COMMISSION OF THE EUROPEAN COMMUNITIES

industrial health and safety

Maintenance and repair work

on gas lines and apparatus
Water seals and drain seal pots

COMMISSION OF THE EUROPEAN COMMUNITIES

industrial health and safety

Maintenance and repair work

on gas lines and apparatus
Water seals and drain seal pots

Steel Industry S a e l / and hfnlth Commission

Working Party
'Safety Gas Mains'

Directorate-General 'Employment and Social Affairs'

1978

EUR 6048 DE, EN, FR, IT, NL

Published by the
COMMISSION OF THE EUROPEAN COMMUNITIES
Directorate-General
Scientific and Technical Information and Information Management'
Btiment Jean Monnet
LUXEMBOURG

LEGAL NOTICE
Neither the Commission of the European Communities nor any person acting on
behalf of the Commission is responsible for the use which might be made of the
following information

A bibliographical slip can be found at the end of this volume

ECSC-EEC-EAEC, Brussels-Luxembourg, 1978

Printed in Belgium
ISBN 92-825-0625-8

Catalogue number : CD-NQ-78-013-EN-C

C O N T E S T S

1.

Water s e a l s

2.

Drain Seal Pots

3.

Operation of Water Seals and Drain Seal Pots

Figures

10

-1-

Water seals are shut-off devices in a gas mains systems which

perform an isolating function by means of a seal trap.
Drain seal pots are devices designed to perform two functions
simultaneously in accordance with operating requirements: the removal of
water contained in the gas, or supplies to a water seal, and isolation of
gas in the mains from the surrounding atmosphere. Drain seal pots also
contribute towards reducing dust and other contaminants in the gas as they
become entrained in the condensate and are drained out.
The purpose of this study is to ensure that gas distribution systems in Iron and Steel Works are as safe as possible. The recommendations
which follow take account of the various incidents which may occur in
connection with water seals and drain seal pots (loss of water pressure,
excessive gas pressure, explosion).
It should be noted, however, that isolation systems based on the
use of water seals are, by their very nature, inadequate as a safeguard
against excessive gas pressure and explosion. In the event of such incidents a water seal may fail to contain the gas.
Very strict compliance with the following general recommendations
is, therefore, necessary.
A water seal is not an adequate means of isolating a gas main
system for the purpose of carrying out repairs or other operations which
are without anti-gas precautions or which involve the presence of workmen
inside the pipes. A blank flange or closed spectacle plate valve provides
real protection against explosions.
At all points (in buildings, vessels, trenches etc.) at which gas
might accumulate if the seal were to fail to contain the gas only gas
tight drain seal pots may be installed. Particular attention must be paid
to the points at which the outlets of the vents or gas pipes are located
(proximity of occupied premises, windows, work areas etc.) so that any gas
released could not cause gassing or result is a potentially explosive atmosphere.

-2-

During winter periods the making of water seals may be dangerous

because of the freezing risk so it is necessary that specific measures be
taken to take account of possible falling in temperature.
1. Water Seals

1.1. Water Seals for Sas Distribution Systems and Non-High Top
Pressure Blast Furnaces
1.1.1
The only acceptable type of water seal i s that shown in
Figures 1 and 2. I t i s in the form of a U-bend or loop in the
pipe. All other types must be rejected since i t i s not possible
to check the condition of t h e i r inside walls. Figures 1 and 2
i l l u s t r a t e the U-bend type.
In some instances a butterfly valve located at the bottom of the
U limits the effects of an explosion as well as movement of water
contained in the closed water seal.
1.1.2
The seal gas release pressure of a water seal must be at
least three times the maximum working pressure of the gas system.
The minimum trap seal i s obtained by locating the over-flow pipe
of the water seal at a v e r t i c a l distance above the t r a p dip equivalent to three times the maximum working pressure of the d i s t r i bution system i f the over-flow i s situated on the up-stream leg of
the water seal (Fig. 1.) and four times the working pressure i f i t
i s situated on the down-stream leg (Pig. 2.)
1.1.3
There must be a separate drain seal pot for each water
seal drain and over-flow pipe.
1.1.4
During the f i l l i n g of a water seal a continuous flow of
sufficiently clean water should be maintained.
1.1.5
The pipework supplying water to a water seal must be large
enough to provide a sufficient flow of water to f i l l the seal
rapidly. When the seal i s made i . e . when water i s seen to flow
through the over-flow pipe, the continuous water flow may be r e s t r i c t e d , taking into account the quality of water being used.

-3-

To this end, a small diameter by-pase is installed parallel to the

water supply pipe, as per Pig. 3i and is opened as soon as the
water seal has been filled. The valve in the main pipe is simultaneously closed and padlocked.
The water supply pipework must be in form illustrated in Figure 3.
It is made up of the following items which are listed in sequence
with the direction of water flowi- a manually operated valve:
- a branch with air vent valve:
- a second manually operated valve which can be padlocked and is
by-passed with a smaller diameter pipe fitted with a shut-off
valve.
When the water seal is opened i.e. when gas is flowing normally
through the main, the three water supply valves are closed and the
air vent valve is open: the vent pipe discharging any gas leakage
to a sufficient height avoiding all risk to personnel.
1.1.6

The water supply should preferably be connected to the

down-stream leg of the water seal.

If, however, it is connected to the up-stream leg, the water supply
pipework must also include a U-seal such that the gas release
pressure is three times the operating pressure in the gas main
together with an air vent on the down-stream leg of the U-seal so
that the water can be retained in the U-seal if siphonage of the
water in the pipe occurs e.g. as a result of failure in the water
supply.
Fig. 2 illustrates such an arrangement.
1.1.7

If insufficient pressure is available in the water supply

to a full water seal either because of repairs to the water supply

system or because of an accident, action must be taken to establish
an emergency water supply to the seal.
1.1.b

The over-flow pipe of the water seal must be of slightly

larger diameter than the water supply pipe. Its diameter will normally be 4" or 5".

Generally speaking, the over-flow pipe should be positioned on the

opposite leg of the Useal from the water supply. If necessary,
however, the over-flow and supply pipes may both be placed on the
down-stream leg providing the water supply cannot pass directly
into the over-flow pipe thus giving a false impression that the
seal is made.
1.1.9

In cold weather, the water in the seal must be kept at a

sufficiently high temperature. Braziers must not be used but a

warm air draught is permissible.
The air heater should operate on the principe of electrical heating
elements rather than combustion of any type of fuel whatsoever.
1.2

Water Seals for High Top Pressure Blast Furnaces

To isolate a furnace top from the gas cleaning plant and
gas distribution system, spectacle/plate valves or a water seal
with spectacle/plate valves are used. Basically such a water seal
isn't different from a low pressure water seal because when it is
made, the gas pressure on the furnace side is greatly reduced.
However, drain seal pots are not used, but siphons are, in order
to achieve gastightness of the over-flow pipes and in emptying the
water seal.
In fact under the high gas pressure of a high top pressure
blast furnace, if drain seal pots were to be used it would be
necessary for their dimensions and water capacity to be much too
great. This is why siphons are used having a head greater than the
maximum furnace gas pressure. Moreover, the water supply is similarly installed to give the same pressure head. The three siphons
(water supply, over-flow and drains) have water constantly circulating.
A water reservoir with a capacity greater than that of the
water seal ensures a very rapid filling of the seal and it is connected in such a way that it constitutes a reservoir for maintenance of the siphon water level in case of water supply failure.
Such a water seal is shown in (Fig. ).

-5-

The water supply must be sufficiently clean and adequate,

also non hazardous means must be provided to prevent the water
from freezing (see 1.1.9 and 2.1.9). The provisions of paragraph
1.1.9 apply to high top pressure furnace water seals and paragraph
2.1.9 to water seal siphons.
2. Drain Seal Pots
2.1. Open Drain Seal Pots
2.1.1.

Open drain seals (see Fig. l) should be installed only in

the open air at points where there is no danger of gas accumulating

or infiltrating into occupied premises if the seal fails to contain
the gas.
2.1.2.

There must be a separate seal pot for every condensate

drain pipe, water seal drain and over-flow pipe. There must not be
more than one condensate pipe draining into each drain seal pot.
2.1.3.

The dip pipe must be at least 2 inches in diameter. The

seal gas release pressure must not be less than three times the
maximum working pressure of the gas system. The diamter of the
drain seal pot must be at least ten times that of the dip pipe.
2.1.4.

The drain seal pots must be continuously fed with running

water through pipes sufficiently large in diameter to prevent any

danger of blockage.
2.1.5

The gap between the lower end of the dip pipe and the

bottom of the seal pot depend on the frequency of washing out and
the cleanliness of the gas at the point in question. It must be
sufficient to ensure that the accumulated sediment cannot block the
dip pipe.
2.1.6.

In order to prevent corrosion:-

- drain pots must stand a few centimeters clear of the ground;

- only non-corroding materials may be used for the dip pipes;
fibre glass
- only steel valves may be used in the drain pipes, over-flow
pipes or water seal drawe-offe in order to avoid electrolytic
oorrosion.

-6-

2.1.7

The valves in the drain pipes and over-flow pipes or

drains of water seals must not be of cast iron as this metal is too
fragile.
They must be placed as close as possible to the main gas line.
Safe and easy means of access must be provided so that they can be
operated quickly and without risk.
Between the gas main and valve in a condensate downcomer a set of
flanges may usefully be fitted to accommodate a blank flange,
especially in the case of pipes more than 3 or 4 inches in diameter.
2.I..

The drain seal pot must be drained by a pipe which must be

at least 4 inches in diameter and as short as possible. The pipe

end must be fitted with a flange to which a blank flange is bolted,
with an elastic ring joint being used. Better still, the drain
pipe should terminate in a flanged valve to which a blank flange
is bolted and rendered water tight by means of an elastic ring
joint.
2.I.9.

Measures must be taken to prevent freezing of:

- drain seal pots

- drain pipes
- water supply lines
Such measures must comprise heating of these elements by means of
electric resistors or steam coils and lagging.
If electric resistors are used an ammeter or indicator lamp will
show whether the system is in good working order.
The use of braziers as a means of frost protection must be prohibited. The drain seal pot may be heated internally or externally
and the water temperature must be continuously maintained at an
adequate level (Thermostatic control is recommended). Such heating
is not, however, necessary if water is supplied to the pot at an
adequate flow rate and temperature. This may be achieved either by
using clean industrial waste water at this temperature or by employing a special unit to heat the water supply. In such cases the
water is delivered by a dip pipe of non-corroding material, the
distance between the pipe outlet and the bottom of the pot being

-7-

about 1/6 of the trap seal. An air vent comprising a tube at an

acute angle to the direction of water flow is fitted to the dip
pipe level with the over-flow to prevent siphoning of the water in
the pot in the event of an accidental fracture of the water pipe.
Figure 5 illustrates a drain seal pot supplied with heated water
through a dip pipe.
2.1.10.

In order to prevent accidental entry of gas into the

water pipe, the latter shall incorporate two manually operated

valves in series with an intermediate air vent valve. These should
be installed immediately up-stream of each pot serving a condensate
pipe or group of seal pots serving a single water seal. The water
supply pipe serving each seal pot must incorporate a U-bend with a
seal trap of at least 50 cm head to prevent entry of gas into the
water supply system.
2.1.11.

The pipe by which the water is drained off to the main

drains must also incorporate a U-bend with a seal trap of at least

50 cm head to prevent leakage of gas into the drains or movement
of 'sewage gas' in the opposite direction.
Recommendations 2.1.10. and 2.1.11. may appear too severe. It should,
however, be noted in this connection that there have been many cases of
gas poisoning at points a considerable distance from the areas in which
gas is produced, transported or used, as a result of the gas spreading
through sewers, drains or water lines temporarily not in use.
2.2. Airtight Drain Seal Pots
2.2.1. Only airtight drain seal pots may be used in cellars,
trenches, buildings and at other points where gas might accumulate
or infiltrate into buildings if the seal were to fail to contain
the gas.
2.2.2. These drain seals (see figure 6) are isolated from the surrounding atmosphere but have an air vent pipe which, if the gas
pressure becomes too high, will bleed off the gas outside the
premises at a sufficiently safe height. The pot over-flow has a
0-eeal whose gas release pressure is greater than that of the drain

seal pot itself.

The dimensions of this type of drain seal should be as follows:
- diameter Of dip pipe: 2" minimum
- diameter of drain seal pot: 12.5 times the diameter of the dip
pipe but not less than I50 mm
- diameter of air vent pipe: 3 times the diameter of the dip pipe,
but not less than I50 mm
- gas release pressure of drain seal pot: 3 times the maximum
working pressure of the gas system
- gas release pressure of the over-flow U-seal: 5 times the
maximum operating pressure of the gas system
- maximum diameter of overflow: 2".
2.2.3

The vent pipe must be of constant cross-section and, if

possible, straight. If, however, the pipe must have a bend in it,
the radius of curvature must be not less than 10 diameters in order
to minimise the amount of water discharged from the U-seal if
excessive pressures develop.
2.2.4. All recommendations given in Section 2.1 "Open drain seal
pots" also apply to airtight drain seals with the exception of
points 2.1.1.1. and 2.1.3
?.3. Drain Seals of Sunken DeBign
2.3.I. Drain seals of sunken design have the advantage of being
less susceptible to freezing. Apart from

this aspect, the same

requirements apply as to open drain seal pots.

1. 4. Improved Seal Pots
The hazards caused by seal pots failing because of pressure
surges, or explosion, are such that various attempts have been made
to limit the quantity of gas released, and to reestablish the seal
with a sufficient head of water at the end of a pressure surge.
Such improved seal pots are already in use in various
works but there is insufficient experience of them to be aware of
any drawbacks or faults. They are based on the principles of
limiting to a minimum the volume of water expelled by a pressure

-9-

surge, and maintaining a sufficiently large reservoir of water to

re-establish the water seal at the end of a pressure surge.
The General Commission hopes that steel companies, study
institutes and manufacturers acquire up-to-date information on
such improved seal pots when designing new installations.
In time, the General Commission will not fail to supply
its own evaluations as soon as it is able to.
As far as condensate drains are concerned, mention must be
made of the automatic float drainage system which is in use in
Germany, and which is satisfactory when used on blast furnace gas
and coke ovens gas systems.
3. Operation of Water Seals and Drain Seal Pots
3.1. Daily inspections must be made to ensure that drain seal water is
flowing freely and that it is at a suitable temperature during
periods of cold weather.
3.2. Valves in water seal drains and over-flow pipes must be capable of
being tightly shut (ball valves are recommended). The open and
closed positions must be readily identifiable.
3.3 When water seals are made, the water drain valves must be shut and
padlocked.
3.4 When water seals are open, their overflow valves must be closed.
3.5. When butterfly valves are installed up-stream or down-stream of a
water seal, it is recommended that they be shut before filling the
seal.

-10-

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European Communities Commission

EUR 6048 Maintenance and repair work on gas lines and apparatus Water
seals and drain seal pots
Luxembourg : Office for Official Publications of the European Communities
1978 - 22 p. - 14.8 21.0 cm
Industrial Health and Safety series
DE, EN, FR, IT, NL
ISBN 92-825-0625-8
Catalogue number: CD-NQ-78-013-EN-C

BFR
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This study, carried out by a group of experts within the Steel Industry Safety and
Health Commission, illustrates the many conditions in which water seals and
drain seal pots in gas production plant in the steel industry (blast furnace and
coke oven gas) may be found, with a view to ensuring maximum safety from the
risks of gassing by or explosions of these gases.

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ISBN 92-825-0625-8