Identification and assessment of hazard in the Refractory Brick Production Company of Gonabad, Iran, using the hazard and operability technique

Abstract

Background: In the refractory brick manufacturing industry, because of the high risks associated with the level of dust in the factory environment and thermal stress, a precise identification of industrial hazards is required as a part of safety analysis. The aim of this study was to introduce a preventive approach to risk identification and assessment in the refractory brick production line. Materials and Methods: In this paper, methods such as observation of factory operations, process analysis through the factory diagrams, and interviews with employees were used. In addition, the risk levels of the factory were investigated using the risk matrix. Results: The results of the study showed 97 deviations from the main process with various causes and consequences. None of the deviations were in the unacceptable category with 3.09% falling in the undesirable category, 3.09% in the acceptable but in need of revision category, and 92.78% in the acceptable category. Conclusions: The results showed that 40.2% of the risks were caused by human errors. The installation of a secondary control valve in the transfer route of the glue vapors to the workplace, an alternative pressure control system, a secondary ventilation system, several fans near the furnace (redundancy), and a real-time phenol monitor are recommended. Moreover, regular analysis of safety, health, and environmental risks are some of the recommendations proposed to reduce the identified risk level.