A TRAINING PROGRAMME ON

GAS SAFETY
FOR
Southern Iron and Steel Company
Limited
(from 06109/2004 to 08/09/2004)

Organised By
ENERGY MANAGEMENT
DEPARTMENT

BHILAI STEEL PLANT

STEEL AUTHORITY OF INDIA LIMITED

INDEX
S. No.

Particulars
Page No.

1.

Properties 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 jobs

5.

Guide lines for protocol for gas

14 - 15
hazardous work

6.

General gas safety precautions

15 - 16
r
e
q
u
i
r
e
d
f
o

r
g
a
s
l
i
n
e
r
e
p
a
i
r
(
I
s
o
l
a
t
e
d
/
L
i
v
e
l
i
n
e
s
)
7

Standard maintenance practices

16 - 18
(S MP) for live / isolated gas lines

8.

Gas line components and its

18 - 22

accessories

PROGRAMME
SCHEDULE

SESSIONS TOPIC
TIME

1.

Steel Plant Gases and

09:00 - 10:30 AM.
Their properties

2.

Gas Hazards
10:30 - 11:46 AM.

3.

Safe system work procedure

11:46 - 01:00 PM.
& protocol for gas hazardous jobs

LUNCH

4.

BREAK
01:00 - 02:00 PM.

Gas Safety Rules & SMPs

02:00 - 03:30 PM.

5.

Gas Line Maintenance

03:30 - 04:30 PM.

6.

Group Discussion and Presentation

7.

Summing up/Feed back

06:30 - 06:00 PM.

04:30 - 05:30 PM.

1.

PROPERTIES OF GASES

Fuel gases having sufficient calorific 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 BUT A
BAD MASTER IF HANDLED IMPROPERLY".
SOME CAUSES OF GAS LINE ACCIDENTS
IGNORANCE
LACK OF SERIOUSNESS
S
L
A
C
K
N
E
S
S
I
N
S
U
P
E
R
V
I
S

I
O
N
I
M
P
R
O
P
E
R

NM

C
O
M
M
U
N
I
C
A
T
I
O
N
OVER CONFIDENCE
NON ADHERENCE TO THE LAID
DOWN PROCEDURE

TYPICAL ANALYSIS & PROPERTIES OF THESE GASES ARE

GIVEN BELOW:

CONSTITUENTS

B.F.GAS

(% By Volume)

1
2
3
4
5
6

Carbon Monoxide (CO)

2. Carbon Dioxide (CO2)
Hydrogen (H2)
Methane (CH4)
Nitrogen (N2)
Oxygen (02)

27-30
9-15
1.5-2
0.3-0.5
55-58
0.5

L.D.GAS

(% By Volume)

6-7
2-3
55-60
25-28
6-8
0.3-0.5

COKE
OVEN
GAS
(% By
Volume)

65-67
15-20
2-3
15-20

PROPERTIES :
''''BtJrns
with

B.Fce.
E
x
pl
o
si
v
e
R
a
n
g
e
D
e
n
si
ty
C
al
or
ifi
c
V
al
u
e

C.O.

40-70%
6-30%
.'(
1.33 Kg/NM3
Kg/Nm3

0.46

800 KCal/Nm3
K.Cal/Nrn3

4300

Very poisonous
Poisonous,
Colourless
explosive,
Odourless

Slightly
Highly

Colourless Typical
smell
of
hydro
gen
sulphi
de
and
Naphthale
ne
Blue flame
flame
Heavier than
than
air

Yellow
Lighter
air

poisonous
Colourless,
Odourless

L.D.
20-70% (By Volume)

1.37 Kg/Nm3
B
lu
e
fl

1800 K.Cal/Nm3
Dea
dly

S
O
U
R
C
E
S

O
F

O
A
S
E
S

a
m
e
H
e
a
vi
er
th
a
n
air

B
L
A
S
T

F
U
R
N
A
C
E

G
A
S

:
B.Figas is generated in Blast Furnace where Coke
is burnt to produce
heat and reducing gases, B.F.gas contains 27-30% by
volume
of
Carbon

Monoxide. Workers engaged in the concerned areas can

get exposed to its hazards. Following are the gas
hazardous areas where B.F.gas may be present :a) Blast Furnace Cast House, Hoist House and Dust
Catcher
b) Stoves Area
c)
Blast Furnace Top
d) Gas Cleaning Plant
e) Gas Boosting Station
f)
Areas close to B.F.gas lines and B.Fgas
equipments
such as drip pot, goggle valves etc.
g) Consumer Deptts.

COKE OVEN GAS :

It is a by-product of Coke Ovens and the
percentage of Carbon
Monoxide ranges from 6 to 7%. Following are the areas where this
pas may be present
a) Coke Oven cellars
b) Coke Oven top

c) Old as well as New By-Product Plants

d) Main Boosters and Exhauster Houses
e) Area close to C.O. gas lines, drip pot, goggle valves
etc.
f) All instrument control cabins in the Coke Oven and ByProduct Plant
g) All C.O. gas consumers in plant

CONVERTOR GAS :
This gas is generated at Converter Shop in the L.D.
Converter during the
Steel Melting Process. it contains about 65 to 67% of
Carbon Monoxide by volume. it is used after mixing
with Coke Oven Gas. Following are the important
areas where this gas may be present.
a) Converter Shop l.D.Fan room, Valve changing station
etc.
b) L.D. Gas Holder
c) Entire Converter Gas piping and its accessories.
d) Gas Mixing and gas booster station.
2.

GAS HAZARDS :
FIRE
EXPLOSION
GAS POISONING

FIRE
Fire is a controlled
burning reaction of
gas

mixture.

Action to be taken
in case of fire in
Gas Main
If gas catches fire during work or
through some crack, or because of some
leakage,
it should be extinguished
with clay, steam, 002 extinguishers,
water, Dry Chemical Powder etc. The
portion of the gas main should
be
cooled down with water and only after
the fire is extinguished, should the main
valve be closed completely for carrying
out repairs,
it should be remembered that the valve
is not to be closed when fire is still there
and the pressure in the main should not
go down below 100 mmwc.

THE TETRAHEDRON OF FIRE

1.
2.
3.
4.

Heat
Oxygen
Fuel
Chain of reaction

EXPLOSION
Explosion is a fast rate of reaction of explosive
mixture releasing energy in the form of sound, pressure
and heat.
The following two conditions can cause explosions :-

i.

The gas and air mixture must be within their

explosive range.
The heat must be sufficient enough
to ignite the resultant mixture of gas
and air. If the mixture of gas and air
is below the "lower limit" or above
the "upper limit" of explosive range
of gas or if the heat is not sufficient
to ignite the explosive mixture,
obviously, there will be no explosion.

GAS

LOWER EXPLOSIVE
UPPER EXPLOSIVE
LIMIT OF GAS IN

LIMIT

THE MIXTURE

THE

(% By Volume)

(%

OF GAS IN
MIXTURE
By Volume)
with respect to air
CARBON MONOXIDE
METHANE
HYDROGEN
ACETYLENE
COKE OVEN

12.5
74.2
5
.15,
4
75
2.5
92
6
30

BLAST FURNACE
CONVERTER
L.P.G.

40
70
20
70
1.9
9.5

CONDITIONS WHICH CAN CAUSE EXPLOSION

The following
operating
conditions
in
handling gas are conducive to the formation of an
explosive mixture and causing explosion.
a.
Improper purging of gas lines and equipment.
b.
Improper charging of a gas main.
c.
Adopting the wrong procedures in lighting a
furnace.
d.
Bleeder discharging gas into a space where gas
is likely to come in to
contact with a source of ignition.
e.
Ignoring the dead pockets (Trapped explosive
mixture) in the shut off
gas lines.
f.
Gradual and unexpected gas leakage from
broken or cracked
valves/gas lines (specially coke ovens
gas) into closed and semi-closed spaces
which may include pockets under the
furnace platforms,
underground or overground galleries, or
unauthorised sheds around or near the
fume:saes.
g.
Delay in applying ignition source while lighting
up a furnace.
h.
Leakage of unburnt gas into furnace

i.

Flame extinguishment after lighting up due to :

a,
Lack of ventilation
b.
Poor draft
c.
Insufficient air supply
d.
Improper gas supply

j.

Blowing out of torch used for lighting up, either due

to weak torch or

opening too much gas.

k.
Using improper tools, when opening flange joint of
gas lines.

GAS POISONING AND FIRST-AID

Carbon Monoxide combines easily with the
haemoglobin of the blood, forming unstable compound
called carboxy-haemoglobin. The affinity of Carbon
Monoxide for the blood is 210 times more than that of
oxygen. So, even if a small amount is present in the air,
the haemoglobin will absorb CO in preference to
Oxygen. When this happens, the capacity of the
haemoglobin carrying oxygen to the tissues of the body
is reduced. More and more breathing of CO displaces
oxygen, causing the body to suffer from Oxygen
starvation resulting in asphyxia.
SOURCES OF CARBON MONOXIDE IN STEEL PLANT
1)
2)
3)
4)
5)
13% to 17%

Coke Oven gas

Blast Furnace gas
L. D. Converter gas
Mixed gas
Foundries

6% to 8%
25% to 30%
65% to 70%
15% to 30%
Cupola Section

SYMPTOMS AND EFFECT

a)
chest

Headache

e)

Tightness in

b)

Dizziness

c)
d)

Mental dullness
Yellowness in front of eyes
Unconsciousness

Weakness in

limbs
g)
h)

Vomiting

PERMISSIBLE LIMIT
1,
Threshold Limit Value (TLV)
mg/It.

= 50 ppm or 0.057
=.0.005% for 8 hrs.

duration.
2,
Short term exposure limit (STEL)
duration

= 400 ppm for 15 min.

FIRST AID IN CASE OF GAS POISONING

1)
2)
direction.
3)
victim.
4)
5)
6)
Centre.
7)

Do not become panicky.

Take the victim to the fresh air against the wind
Loosen the tight fitting clothes, shoes and belt of the
Ask the victim (if conscious) to take longer breathing.
Arrange Oxygen for the victim,
If unconscious, send the victim to nearest Medical
Inform Gas Safety to take sample of the area.

DO-NOT
1)
2)
3)
4)
5)
6)

3,

Never crowd around the victim,

Do not allow the victim (if slightly unconscious) to sleep.
Never give anything to eat or drink.
Do not allow the victim to run.
In no case leave the patient alone,
Do not ignore any symptoms,

GAS SAFETY RULES

The gas safety rules are laid down for the

guidance of all workers particularly those connected
with the gas fired furnaces, drying ovens and
maintenance of gas lines. These rules refer to hazards
of gas poisoning, gas explosions and fire.
1
it is prohibited to make a fire or to smoke near the gas
valves, gas line joints,
compensators, water drainers, in gas booster
and mixing station and where gas job is going
on.
2
No one should take rest or sleep near gas valves gas lines
joints, seal pots and
in gas dangerous areas.
3
No gas burners shall be kept burning inside the furnace or
in closed space
without an attendant.
4
Gas masks should be used while working in atmosphere
contaminated with
poisonous gases,
5
The maximum allowable concentration of Carbon
Monoxide in air is
0.05
mgfiltre for eight hours duration.

6
Not less than two persons should be allowed to work in the
gas hazardous
areas.
7
Wearing of shoes with iron nails on gas lines are strictly
prohibited.
8
Control room, booster house or other room where gas pipes
and impulse lines
are taken for connection to instruments, should always be
properly ventilated.
9
When a furnace is taken down for repair, a blank plate
should be inserted into
the gas main preferably on the down stream side of the valve,
10

When some portion of a gas line is to be isolated for repairs, a

blank plate must

be inserted, even If the valve or valves are closed.

11

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,

12
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 after
the valve.
13
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 rectified immediately and in the mean-time no
body should be allowed to stay in that area.
14
Checking for leakage of gas should only be done by soap
solution 'or by Carbon
Monoxide gas monitor.
15
For welding jobs on gas lines, it must be done only after a blank
plate is inserted
before the place where welding is to be done and the
line
has
been
steamed
out and proper sample analysis has been carried out,
16
All gasmen and workers dealing with gas equipments should
be regularly
trained in using gas masks, first aids (including artificial
respiration)
17
"Gas Danger" or Caution Boards should be fixed at all the
gas dangerous
places in all the shops.
18
When working on gas lines at height, a suitable platform
with convenient
escape routes should be erected.
19
Never use naked light in the vicinity of any enclosed space
which may contain
inflammable gas or near any gas main or equipment.

20
No
ected with the maintenance of gas lines/equipment
welding &
and
operation
of
cutting jobs
gas fired furnaces/drying ovens must undergo basic
are allowed
and
refresher
course
in
in the areas
Gas Safety Practices.
where gas is
likely to be
22
For all daily routine jobs in the shops a job card should be
present
flied up before
withou
starting the work.
Such job cards are issued by
t
Gas
Safety
Section
and
clearan
available with Gas Safety Man/C-1as Safety station
ce
from
attending the job.
Gas
Safety. 23
All shop in-charges snail arrange to draw out emergency plan
and day to day
21
All
operational instruction in connection with use of
those who are
gas
in
their
shops,
which
required to
should
be
made
available
in
the
control
work in gas
rooms/production control, all the time.
hazardous
places and all
24
A systematic scheme of gas lines in the shop indicating all the
those who
valves,
throttles,
a
bleeders, water drainers, position of steam points and
r
position
of isolating point should be displayed in the
e
control room, Such a scheme helps in a normal work
as well as in emergency situations.
c
o
25
Avoid the formation of explosive mixture by purging the gas
n
main
with
steam or
n
Nitrogen

26
Prevent the suction of air into the gas main under all
circumstances.
27
Routine maintenance of gas lines, taking quick action for
stopping leakages
when found, proper ventilation of enclosed
spaces quick steam flooding arrangement and
good house keeping help to prevent explosion.
28
No gas job should be carried out in night hours unless in case
of breakdowns or
emergencies.
29
Explosion proof electric lights must always be used for the
inspection of inside
of gas mains and furnaces and enclosed
spaces where traces of gases are likely to be
present.
30
A manometer should installed in the gas line on which work is
going on under
reduced gas pressure, it should preferably be nearest to the
point of work.
31
Persons engaged in the gas job must wear cotton cloth, hand
gloves, safety
shoes, helmets, goggles, fire resistance suit, etc.
32
Gas job should not done in the premises which are not welt
ventilated or which
are close to running furnaces.
33
The area of work during gas job should be properly cordoned
off and entry of
unauthorised persons should not be allowed.
34
In case of emergency if gas job is under taken in
closed/semi closed area
monitoring of gas concentration must be ensured.
4.
SAFETY SYSTEM
PROTOCOL FOR GAS

WORK PROCEDURE &

HAZARDOUS

Jogs

The danger which may arise from faulty or careless handling of

gases or
equipment associated with their handling, may be broadly into two
classes :
(1)

Gas poisoning due to the presence of Carbon Monoxide.

(2)

Injuries to persons and/or damages to equipment caused

by burns or

explosions.
It is therefore, necessary to understand the basic
safety principles in handling, gases and equipment
such as pipe lines, lighting up and shutting down of
furnaces, etc, to safeguard persons and equipment.
However, the following general safety precautions are
given as a guideline to understand the safety aspect
better.
Gas Distribution System

(0

Gas Pressure :- For the safety of the total gas distribution

system, the gas

pressure in any of the gas mains including the

departmental mains should not be allowed to fall
below 100 mmwo.

Icy

If the pressure falls below the above mentioned

safe limit, there are chances of air entering into
the -gas. main and causing backfires at the
consuming end, which may affect the gas
distribution mains. Under such circumstances,
it is absolutely necessary to curtail the
consumption, as the gas pressure comes close
to the above mentioned critical limits. The
consumption of gas by consumers should be
totally stopped and water seals should be made
up or valve should be closed if the pressure
'falls below the safe limits and Energy Centre
should be informed.
(ii)
Water Drainers :- Water drainers of standard type are to
be provided in gas
mains. The water drainers with their water inlet,
drain and overflow valves and connections
should regularly be inspected and should be in
a condition to be filled up at' a short notice.
The valve should be of gate or cock type in
good
operating
condition
and
easily
approachable. Low pressure water drainer/High
pressure water drainer should be used
depending upon the gas line network pressure.
(iii)

Bleeders and Steam/Nitrogen purging connection

The steam/Nitrogen
purging connection should be at the start of gas
pipe after the isolating valve, while the bleeder
should be at the other extreme end of the gas
pipe. The bleeder on gas pipes should have gate
valves at the tapping point. The bleeder should
discharge gas in open space at a sufficiently high
level, avoiding, places where men work or
E.O.T crane power rails run,
which may
ignite the gas. In any case, particular attention
must be paid, when operating bleeders, so that
the gas is not allowed to blow over men
working in the vicinity. Bleeders and steam
connections must be inspected periodically.

The bleeder height should be minimum 6 feet

above gas line. Proper approach should be there
to operate the bleeder valve.
(iv)

Inspection of Gas Lines

a)
Gas Lines :- Gas lines and accessories should be
inspected thoroughly
at least once in a month. Shop should
carry out joint inspection with E MD
once In a year.
b)
N. D. T. :- Thickness measurement of the gas line
should be carried out
once in a year in order to assess
the pipe line thickness for repair/
replacement of it.

(v)

Charging of gas line headers

The following procedures to be adhered to, after the testing

of gas line
a)
Purge the gas line upto the end bleeder.
b)
Deblank gas line as per standard gas safety practices.
c)
Charge the gas line with inert media upto the end
bleeder.
d)
Stop steam/nitrogen and purge the gas from end
bleeder till oxygen
content comes below 1%.
e)
Finally close the end bleeder, and disconnect
steam/nitrogen hose
connections.

PRO
C)E.,..J1UTDO
S MAINS AND
EQUIPMENT FOR REPAIR
WORK INCLUDING CUTTING 1 WELDING JOB
PLANNING
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.
(b)
For new jobs (Non-repetitive), this plan should be
scrutinized by the Chief of
Energy Management, Chief of the Fire Services and Chief of
Safety.

(c)

The plan should be drawn up well in advance. The plan of

work should ensure

proper (I) 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.
ISOLATION
The isolation of the gas line is completed by the
goggle valve operation or by 'U' Seal water filling or by
inserting a blank plates at predetermined locations with
proper plan. The work involves special technology of
work and special preparatory jobs, like (1)

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 CASE OF 'LP-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.
c)
Isolating flanges and bleeder should be provided on
both sides of the
'U)-Seal.
IN CASE OF GOGGLE VALVE ISOLATION
a)
No two goggle valves should have common
hydraulic/electrical system.
b)
After goggle valve operation the power supply must
be switched off and
fuses should be removed to prevent the mal
functioning of it.
c)
For maintenance of goggle valve an isolating flange
should be provided
before the goggle valve.

All branch pipes on the portion of the pipe to be isolated,

should be cut off by
putting blanks at the nearest flanges.

PURGING
All steam/Nitrogen points, bleeder pipes and valves should
be pre-checked for
proper working. The first steam point should
be close to place of blanking. if steam point is
not there, care should be taken to see purging
is done from blank plate to end of pipe line.
1.

2,
As soon as blanking is over, the purging points and the end
bleeder shouid be
opened and the condensate should be drained out.
Progress of purging should be recorded. The
aim should be at complete replacement of
combustible gas from the point of blanking up to
end of the pipe.
Where there is a chance of gas trapped in a
section, special arrangement and care must be
taken to purge out this portion. Duration of
purging will depend on rate of steaming, size and
length of pipe.
5.
Purging to be carried out for sufficient time from
isolating point to the end
bleeder of gas line.
6.
During Nitrogen purging persons should not stand
near bleeder/open
manholes.

VENTILATION
After proper purging, all the manholes and end
flanges, if necessary should be opened, so that
circulation of atmospheric air is well established from
one end to the other. Duration of ventilation will depend

on size and total length of pipe to be ventilated and

purpose of work.

SAMPLING AND CLEARANCE FOR THE JOB

The Steam/Nitrogen is to be closed and after it
replaced by air, samples are to be drawn from
suitable locations. Suction tube of the
sampling equipment should be inserted well
inside the pipe and sample should be taken from
upper part of pipeline for gases lighter than air,
and Lower part for gases which are heavier than
air.
Samples are to be tested for explosive mixture
by expiosimeter. It should be tested for carbon
monoxide (0.05 mg./liter maximum) and
analysis for oxygen content (20.6% minimum).
2.
Samples are to be taken again and the analysis Is to be
repeated lr the sample
is abnormal.
3.
When steam is available near the place where
cutting/welding job is to be done,
as an additional safety measure, steam
flow in the pipeline may be maintained.

4.
Sampling and testing equipment for gas testing should be in
good condition.
Final clearance for the job including
cutting/welding will be given in the given
proforma when purging, ventilation and test
results are quite satisfactory as ascertained by
joint inspection of Energy Management
Deptt., Shop representative, executing agency,
Safety and Fire Department.
Cautions

.1)

The sequence of jobs should be followed rigidly

2)
No operation should be conducted in haste, which
will jeopardize
safety.
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)
Isolated equipment or main should be monitored for
leakage till
recharging and this should be logged.
6)
The departments will maintain list of authorised
persons.

SUPERVISION
The overall supervision
will be under one
Officer earmarked for the job by the concerned
department.

Specific 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.
GENERAL LIGHTING UP PROCPDURE FOR FURNACES
I.

Ensure
a) Burner gas valves are fully closed.
b) Main isolation valve is fully closed.
c) Chimney damper is fully opened.
d) Furnace doors are fully opened for ventilation.
e) Chimney is having sufficient draft.

II.
ill.

Open steam/N2 in the gas main and purge through end bleeder.
DeblanK me Isolation point.

IV,

Open the main isolation valve and charge the header with gas.

V.

Close all the steam/Nitrogen points and disconnect them.

VI.

Purge the header with gas through the end bleeder.

VII,

Take gas sample which should show Oxygen less than 1%.

VIII.

Start air blower, keeping it at minimum level.

IX.

Place a burning torch in front of the burner.

X.

Open the burner valve and adjust the flame,

ALWAYS
Follow the procedures strictly.
Keep the chimney damper opened.
Keep the burning torch in front of
the burner before opening the gas
Close the burner valve if the torch
extinguishes.
Repeat the procedure again.
GENERAL SHUTDOWN PROCEDURE FOR FI4RNACES
Close gas burner valves.
II. Stop the air blowers.
III.

Keep

the
chimney
damper
fully
opened. IV.

Close

the

isolation
valve of the
furnace.
V.

Inject

steam/Nitr
ogen in the
gas

main.

VI.

Blank

the
isolation
point.
VII. Purge the header with steam/N2
through the end bleeder for a suitable
period.
VIII. Ventilate the furnace properly.
IX Take samples from the isolated gas line which should
show
Oxygen minimum 20.6%
Carbon Monoxide maximum 0.05 mgittr,

ALWAYS
FOLLO
W THE
SEQUE
NCE
STRICT
LY.
PURGE

THROU
GH END
BLEEDE
RS.

KEEP CHIMNEY DAMPER OPENED.

6.
GUIDE LINES FOR PROTOCOL FOR GAS HAZARDOUS
WORK :
All gas line jobs should be done on a protocol
in order to assign responsibility and effective coordination among various agencies involved and also to
provide check lists/points to ensure that no important step
is over looked. The format is as follows :SHOP
A
p
p
r
o
v
e
d
b
y
Heading :- (Write down the main heading for which the hazardous
gas job is planned
DATE :
TIME :
A.
Brief Description :- (Mention in short the necessity of the
above job),
B.
Special Condition Required :- (Technological regime to be
followed; e.g. gas line
pressure reduction, local pressure reduction
etc. and its implications to the plant).
C.

Overall Co-ordinator of the job :-

S.NO. I DESCRIPTION
RESPONSIBILITIES

I (By

Name)
A.
PREPARATORY JOBS :- (With names and designation of
persons
responsible for Execution)
i)
i
i
)
i
i
i
)
B.
ACTUAL JOBS :- (Details of operation in sequence with
name and designation
of persons responsible/section
responsible).
I)
ii)

i
i
i
)
i
v
)
C.
SAFETY PRECAUTIONS :- (All safety precautions including
fire prevention &
rescue steps taken).
i)
ii)
iii)
SIGNATORIES :- (Of all the persons connected
with the loDfi to be mentioned nere
with names. designation and
cieoamri envr.

OTHER DOCUMENTS NECESSARY :A.

Drawings, sketches and other technical documents to be
attached, wherever
necessary.
B.
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.

6.
GENERAL GAS SAFETY PRECAUTIONS FOR GAS LINE
REPAIR WORK
(ISOLATED / LIVE LINES)
1.
Fire brigade should be on stand by duty for live gas line
repair jobs, and if
required for isolated gas line repair job.
2.
All live repair work should preferably be carried out in day light
hours onty.
Safety appliances as prescribed by SED should be used by
the working group.
3.

4.
During lifting/positioning of the clads/pipes, the nearby
accessories/pipelines
should not be damaged.
If required additional structural supports should
be provided for the replacement of gas pipe lines
in consultation with designer.
6.
All the lifting devices, slings, ropes etc. should be property
tested and ensured
before using them.

All the repair work should be carried out under

proper guidance and
supervision.
8.
All welding transformers should be properly earthed
and cable properly
insulated.
9.
No smoldering objects should be left at the work spot on
stoppage of work. It
should be extinguished before leaving the spot.
10.
Proper scaffolding/platform should be made with escape
route for carrying out
the job safely.
11.
A protocol should be made fiar all gas line jobs, listing all the
safety precautions
required for it.
12.

Clearance from gas safety to be taken for the start of work.

13.
Open steam hose should be made available near me point or
work.

14.
For live line repair job, leakage arresting tools should be
made available at the
spot.
15.
Welding cable joint should not touch nearby auxiliary lines.
16.
Only experienced welders should be deployed for working on
gas lines.
17.

Oxygen and D.A. cylinders should be kept away so that while

cutting/welding spark should not fall on them.

7.

STANDARD MAINTENANCE

FIFLACTNELigglipAllygiISOLATED
GAS LINE

(a) SMP's for isolated as lIne

1
Purge the isolated gas line from blank to end bleeder of
line with steam
/
nitrogen for sufficient time.
2.
After purging, open manholes, bleeders, end flanges as per
site condition.
3.
After thorough ventilation of line, take bleeder sample from
inside the .pipe line
from as many locations as possible and also test with
explosimeter.
4.
If the sample is as per norm (Oxygen = 20.6%, CO <=0.05
mg/it.), clearance
can be given for cutting/welding in the prescribed form.
5.
in case, cutting of pipe line is planned water spraying should
be done from the
nearby manhole/ or by cutting pocket where
as for welding slight steam / nitrogen should be
kept on.
6.
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.
7
As far as possible air circulation inside pipe line should be
avoided by closing
manholes/end flange & putting inert media during
cutting/welding.
8.
While welding new pipe/compensator with old pipe, the
matching portion should
be free of any deposits.
During cutting/welding of gas line depending
upon site conditions efforts should be made to
remove muck from the gas line.
10.
Cladding on isolated gas line should be done in presence of
inert media to
avoid spontaneous combustion of deposits.

11.
After the completion of repair/replacement work of pipe line,
all opening should
be closed for leakage testing.

12.
Gas line should be tested with steam/air/nitrogen. In case
of nitrogen/air soap
solution should be applied and if steam is used
it should be ensured that all welded joints are
coated with lime.
13
. After. identification of leakages manholes near blank
should be opened and
sample should be checked for leakage.
14.
Re-welding of defective portion should be done preferably
in presence of inert
media.
15.
Retesting should be done after rectification of defect by
following the previous
mentioned methods.
16.
If there is any interconnection of water drainer, bleeders,
steam connections and
impulse lines of two different gases, it should
be isolated by inserting a blank plate.
17.
Sampling should be carried out, while doing job near blank
point.
18.
If blanking is done before valve, the valve should be kept
open to release the
gas pocket between blank and gate.
19.
Cutting/welding and smoking by unauthorized persons
should not be done near
isolated gas line.
20.
Localised "BLIND" can be formed with sandbags/bricks in
order to keep the
water level maintained inside pipeline in case fire travels in
gas lines.
21.
While cutting pipe near blank, the isolating flanges should be
welded in order
to prevent gas leakage due to release of pipe tension.

22,
To provide support to auxiliary lines area sample should be
checked.

(b) SMP's for live am; line

1. If leakage is observed, it should be plugged and

area
sample
should
be
ensured for safe working.
2,
Prepare half clad/patch as per the profile of the gas line.
While welding on gas lines low current is preferred,
so
welding
transformers
4. should be checked for proper regulation of current.
Pipe line thickness of defective area must be measured
before
the
start
of
job,
5. this will help in arranging proper size of
clad/patch/electrodes.
Besides
this,
it
will also help in proper regulation of welding current.
6.
Only experienced and trained welders should be allowed
to work, as the line will be in charged condition.
As the as line is changed: gob should be done only durin
hours.

g day light

7.
Clad/patch should be properly positioned and welded
without excessive
hamMering On gas line.
8.
As far as possible clad should be welded to the fully welded ribs.
Where ever possible saddle supports of gas
lines should be temporarily supported and
then saddle should be removed for welding
of clads. After complete welding of clads,
saddle supports should be repositioned.
10.
While positioning of dads at the temporarily plugged leakage
point, steam
nipple should be welded to the dads for supply
of steam. This will help in avoiding fire.
11.
if cladding is done at the spot where leakage is there, that
particular spot should
be completely welded to prevent the travel of gas to other dads.
12.
As experienced, if more number of clads are tack welded gas
travels from one
clad to another, therefore less number of
dads should be first completely welded and
then others should be positioned.
13.
Places where complete welding is not possible, clads should not be
positioned.
14.

Not less than two rounds of welding should be done on clads.

15.
After the completion of job, all temporary supports should be
removed and
scrap should be properly stacked for disposal and disposed.
16.
All welding/earthing connections should be removed from
the spot on
completion of the work.
17.

Open steam hose should be made available near the place of work

18.
Welding work on charged gas line should be done very
cautiously and without
any haste.

19.

Welding transformer should preferably have the return cable lines.

8.

COMPONENTS OF GAS LINE AND ITS ACCESSORIES

Like the arteries in human body, gas pipe lines

are the vital energy carriers to the various energy (Fuel)
consuming units of a Steel Plant. As the choking of
arteries in human body' paralyses the complete system
similarly improper maintenance of gas network results
in premature failure of gas line.
The pipe line carrying gas to different consumers
is made up of mild steel quality of thickness 8.10 mm..
Gas fine of dia. 1600 mm. And above shall be provided
with
stiffening ribs normally 3 metres apart. These stiffening ribs
takes care of circumferential load on gas line caused due
to gas pressure. These are also used for welding the

supports for auxiliary pipes and walk ways along the

entire length of the pipe with hand

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 :

1.
2.
3.
4.
5.
6.
7.

9.
10.
12.
13.
1.

Compensators
Water drainers
Bleeders
ISolating facilities
Butterfly valve
Orifice plate
Rupture disc / Pressure relief valve
Manholes & hand holes
End flanges I Steam / Nitrogen points
Flanges / Packings / Saddle supports etc.
Goggle Wives

COMPENSATORS

These are installed on gas lines to take care of

axial expansion and contraction of gas line. During the
gas job these compensators help in giving way for gap
which is necessary for manual insertion I taking off of
blank plate.
The following two type of compensators are generally used on
gas lines :a)
Slip joint or gland type compensator for Coke Oven gas
line.
b)
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.

WATER DRAINERS

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
drainers.
Problems due to poor upkeep of water drainers are :a) Gas leakage due to puncture in drainer body or its
accessories.
b) Gas pressu-re fluctuation due to water accumulation.
c) Fast corrosion of gas line.

3.

BLEEDERS

These are installed in gas lire to discharge

gas or steam/nitrogen mixture during charging or
shutdown of gas lines. Their location depends upon the
layout of the as line keeiDina in view the eretoer
chaminer/oureine of eas line-.

These shall be installed as per :a)

Selection of bleeder shall ensure 5 times
discharge of the gas
volume in 10-30 min.. They shall be more
than
19 mm. in
diameter.
b)
The bleeder shall be located above the roof
level more than 4
metre.
c)
For inter plant pipe line the height of the bleeder
on gas line shall
be more than 4 metre from the gas
pipe upper axis'. The exit point of
bleeder on gas line shall 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
atmospheric dust. The bleeder
shall also have point for collection
of gas samples.
4.

ISOLATING FACILITIES

A)
Gate Valve :- These are used to isolate a certain portion of
gas line from main
gas line. Regular greasing of spindle, protection
of the same from the dust and revisioning of
valves during capital repair will keep the valve
in good working condition.

Maintenance like cutting I welding on such

gas line is done only after the manual blanking /
goggle valve turning by closing the gate valve.
B Goggle Valve :- These are remote operated isolating
) valve.
The
closing
of
goggle valve ensure 100% isolation of gas line.
Advantages of goggle valve over gate valves are :1.
2.
3.

100% isolation of gas main.

Spread of gas leakage for shorter duration.
Very less manpower is required.

C "U" Seal :- This is the safest method for 100% isolation

) of
gas
line.
By
filling
the

water in U-Seal to create a water column, the gas

main
is
isolated
in
a
very
short duration.
Advantages of U-Seal are :1.

No gas teaKage

2.

atmosonere.
1009/0 isolation of aas

3.
for

5.

No moving parts, hence no maintenance. (Except

maintenance of water drainer)

4.
Very less manpower required to create water seal.
BUTTERFLY VALVE

These are used to regulate gas pressure in

the gas line. They are either pneumatically or
hydraulically operated. Over the period of time dye to
deposits in gas lines their operation becomes sluggish.
During repair of gas lines cleaning of gas line with
steam and high pressure water takes away the
deposits and valve operation become smooth,
6.

ORIFICE PLATE

To measure the rate of gas flow in the gas line,

orifice plates are installed. To both side of orifice plate
impulse tapping is given to measure the difference in
pressure which is converted by an instrument to
measure flow and the same is displayed in cubic
metre per hour During repair this impulse line should
be disconnected from instruments to prevent the steam
entering and damaging the instruments. All impulse
lines on gas line should be separately steamed to clear
choking.

7.

RUPTURE DISC / PRESSURE RELIEF VALVE

Rupture disc are made up of 3 mm. Aluminium

sheet, tightened between two flanges and located after
a gate valve. These disc ruptures shenever the pressure
in the gas line exceeds a certain value or in case
explosion this gives way for liberating the force of
explosion thus preventing the gas line and its
equipments from damage. Whenever the disc ruptures
the gate valve is immediately closed to stop the spread
of the gas leakage.
The function of relief valve is same as that of
rupture disc. A counter weight with pivot arrangement is

given to release excess pressure on explosion. After its

functioning the counter weight seals the gas leakage.
The rupture disc and relief valve are located
at places where no possible exposure of gas to work
man or any fire source is suspected.
8.

MANHOLES / HANDHOLES

Manholes are given on gas line to facilitate

work man to enter into the gas line during shut down
and also for ventilation purpose. This can be also
converted into a gas line tapping by a special
deblanking process. Manholes are generally located
near gate valves, compensators or at locations where gas
pocket can form.
Hand holes are given on bends and smaller dia.
Pipe lines for cleaning, flushing and ventilation of gas
line.
9.

END FLANGES / STEAM / NITROGEN INSPECTION POINTS

End flanges as the name suggest are located at the end of gas
line. These are

coanoci dwrine cwt 4Awrt few ventiletiern elf arls iin

The steam / 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 / PACKINGS f SADDLE SUPPORTS

Flanges are used with all type of isolating valves,

butterfly valves, compensators, orifice plate etc.. After
gate valve and goggle valve a separate isolating flanges
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 supports 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.