siderosis

Raw Risk
S L R
cause collisions.
ladders.

Parameter: Safety
Intention: improper ignition source storage and handling, and negligence of electrical system
Raw Risk
S L R
92
Raw Risk
S L R
maintenance
of electrical
parts
equipment regularly
Node: 11. burn out

Intention: high temperature
Raw Risk
S L R
high over or 1. Burnout furnace temperatures 1.1.1. Severe burns and thermal 1 2 2 1.1.1.1. Installation of advanced 1.1.1.1. Regularly inspect and
temperature uncontrolled exceed safe limits due to control injuries from exposure to high temperature control and monitoring maintain temperature control
heating system failure or improper settings temperatures and hot surfaces. systems with safety interlocks and systems to ensure safe and
alarms. accurate operation, and establish
preventive maintenance programs.
2. Inadequate thermal protective 2.1.1. Disfigurement and tissue 1 2 2 2.1.1.1. Provision of high-quality 2.1.1.1. Provide workers with
equipment for workers. damage due to contact with hot thermal protective suits, gloves, face advanced thermal protective suits
equipment and surfaces. shields, and other personal that consider factors like heat
protective equipment (PPE). resistance, comfort, and mobility,
and conduct fit-testing to ensure
proper fit.
2.1.2. Explosions and fires resulting 2 2 3 2.1.2.1. Implementation of strict 2.1.2.1. Develop comprehensive
from improper handling of flammable operating procedures and safety standard operating procedures for
materials and equipment. protocols, including hot work permits, the burnout process, including
lockout/tagout procedures, and thorough equipment checks, pre-
regular safety audits burnout inspections, and emergency
response plans.
Node: 11. burn out

Parameter: Reaction
93
Raw Risk
S L R
high/more chemical 1. exposure to burnout chemicals 1.1.1. skin irritation 2 2 3 1.1.1.1. provide chemical-resistant 1.1.1.1. Conduct regular equipment
exposure gloves/aprons inspections, establish emergency
response procedures
Node: 11. burn out

Intention: control system failure and improper settings
Raw Risk
S L R
low/less control 1. Burnout furnace temperatures 1.1.1. Severe burns and thermal 2 2 3 1.1.1.1. Installation of advanced 1.1.1.1. Regularly inspect and
system exceed safe limits due to control injuries from exposure to high temperature control and monitoring maintain temperature control
failure and system failure or improper settings temperatures and hot surfaces. systems with safety interlocks and systems to ensure safe and
improper alarms. accurate operation, and establish
settings preventive maintenance programs.
2. Inadequate thermal protective 2.1.1. Disfigurement and tissue 1 2 2 2.1.1.1. Provision of high-quality 2.1.1.1. Provide workers with
equipment for workers. damage due to contact with hot thermal protective suits, gloves, face advanced thermal protective suits
equipment and surfaces. shields, and other personal that consider factors like heat
protective equipment (PPE). resistance, comfort, and mobility,
and conduct fit-testing to ensure
proper fit.
2.1.2. Explosions and fires resulting 2 2 3 2.1.2.1. Implementation of strict 2.1.2.1. Develop comprehensive
from improper handling of flammable operating procedures and safety standard operating procedures for
materials and equipment. protocols, including hot work permits, the burnout process, including
lockout/tagout procedures, and thorough equipment checks, pre-
regular safety audits burnout inspections, and emergency
response plans.
Node: 11. burn out

Parameter: Safety
Raw Risk
S L R
94
Raw Risk
S L R
maintenance
of electrical
parts
equipment regularly
Node: 12. pouring and solidification

Intention: material contamination,content other than required
Raw Risk
S L R
3. Liquid metal spilled out in contact 3.1.1. burns, systemic thermal 2 2 3 3.1.1.1. tools should be preheated 3.1.1.1. gas produced from metal
with water.Charging furnace with wet shock, and catastrophic injuries. and dried before use to minimize the furnaces and during metal pouring
ingots or crumbs risk of explosion into mold process
4. When wet tools, molds and 4.1.1. 2 2 3 4.1.1.1. Installation of controlled 4.1.1.1. Provide workers with
materials are in contact with liquid pouring systems with temperature appropriate heat-resistant PPE,
metal. regulation, anti-splash measures ensuring full coverage and
Parameter: Safety protection, and conduct regular fit-
Intention: improper ignition source storage and handling, and negligence of electrical system testing and training sessions on
proper usage.

Parameter: Level
Intention: more than normal sound,vibration and emission
95
Raw Risk
S L R
noise.
environment;
equipment
mounts
96
Raw Risk
S L R
work rate;
radiation.
36°C
blistering

Parameter: Reaction
Raw Risk
S L R
high/more additives 1. addition of additives to improve 1.1.1. splashing 1 2 2 1.1.1.1. tools should be preheated 1.1.1.1. proper sign board should be
reacts with properties sometimes reacts with and dried before use to minimize the installed such that no one other than
molten molten metal or atmosphere risk of explosion intended enter the vicinity of the
metal process
1.1.2. explosion that may cause 1 2 2 1.1.2.1. Refractory linings should be 1.1.2.1. gas produced from metal
severe injuries to worker regularly inspected for wear. furnaces and during metal pouring
into mold process so careful handling
is importnt
97
Raw Risk
S L R
2. uncleaned residue reacts with the 2.1.1. disfiguring, incapacitating or 1 2 2 2.1.1.1. the process should be
additives fatal burns. controlled from the safe distance
2.1.2. Damage to Personal 2 2 3
Protective Equipment (PPE)
2.1.3. Damaging the apparatus and 2 2 3
vicinity

Intention: improper ventilation and surface finishing
Raw Risk
S L R
1.1.2. alteration to the structure of 2 2 3 1.1.2.1. Install local exhaust 1.1.2.1. Regularly inspect and
the mucous membrane lining of the ventilation system maintain electrical equipment,
nasal cavity ensuring proper grounding and
safety protocols.
asthmatic condition
and cause siderosis
and beryllosis
98
Raw Risk
S L R
or short circuit.
grease

Intention: uncontrolled pouring ,improper setup for pouring,improper marking of sharp edges
Raw Risk
S L R
thermal load
a distance
99
Raw Risk
S L R
scratches

Intention: higher than safer limit
Raw Risk
S L R
of melting lead.
100
Raw Risk
S L R
vapors
working shifts

Parameter: Safety
Raw Risk
S L R
maintenance
of electrical
parts
equipment regularly
Node: 13. shell knock-off

101
Parameter: Pressure
Intention: excessive air pressure
Raw Risk
S L R
high/more Excessive air 1. Inaccurate air pressure regulation 1.1.1. Injury from high-pressure air 2 1 2 1.1.1.1. Implementation of pressure 1.1.1.1. Provide proper training to
pressure and control mechanisms. jet contact, causing cuts, abrasions, control devices to limit air pressure operators on safe knock-off
during shell and eye injuries. during knock-off operations. procedures and handling of high-
knock-off pressure equipment.
process
1.1.1.2. Conduct regular
maintenance and calibration of air
pressure control systems to ensure
safe and controlled knock-off
operations.

Parameter: Level
Intention: more than normal sound,vibration
Raw Risk
S L R
emission of sound involving breaking of shell duration of exposure of workers and
and Inadequate noise control compare it with exposure limits
measures or absence of hearing
protection.
noise.
environment;
102
Raw Risk
S L R
equipment
mounts

Parameter: Addition
Raw Risk
S L R
time.
3. Repetitive work and tasks with 3.1.1. Repetitive work and tasks with 2 3 4 3.1.1.1. Temporary work phases 3.1.1.1. Provide workers with
little variety little variety and/or few events may should be checked and temporary ergonomic tools and adjustable
103
Raw Risk
S L R
lead to boredom and errors being workers informed. workstations to minimize physical
made. strain and fatigue.
4. Poor workstation design and lack 4.1.1. Musculoskeletal disorders 2 2 3 4.1.1.1. Ergonomically designed 4.1.1.1. Implement regular training
of ergonomic considerations. from repetitive motions and poor workstations and tools, including sessions on proper lifting techniques,
ergonomic conditions. adjustable tables, ergonomic grips, body mechanics, and awareness of
and anti-vibration gloves. RSIs

Parameter: Reaction
Raw Risk
S L R
high/more Exposure to 1. exposure to toxic chemicals or 1.1.1. skin irritation, chemical burns, 2 2 3 1.1.1.1. Establish proper storage 1.1.1.1. Ensure compliance with
hazardous corrosive substances. and handling procedures for safety protocols for chemical
chemicals chemicals, including labeling and handling and storage.
without ventilation.
appropriate
2. exposure to shell knock-off 2.1.1. 2 2 3
control
chemicals
measures

Raw Risk
S L R
1.1.2. alteration to the structure of 2 2 3 1.1.2.1. Install local exhaust 1.1.2.1. Implement comprehensive
the mucous membrane lining of the ventilation system dust control measures, including
104
Raw Risk
S L R
nasal cavity regular cleaning, use of personal
protective equipment (PPE), and
proper disposal of dust waste.
1.1.4. manifest itself as a skin rash, 2 2 3 1.1.4.1. Installation of dust collection
inflammation or as an systems and local exhaust
asthmatic condition ventilation to minimize dust
generation.
and cause siderosis
and beryllosis
or short circuit.
grease
105

Intention: mechanical hazards
Raw Risk
S L R
low/less improper 1. Lack of means of shielding, 1.1.1. Falling into or entering the 2 2 3 1.1.1.1. platforms and walkways 1.1.1.1. sufficient safe clearance to
scratches
of
instruments
while handling
time.
106
Raw Risk
S L R
equipmen

Raw Risk
S L R
cause collisions.
ladders.

Parameter: Safety
Intention: negligence of electrical system and no obstruction from flying objects
Raw Risk
S L R
low/less no 1. entanglement, pinch points, and 1.1.1. leading to property damage 2 2 3 1.1.1.1. control the process from 1.1.1.1. make sure workers other
obstruction impact injuries and potential harm to personnel. distance than involved should not enter
from flying strictly
objects and
non
maintenance
of electrical
equipment regularly
107
Worksheet
Raw Risk
S L R
parts 3. .Mechanical hazards 3.1.1. damaging apparatus in vicinity 2 2 3 3.1.1.1. create the protective barrier 3.1.1.1. properly training workers in
the risk involved
3.1.2. can make worker to loose 2 1 2 3.1.2.1. provide appropriate safety 3.1.2.1. proper supervision and
Node: 14. cut-off and finishing

Parameter: Level
Intention: more than normal sound,vibration
Raw Risk
S L R
noise.
environment;
equipment
Generated using PHAWorks Lite

108
Worksheet
Raw Risk
S L R
mounts

Parameter: Reaction
Raw Risk
S L R
high/more chemical 1. Lack of awareness and 1.1.1. chemical burns or sensitization 2 2 3 1.1.1.1. Use of appropriate PPE, 1.1.1.1. Conduct comprehensive risk
exposure compliance with safety protocols for including respirators, gloves, and assessments of finishing chemicals
and potential chemical handling protective clothing. and provide suitable PPE based on
health their hazardous properties.
effects
2. Skin contact with corrosive or 2.1.1. 2 2 3 2.1.1.1. Establish proper storage 2.1.1.1. Ensure compliance with
toxic substances and handling procedures for safety protocols for chemical
chemicals, including labeling and handling and storage
ventilation

Intention: improper ventilation system
Raw Risk
S L R

109
Worksheet
Raw Risk
S L R
of loose sand
asthmatic condition
and cause siderosis
and beryllosis
or short circuit.

110
Worksheet
Raw Risk
S L R
grease

Intention: improper cutting tool design
Raw Risk
S L R
low/less improper 1. Lack of means of shielding, 1.1.1. Falling into or entering the 2 2 3 1.1.1.1. platforms and walkways 1.1.1.1. sufficient safe clearance to
scratches
of
instruments
while handling

111
Worksheet
Raw Risk
S L R
time.
equipmen

Raw Risk
S L R
cause collisions.
ladders.

Parameter: Safety
Intention: improper safety cover ,negligence of electrical system

112
Worksheet
Raw Risk
S L R
low/less no 1. entanglement, pinch points, and 1.1.1. leading to property damage 2 2 3 1.1.1.1. control the process from 1.1.1.1. make sure workers other
obstruction impact injuries and potential harm to personnel. distance than involved should not enter
from flying strictly
objects and
non
maintenance
of electrical
equipment regularly
parts
3. .Mechanical hazards 3.1.1. damaging apparatus in vicinity 2 2 3 3.1.1.1. create the protective barrier 3.1.1.1. properly training workers in
the risk involved
3.1.2. can make worker to loose 2 1 2 3.1.2.1. provide appropriate safety 3.1.2.1. proper supervision and

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EVALUATION OF SAFETY PRACTICES

IN FOUNDRY INDUSTRIES USING

DEPARTMENT OF CHEMICAL ENGINEERING

Place: NITK-Surathkal Mr. Neelakanthraddi B Patil

Engineering NITK, Surathkal

Dr. Raj Mohan B. Dr. P E Jagadeeshbabu

Neelakanthraddi B Patil (212ES024)

Table 2.2 Effect of foundry hazard on workers .............................................................................. 27

Table 3.1 Risk Grid......................................................................................................................... 36

Table 3.2 Likelihood Ranking ........................................................................................................ 36

Table 3.3 Severity Ranking............................................................................................................ 36

Table 4.1 Node points for Shell Mold Casting ............................................................................... 40

Table 4.2 Node points for Investment Casting ............................................................................... 40

Table 4.3 Node points for Centrifugal Casting ............................................................................... 41

Table 4.4 Node points for Gravity Die Casting .............................................................................. 41

Table 4.5 Node points for Pressure Die Casting ............................................................................. 41

Table 4.6 Node points for Plaster Mold Casting ............................................................................. 42

Table 4.7 Node points for Sand Mold Casting................................................................................ 42

Table 4.8 Overview of worksheet for sand casting......................................................................... 46

Table 4.9 Overview of worksheet for Investment casting .............................................................. 46

Table 4.11 Risks for Sand casting................................................................................................... 47

Table 4.13 Risks Investment casting .............................................................................................. 48

Figure 1.2 Green sand mold (Ghubade & Kumar,

1.1.1 INVESTMENT CASTING

1.1.2 PLASTER OF PARIS MOLDING

1.1.3 DIE CASTING:

1.1.3.1 GRAVITY DIE CASTING

1.1.3.2 PRESSURE DIE CASTING

1.1.6 SHELL MOLDING:

1.2.1 Conduct thorough hazard assessment and monitoring programs

Conducting a comprehensive hazard assessment is crucial in order to identify potential

1.2.2 Workers should wear proper safety equipment and clothing

1.2.3 Minimize the effect of heat :

1.2.4 Reduce the moisture content :

Thorough equipment inspection is essential prior to use, ensuring proper functionality

1.2.6 Provide Adequate education and Training for workers

1.2.7 Prevent and Minimize Harmful Vibration:

1.2.8 Monitor Noise Levels

Effective management of noise risks in a foundry involves implementing various

1.2.9 Reduce the Risk of air borne contaminants Exposure

1.2.10 Perform health assessment for workers

1.3 METHODS OF RISK ASSESSMENTS

1.3.4 Bowtie Analysis

1.3.6 Fault Tree Analysis

2.1.1 Heat Exposure:

2.1.2 Hazardous Chemicals:

2.1.3 Airborne Contaminants:

2.1.7 Molten Metal

2.1.8 Plant And Machinery

S.no. Hazard Effect on workers

S.no Name Description Potential Hazards

1 Pattern/to Manufacturing the Woodworking machinery, Metal working

6 Removal Removing the Noise, Dust, Fumes, Heat, Sharp edges,

11 Material Handling Manual/mechanical handling, Sharp edges,

➢ Possibility of degradation/decomposition of raw materials,

➢ Possibility of a failure of the human factors,

➢ Possibility of an exothermic runaway of reaction, decomposition hazard from the raw

➢ Possibility of undesirable side reactions,

➢ Possibility of a utility failure (Kotek & Tabas, 2012).

The HAZOP analysis process is executed in four phases :