Abstract
This paper provides guidance to key techniques and methods used in the EDM process industry for identifying and documenting environment, safety, and health (ESH) hazards and theircontrols.This is first time that the brainstorming method “what-if” analysis,one of the well-known process hazard analysis (PHA) techniques, is used to predict hazards in electrical discharge machining (EDM) processes. This technique analyzes potential causes and consequences of fires, explosions, releases of toxic or flammable chemicals and major spills of hazardous chemicals, and focuses on fluid system, machining system, electrical & instrumentation system, utilities, human actions and external factors that might impact the process. This analysis helped to identify conditions that can lead to an accident situation and recommendations are givento overcome the risks of these situations. An exhaustive analysis in the EDM process to identify and analyze hazards is presented in this paper and control recommendations are provided to overcome the risks of these hazards.
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