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BFG Safety How To Prevent
BFG Safety How To Prevent
When some portion of a gas line is to be isolated for repairs, aublank plate
must
be inserted, even if the valve or valves are closed.
All steam points, bleeder pipes and valves should be pre-checked before
blanking or deblanking job in the gas line. The first steam point should be near
to the place of blanking or deblanking. Gas, steam and air should freely pass
through bleeders.
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when small furnaces are not in operation the pair of valves before the burner
should be closed and the bleeder between them should be kept opened. if this
system does not exist, a blank must be inserted alter the valve.
The gas equipment, water drainers etc. should be inspected periodically by
competent persons. All joints, valves, cocks, and water seal should be free from
leakages. Gas leakage should be rectied immediately and in the meantime no
body should be allowed to stay in that area.
Checking for leakage of gas should only be done by soap solution or by Garbo
Monoxide gas monitor. '
F-or welding jobs on gas lines, it must be done only after a blank plate is
inserted
before the piece where welding is to be done and the line has been steamed
out and proper sample analysis has been carried out.
All gasmen and workers dealing with gas equipments should be regularly
trained in using gas masks, first aids (including articial respiration)
"Gas Danger or Caution Boards should be xed at all the gas dangerous
those who are required to work in gas hazardous places and all those who
connected with the maintenance of gas lineslequipment and operation of
red furnacesfdryirrg ovens must undergo basic and refresher course in
Safety Practices.
For all daily routine jobs in the shops a job card should be lled up before
starting the work. Such job cards are issued by Gas Safety Section and
available with Gas Safety Man/Gas Safety station attending the job.
All shop in-charges snail arrange to draw out emergency plan and day to day
operational instruction in connection with use of gas in their shops, which
should be made available in the control roomslproduction control, all the time.
A systematic scheme of gas lines in the shop indicating all the valves,
throttles,
bleeders, water drainers, position of steam points and position of isolating
point
should be displayed in the control room, Such a scheme helps in a normal work
as well as in emergency situations.
Avoid the formation of expiosive mixture by purging the gas main with steam or
Nitrogen .
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Prevent the suction of air into the gas main under all circumstances.
Routine maintenance of gas lines, taking quick action for stopping ieakages
when found, proper ventilation of enclosed spaces quick steam ooding
' arrangement and good house keeping help to prevent explosion.
No gas job shouid be carried out in night hours unless in case of breakdowns or
emergencies.
Explosion proof eiectric lights must always be used for the inspection of inside
of gas mains and furnaces and enclosed spaces where traces of gases are
likeiy to be present.
A manometer should installed in the gas line on which work is going on under
reduced gas pressure. it should preferabiy be nearest to the point of work.
Persons engaged in the gas job must wear cotton cloth, hand gioves, safety
shoes, helmets, goggles, re resistance suit, etc. '
Gas job should not done in the premises which are not well ventilated or which
are close to running furnaces.
The area of work during gas job should be properly cordoned otf and entry of
unauthorised persons should not be aliowed
in case of emergency if gas job is under taken in closedisemi ciosed area
monitoring of gas concentration must be ensured.
(ii)
if the pressurefalls below the above mentioned safe limit, there are chances of
Proper plan of work should be drawn out by the department concerned with the
job (owner of the assets).
(a) For repetitive work, the plan should be drawn up by the shop. Where
necessary,
the expert agencies should be consulted. T ~
(b) For new jobs (Non-repetitive), this plan should be-scrutinized by the Chief
of
i Energy Management, Chief of the Fire Services and Chief of Safety.
(o) The plan should be drawn up well in advance. The plan of work should ensure
proper (1) isolation (ii) Purging (iii) Ventilation (iv) Sampling and clearance
(v)
Supervision.
A scheme of gas line under consideration should be appended with the plan of
work. it should show the locations of blanking, branches, bleeders, valves
(size)
steaming points (size and Nos), sampling points, diameter and total length of
the pipe
to be purged.
!SOLATlON
The isolation of the gas line is completed by the goggle valve operation or by
U
Seal water lling or by inserting a blank plates at predetermined locations with
proper
plan. The work involves special technology of work and special preparatory jobs,
like (i)
size and type of blanks ' (ii) good working platforms with escape routes (iii)
arrangement for lifting the blanks and jacking for making the gap (iv) use of
non
sparking tools during working (v) adhering to the goggle valve operation check
list.
IN CI-\SE_ OF U--SEAL ISOLATION
a) Overflow of water in U-Seal outlet must be ensured.
b) If the shutdown is for the longer duration a blank plate should be
inserted on the non gas side.
o) isolating anges and bleeder should be provided on both sides of the
U-Seal.
IN case or ocean: VALVE ISOLATION
1.
The Stearrilhiitrogen is to be closed and after it replaced by air, samples are
to
be drawn from suitable locations. Suction tube of the sampling equipment
shouid be inserted well inside the pipe and sampie should be taken from upper
part of pipeline for gases lighter than air, and lower part for gases which are
heavier than air.
Sampies are to be tested for explosive mixture by explosimeter. it should be
tested for carbon monoxide (0.05 mg./liter maximum) and analysis for oxygen
content (20.6% minimum).
Samples are to be taken again and the analysis is to be repeated if the sampie
is abnormal.
When steam is available near the place where outtinglwelding job is to be done,
as an additional safety measure, steam ow in the pipeline may be
maintained.
_ Cautions _:
Sampling and testing equipment for gas testing should be in good condition.
Final clearance for the job including cuttingfwelding will be given in the given
proforma when purging, ventilation and test resuits are quite satisfactory as
ascertained by joint inspection of Energy Management Deptt, Shop
representative, executing agency, Safety and Fire Department.
The sequence of jobs should be followed rigidly.
' 2) No operation should be conducted in haste, which will jeopardize
safety. ~
3) Night operations should be avoided unless in cases of
' ' emergency.
4) No work should be taken up till the clearance is clearly given and
accepted by authorised person. All personnel except working
group for cutting operations, to be removed from the entire area.
5) isoiated equipment or main shouid be monitored for leakage till
recharging and this should be logged.
6) The departments will maintain iist of authorised persons.
SUPERV|SlbN
The overall supervision will be under one Otticer earmarked for the job by the
concerned department.
Specic tasks would be assigned to particular persons, by name when possible
and by Designation in all cases.
A log book should be maintained to show the progress of work and
determination of the end point of purging. All important operations connected to
the shutdown, when this extends over more than one shift, should be
logged. NERAL LIGHTING UP FROG DURE FOR FU N C
GE E 3&1-:s
' iii.
Ensure a) Burner gas valves are fully closed.
in) Main isolation valve is fully closed.
c) Chimney damper is fully opened.
d) Furnace doors are fully opened for ventilation.
e) Chimney is having sulcient draft.
Open steantlhlg In the gas main and purge through and bleeder.
DE.Dlal"lK the Isolation pim.
N. Open the main isolation valve and charge the header with gas.
V. Close all the steamlhlitrogen points and disconnect them. _
VI. V" Purge the header with gas through the end bleeder.
VII. Take gas sample which should show Oxygen less than 1%.
Vlll. start air blower, keeping rt at minimum level.
IX. Place a burning torch in front of the bumer.
X. Open the bumer valve and adjust the flame.
L\_gwAYS
* Follow the procedures strictty.
* Keep the chimney damper opened.
* Keep the burning torch in front ofthe burner before opening the gas
* Close the burner valve if the torch extinguishes.
Repeat the procedure again.
GENERAL SHUTDOWN PROOEQURE FOR Fgegncgs
' I. Close gas burner valves.
ll. Stop the air blowers.
lll. Keep the chimney damper fully opened.
IV. Close the isolation valve of the furnace.
V. inject steamlhlitrogen in the gas main.
Vi. Blank the isolation point.
period. _
Vlll. Ventitate the furnace properly.
ix Take samples from the isolated gas tine which should show
Oxygen minimum 20.6%
Carbon Monoxide maximum 0.05 mglltr.
ALMQ
* FOLLOW THE SEQUENCE STRtCTLY.
* PURGE THROUGH END BLEEDERS.
Vll. Purge the header with etearnlN2 through the end bleeder for a suitable
INDEX
8. No. Particulars Page No
1. Prooerties of gases 1 3
2. Gas Hazards 3 6
3. Gas Safety Rules 6 - 8
4. Safe system work procedure & 8 13
protocol for gas hazardous gobs
5. Guide lines for protocol for gas 14 - 15
hazardous work
6. General gas safety precautions 15 16
required for gas line repair
( isolated I Live lines )
7. Standard maintenance practices '16 - 18
(SMP) for live 1 isolated gas lines
8. Gashnecomponmsands 18-22
aooessoes
OTH
10.
11.
12.
13.
U5 6 :~
Drawings, sketches and other technical documents to be attached, wherever
necessary. #Check list for the safe execution of the gas job to be attached separately with
the protocol. It should include all the necessary check points related to the
jobs
;.._.,and should be signed. (by all concerned) just before the start of the job.
it would
help in counter checking all the activities so that no point is overlooked.
GENERAL GAS SAFETY PRECAUTlON FOR GAS LINE REP-Al max
SOLATED / LIVE LINES)
Fire brigade should be on stand by duty for live gas line repair jobs, and if
required for isolated gas line repairjob.
All live repair work should preferably be carried out in day light hours only.
Safety appliances as prescribed by SEC) should be used by the working group.
During liftingipositioning of the cladslplpes, the nearby acoessoriesfpipelines
should not be damaged. if required additional structural supports should be provided for the
replacement
of gas pipe lines in consultation with designer. All the lilting devices, slings, ropes etc. should be properly tested and
ensured
before using them.
All the repair work shouid be carried out under proper guidance and
supervision.
All welding transformers should be property earthed and cable properly
V insulated.
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15.
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For live line repair job, leakage arresting tools should be made available at
the
spot.
Welding cable joint should not touch nearby auxiliary lines.
Only experienced welders should be deployed for working on gas iines.
Oxygen and [).A. cylinders shouid be kept away so that while
cuttinglwelding spark should not fail on them.
STANDARD MAINTENANCE PRACTICES [EMF] F-QR LIVE I[8OI:[Q
GAS LINE
is) sMP's for isolated gas line
1.
10.
11.
Purge the isolated gas line from blank to end bleeder of line with steam I
nitrogen for sufficient time.
[After purging, open manholes, bieeders, end anges as per sitecondition.
After thorough ventilation of line, take bieeder sample from inside the pipe
line
from -as many locations as possible and aiso test with expiosimeterf
if the sample is as per norm (Oxygen = 20.6%, C0 <==0.D5 mgflt), clearance
can be given for cuttinglwelding in the prescribed form. '
in case, cutting ofupipe line is planned water spraying should be done from the
nearby manhole! or by cutting pocket where as for welding slight steam I
nitrogen should be kept on.
in bigger size of pipes (1500 die. and above) minimum one round Inside and
two round outside welding should be ensured. While welding from inside. proper
ventilation should be ensured.
As far as possible air circulation inside pipe line should be avoided by closing
manhoieslend ange 8: putting inert media during cuttingfwelding.
While welding new pipelcompensator with old pipe, the matching portion should
be free of any deposits.
During cuttinglwelding of gas line depending upon site conditions ettorts should
be made to remove muck from the gas line.
Cladding on isolated gas line should be done in presence of. inert media to
avoid spontaneous combustion of deposits.
After the completion of repairrreplacement work of pipe line, ail opening should
be closed for leakage testing.
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l4.
15.
16.
I7.
18.
I9.
20.
21.
22.
Gas line should be tested with steamlairfnltrogen. in case of nitrogenlair soap
solution should be applied and if steam is used it should be ensured that all
welded joints are coated with lime.
g..After.identlcation of leakages manholes near blank should be opened and
sample should be checked for leakage.
Re-welding of defective portion should be done preferably in presence of inert
media.
Retesting should be done after rectification of defect by following the previous
i mentioned methods.
If there is any interconnection of water drainer, breeders, steam connections
and
impulse lines of two different gases, it should be isolated by inserting a blank
plate. Sampling should be carried out, while doing job near blank point.
if blanking is done before valve, the valve should be kept open to release the
gas pocket between blank and gate. .
Cuttinglwelding and smoking by unauthorized persons should not be done near
isolated gas line.
Locallsed "l3LJND can be formed with sandbagsfbricl-cs in order to keep the
water level maintained inside pipeline in case re travels in gas lines.
While cutting pipe near blank, the isolating flanges should be welded in order
to prevent gas leakage due to release of pipe tension.
To provide support to auxiliary lines area sample should be checked.
lb) SMP's for live gas line
I .
if leakage is observed, it should be plugged and area sample should be
ensured for safe working.
Prepare half oladlpatch as per the profile of the gas line.
While welding on gas lines low current is preferred, so welding transformers
should be checked for proper regulation of current.
Pipe line thickness of defective area must be measured before the start of job,
this will help in arranging proper size of cladlpatchlelectrodes. Besides this,
it
will also help in proper regulation of welding current.
Only experienced and trained welders should be allowed to work, as the line will
be in charged condition.
As the oas line is charoed-. lob should be done onlv durino dav Iioht hours.
10.
11.
12.
I3.
14.
15.
16.
'17.
18.
19.
Cladfpatch should be properly positioned and welded without excessive
hammering on gas line.
As far as possible clad should be welded to the fully welded ribs.
rails. For proper draining of water the slope of gas line towards the nearest
drain pot
should 5 mm. Per metre length of the pipe.
Accessories of gas line :
Compensators
Water drainers
Bleeders
isolating facilities
Buttery valve
Orice plate .
Rupture disc I Pressure relief valve
9. Manholes & hand holes
10. End anges lsteam I Nitrogen points
12. Flanges I Packings I Saddle supports etc.
13. Goggle Valves
_~.C.U.1=-S'-'Nr*
1. COMPENSATOR5
These are installed on gas lines to take care of axial expansion and contraction
of gas line. During the gas job these compensstcrs help in giving way for gap
which is
necessary for manual insertion ltaking off of btank plate.
The following two type of cornpensators are generally used on gas lines :a) Slip joint or gland type compensator for Coke Oven gas line.
13) Disc type compensator for Blast Furnace gas and Mixed gas line.
in disc type compensators drain valves should be provided at the bottom
portion, for draining out condensate at regular intervals. This will improve the
life of the
compensator.
2. warren crwueas
These are installed on gas line at the end of slope of the gas line or at
location
where water accumulation is suspected. Minimum height of the water in the drain
pot
shall exceed by 500 mm. Over the maximum working pressure. Also no water drainer
condensate pipe line should be interconnected. Regular steaming of water drainer
will
prevent the choking of clrainers.
Problems due to poor upkeep of water drains-rs are z
a) Gas leakage due to puncture in drainer body or its accessories.
1)) Gas pressure fluctuation due to water accumulation.
c) F-ast corrosion of gas line. '
3. BLEEDERS i
These are installed in gas line to discharge gas or steaminitrogen mixture
during charging or shutdown of gas lines. Their location depends upon the layout
of the
gas line keeeine in view the era-oer charging/oureina of ass line. i
These shall be installed as per :A)
a) Selection of bleeder shall ensure 5 times discharge of the gas
volume in 10-30 min.. They shali be more than 19 mm. in
diameter.
b) The bleeder shalt be located above the roof level more than 4
metre. *
c) For inter plant pipe line the height of the bleeder on gas line shalt
be more than 4 metre from the gas pipe upper axis. The exit point
of bieeder on gas line shail be at a height not less than 12 metres
from the ground.
d) Bleeder pipes of different gases shall not be connected through a
common vent.
e) Design of the top of the bleeder shall protect against falling of
y atmospheric dust. The bleeder shall also have point for coilection
of gas samples.
ISOLATING FACiLlTlES
Gate Vaive :- These are used to isolate a certain portion of gas line from main
gas iine. Regular greasing of spindle, protection of the same from the dust and
revisioning of valves during capital repair wit! keep the vaive in good working
condition.
Maintenance tike cutting I welding on such gas line is done onty after the
menus! blanking I goggle valve turning by closing the gate valve.
3)
C)
Ggmgle yalve :- These are remote operated isolating valve. The closing of
goggte valve ensure 100% isolation of gas line.
Advantages of goggle valve over gate valves are :~
1. 100% isolation of gas main.
2. Spread of gas leakage for shorter duration.
3. Very iess manpower is required.
"U Seal :- This is the safest method for 100% isolation of gas line. By lling
the
water in USeal to create a water column, the gas main is isolated in a very
short duration. T
Advantages of USeal are :1. No gas realqage in atmos here.
2-. 103 /o isolation of ass ltn -.
Hand holes are given on bends and smaller dia. Pipe lines for cleaning, flushing
and ventilation of gas line.
9. END FLANGES I STEAM I NITROGEN INSPECTION POINTS
End flanges as the name suggest are located at the end of gas line. These are
opened during shut nlrawn for ventilation of ems: tine2'?
The steam I nitrogen points are given after every blanking location or at places
where gas pocket accumulation is suspected. These are used for purging the gas
from
gas line.
10. FLANGES I PACKINGS I SADDLE SUPPORTS
Flanges are used with all type of isolating valves, buttery valves,
compensators,
orice plate etc.. After gate valve and goggle valve a separate isolating anges
should
be given for quick and safe isolation purpose. .
in gas line graphited asbestos rope packing or permanite packing is given to
seal the gas leakage. This should be properly greased to prevent them from
getting
dried up. White asbestos rope socked in salt water is used at places, which are
exposed to high temperature.
Saddle supports are given after every isolating valve, compensator and at
regular distances to support the gas line with Ferro concrete columns. The
saddle
suppoits should be of roller type so that the gas line does not get damaged
during gas
job or at times when gas line expand or contract linearly due to varying
temperature.
..,-;-- - _.f,,,
PROGRAMME SCHEDULE
SESSIONS TOPiC
1
TIME
Steel Plant Gases and
Their properties
Gas Hazards
Safe system work procedure
8. protocol for gas hazardous jobs
L U N C H B R E A K
Gas Safety Rules & SNIPS
Gas Line Maintenance
Group Discussion and Presentation
Summing up I Feed back
09:00 -10:30 AM.
10:30 - 11 :45 AM.
11 :45 - 01:00 PM.
01:00 - 02:00 PM.
02:00 - 03:30 PM.
03:30 - 04:30 PM.
04:30 - 05:30 PM.
05:30 - 06:00 PM.
1 . PROPERWES OF GASES
Fuel gases having sufcient caloric value are used for heating purposes in
different Furnaces, Stoves, Coke Oven Batteries etc.. The danger involved in
handling
such gases are Fire, Explosion and Gas poisoning. Improper handling of such
gases
may lead to hazardous conditions hampering the production flow and may also
result in
loss of human life.
One should always remember that GAS IS A GOOD SERVANT IF HANDLED
PROPERLY, BUTA BAD MASTER IF HANDLED IMPROPERLY".
SOME CAUSES OF GAS LINE ACCIDENTS
- - KENORANCE
- LACK OF SERIOUSNESS
- SLACKNESS 1N SUPERVISION
- IM PROPER COMMUMCATION
- OVER CONFIDENCE
- NON ADHERENCE TO THE LAID DOWN PROCEDURE
TYPICAL ANALYSIS *8: PROPERTIES OF THESE GASES ARE GIVEN BELOW:
..::u_
CONSTITUENTS B.F.GAS COKE OVEN GAS L.D.GA$
(la By Volume) (A By Volume) (% By Volume}
1. Carbon 2730 6-7 65-67
Monoxide (CO)
2. Carbon 9-1 5 243 I 5-20
Dioxide (CO2)
3. Hydrogen (H2) 1 .5-2 55-80 2-3
4. Methane (CH4) 0.3-0.5 25-28 ~
5. Nitrogen (N2) 55-58 6-8 15-20
6. Oxygen (O2) 0.5 0.3-0.5
PROPERTHES 2
B.F.gas may be present :a) Blast Furnace Cast House, Hoist House and Dust Catcher
b) Stoves Area
:2) Blast Furnace Top
Cl) Gas Cleaning Plant
e) Gas Boosting Station
f) Areas close to B. F. gas lines and BF. gas equipments
such as drip pot, goggle valves etc.
g) Consumer Deptts. '
COKE OVEN GAS 1