Application of Systems-Theoretic Process Analysis and D-HiGraph Modeling for Risk Analysis in a Continuous Casting Machine
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Date
2026-01-31
Journal Title
Journal ISSN
Volume Title
Publisher
International Journal of Safety and Security Engineering Vol. 16, No. 1, January, 2026, pp. 43-53
Abstract
Continuous casting machines (CCMs) play a crucial role in steel production, but their
complexity and high level of automation pose significant challenges to ensuring
operational safety. This study explores a combined approach using Systems-Theoretic
Process Analysis (STPA) and D-HiGraph modeling to identify and better understand
potential hazards in a CCM unit. STPA is used to define possible losses, hazards, and
unsafe control actions (UCAs) within the system. To support the analysis, a control
structure model is developed using D-HiGraph, which provides a clear, hierarchical view
of how controllers, sensors, actuators, and human operators interact. The results highlight
several critical UCAs, particularly in areas such as mold level regulation, adjustment of
withdrawal speed, and emergency shutdown procedures. By visualizing these
relationships with D-HiGraph, it becomes easier to trace the origin of unsafe scenarios
and gain deeper insight into system behavior. Overall, this integrated method offers a
structured and effective way to improve safety analysis in CCMs and contributes to more
robust design and operational strategies in steelmaking environments.