Gas safety

In
P&bs2
introduction
THE FATAL ACCIDENT THAT HAS OCCURRED
IN BHILAI STEEL PLANT IS AN EYE-OPENER
FOR ALL OF US. WE MUST DRAW LESSONS
FROM THE INCIDENT. THIS PRESNTATION
IS TO RE-LOOK AT OUR SYSTEM, FINDING
ANY UNSAFE POSSIBILITIES AT OUR GAS
AND RELATED WATER NETWORKS AND
TAKING MEASURES ACCORDINGLY
CO GAS U-SEAL
AND
SEAL POT
Gas composition
Constituents Unit COG BFG BOF
Mixed
Gas(BFG+BOF)
CBM
CO2 % vol 3-4 23.3 16.2 22.38 1-2
CO % vol 6-7 26.9 69.3 32.4
N2 % vol 4-7 46.2 14.5 42.1
H2 % vol 52-59 -- -- --
CH4 % vol 24-28 -- -- -- 95-97
Other gases % vol 1.5-2.5 3.6 -- 3.14 2-4
Calorific Values Kcal/Nm3 4250 914 2000 1054
8300
(NCV)
Gas properties
SN COG BFG
Source
Coke oven gas, is the gas
obtained when coal is
heated in an air tight
place
Blast furnace gas, a by-
product of blast furnaces,
is generated when the iron
ore is reduced
with coke to metallic iron
Hazardous or
Not
Categorized as
hazardous/toxic gas
Categorized as
hazardous/toxic gas
Colour Yellowish Colourless
Odour Pungent Odourless
Density
Lighter than air (0.45
times lighter).
Heavier than air
Schematic arrangement of CO GAS U-SEAL AND
drain POT & water supply lines
Salient points of our cog water seal
There are one goggle valve at the COG inlet line at PBS2.
There are 2 drain pots in COG common header.
There are total 3 U-seal one in each individual gas lines taken
from COG header.
There are one drain-pot connected to each U-seal of
individual boiler.
Color code for gas line is yellow and color code for water line
is sea green.
Our U-seal water line has been taken from ACW pump header.
Our U-seal water filling line is having U-seal to restrict back
flow of gas to water circuit in case of water pressure loss.
Backflow of gas in the drain-pot water filling line will be
restricted by drain-pot water column itself
CO GAS U-SEAL
AND
SEAL POT
CO GAS U-SEAL
1. In main gas line the effective height of
the U seal shall be 2.5 times of the
working gas pressure.

2. The effective height of gas line is
overflow point of the water pipe in gas
line to the top of the U bend in gas line.

3. Inlet water line U seal is TO BE provided
to avoid flow of gas in water line if the
pumps gets dry or water line is empty.
U-SEAL facts
CO GAS
SEAL POT
1. Drain pot is a device to collect
the Condensate accumulated in gas
pipe line.

2. It also helps in releasing the
pressure in gas pipe line if the gas
pressure becomes TOO high .

3. It works on the principal of U-
Tube manometer.
At Normal Condition P < 2000mm WC
it remains in stable condition.

When pressure rises above 2000
mm WC, then it throws out the
water from the over flow outlet.
2000
Mm
WC
P
Safety in
cable cellars
Cable galleries at P&BS2

1. below 33kV GIS room which handles 33kV
cable, 6.6kV cable, 415V cable and 220V
DC cable
2. Second below Main LT Switchgear which
handles 415V cable and 220V DC cable

Cable trenches in P&BS2

1. Near Boiler Area
2. Near DM Plant
3. Near Cooling Tower
4. Near Cooling water Pumphouse
Use CO gas sensor to measure any presence
of CO gas near cable trench before entering.
Incase of detection of CO gas, go away from
the source of CO gas; preferably to an open
area and inform control room in-charge and
plant in-charge.
Ensure no steam is coming into the
gallery/trench.
Keep someone outside the cable trench.
Keep walkie-talkie tied with you if possible.
Use 24V Lamp/Torches inside the trench.
Safety in cabale galleries & trenches
Ensure running earthing in the cable trench and the
connectivity with the earth grid. Use local earth in
the cable tray.
Use mask, gum boot, hand gloves, helmet, and
goggles.
Ensure no insects/snakes inside.
Do not use metallic material for cleaning. Use
wooden stick or bamboos.
Do not take flammable material.
Ensure both side entry of cable trenches are packed
with fire retardant boards and packing material.
Do not touch open cables if found inside and
immediately inform to the EIC.
Safety in cabale galleries & trenches
ADDITIONAL MEASURES TO BE TAKEN
THROUGH SOPS & SMPS
Always ensure overflow in the Drain-pot
and
Always ensure overflow in U-seal when U-
seal has been done for gas isolation.

Whenever the overflow is not found in a U-
seal or Drain-pot, same to be attended only
after ensuring by a gas detector that there
is no CO gas in the vicinity of U-seal or
Drain-pot.
.
ADDITIONAL MEASURES TO BE TAKEN
THROUGH SOPS & SMPS
Whenever a gas line is
isolated by U-seal for a
maintenance job, in addition
to ensuring overflow, ensure
that drain valve is closed
with tag DONT OPERATE or
preferably keep the drain
valve locked.

ADDITIONAL MEASURES TO BE TAKEN
THROUGH SOPS & SMPS

Whenever there is a total shutdown of
all ACW pumps, it is to be ensured
through a gas detector that there is no
CO gas in the CW pump house before
starting any job.

Never keep any gas vent open during
Thunderstorm.

ADDITIONAL MEASURES TO BE TAKEN
THROUGH SOPS & SMPS
Whenever a job is to be
taken inside furnace ensure
with gas detector that no CO
gas is present inside, also
ensure O2 content is 21%.
Keep a gas detector at
working place throughout the
job duration to be alert for
any seeping CO gas during
the job.

ADDITIONAL MEASURES TO BE TAKEN
THROUGH SOPS & SMPS
Whenever a job is to be
taken in a confined place like
Boiler Drum, Main Oil Tank,
LDO Storage Tank, Condenser
etc, ensure that O2% inside
is 21% before starting the
job.
ADDITIONAL MEASURES TO BE TAKEN
THROUGH SOPS & SMPS
Dont charge COG/BFG/BOF Gas
in an empty pipeline without
purging with N2 or steam.

Always ensure that Oxygen
content in the purged line is less
than 2% before admitting Gas.
ADDITIONAL MEASURES TO BE TAKEN
THROUGH SOPS & SMPS
Never allow Boiler area, cable cellars to
be used as resting place.

Never allow use of any tapping in the
water network of boiler area for
washing or drinking.

Cable cellars, Boiler area are to be
treated as restricted places with no un-
authorized entry
Summary
We have total 5 drain-pots and 3 U-seals in COG
network
Drain-pot & U-seal overflow to be ensured always
During gas isolation by a U-seal it is to be ensured
nobody opens the drain valves inadvertently.
Though we have U-seal in the water filling line we
should check the CO gas with detector at the place
of work if ACW system shutdown is taken.
We should take requisite precaution as said while
working in confined places, cable cellers etc.
We should never allow PBS2 Boiler area to be used
as resting place.
Any tapping of the water network in Boiler area
should never be used for washing or drinking
Never Always
Never fail to
anticipate
emergencies. Do not
wait until something
happens to start the
thinking process
Always study every
conceivable
emergency and plan
exactly what moves
to make.
SAFETY RULES DURING AN
EMERGENCY
Never Always
Never start to
manage
emergency without
understanding
what exactly has
happened
Always proceed to proper
valves or switches rapidly
but without confusion in
time of emergency. You
can better walking than
running.
SAFETY RULES DURING AN
EMERGENCY