i.

Flame extinguishment atter lighting up due to 1

a. Lack of ventilation
b. Poor draft
0. lnsuificient air supply
d. improper gas supply
j. Biowing out of torch used for iighting up, either due to weak torch or
opening too much gas.
l<. Using improper tools, when opening flangejoint of gas iines.
In.
one POl_<_)NlNG ANQ FIRST-AIQ
Carbon Monoxide combines easily with the haemcgiobin of the blood, forming
unstable compound cailed oarboxy-haemoglobin. The affinity of Carbon Monoxide
for
the blood is 2'30 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
sutfer
from oxygen starvation resulting in asphyxia.
sourzces OF CARBON Mgiygxiog IN sT_eL Pi.A_rg_1;
1) Coke Oven gas 6% to 8%
2) ' Blast Furnace gas - 25% to 30%
3) L. D. Converter gas - 65% to 70%
4) Mixed gas 15% to 30%
5) Foundries Cupola Section 13% to 17%
SYMPTOMS AND EFFECT
a) Headache e) lightness in chest
b) Dizziness i) Weakness in limbs
c) Mentai dullness g) Vomiting
d) Yellcwness in front of eyes h) Unconsciousness
PERMISSIBLE LIMIT
1. Threshold Limit Value (T W) = 50 ppm or 0.05? rngllt.
-_-0.005% for 8 hrs. duration.
2. Short term exposure limit (STEL) = 400 ppm for 15 min. duration
FIRST Alp IN orig OF eras POiSONlN(_3__
1) Do not become panicky
2) Take the victim to the fresh air against the wind direction.
3) Loosen the tight tting clothes, shoes and belt of the victim.
4) Ask the victim (if conscious) to take longer breathing.
5) Arrange Oxygen for the victim.
6) if unconscious, send the victim to nearest Medical Centre.

7) inform Gas Safety to take sampie of the area.

1) Never crowd around the victim.

2) Do not allow the victim (if slightly unconscious) to sleep.
3) Never give anything to eat or drink.
4) Do not allow the victim to run.
5) in no case leave the patient alone.
6) 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 red furnaces, drying ovens and maintenance of gas
lines. These rules refer to hazards of gas poisoning, gas explosions and fire.
1
'10
11
_lt is prohibited to make a fire or to smoke near the gas valves, gas line
joints,
oompensators, water drainers, in gas booster and mixing station and where gas
job is going on.
No one should take rest or sleep near gas valves gas lines joints, seal pots and
in gas dangerous areas. a
No gas burners shall be kept burning inside the furnace or in ciosed space
without an attendant.
Gas masks should be used while working in atmosphere contaminated with
poisonous gases.
The maximum allowable concentration of Carbon Monoxide in air is 0.05
mgflitre for eight hours duration.
Not less than two persons should be allowed to work in the gas hazardous
areas.
Wearing of shoes with iron nails on gas lines are strictly prohibited.
Control room, booster house or other room where gas pipes and impulse lines
are taken for connection to instruments, should always be properly ventilated.
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.

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.

12
13
'14
15
I6
i7
18
'19
20
21
22
23
24
25
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

places in all the shops.

When working on gas lines at height, a suitable platform with convenient
escape routes should be erected.
Never use naked light in the vicinity of any enclosed space which may contain
inammable gas or hear any gas main or equipment.
No welding 8. cutting jobs are allowed in the areas where gas is likely to be
present without clearance from Gas Safety.
All
are
gas
Gas

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 .

26
27
28
29
30
31
82
33
34
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.

AFETY YSTEM WORK PROCDUR__E_ 8- PROTOCOL FOR GAS

HAZARDOUS JOBS
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
_(i)
<2)
'1rgases
etc. to safeguard persons and equipment.
Gas poisoning due to the presence of Carbon Monoxide.
Injuries to persons andior damages to equipment caused by burns or
exptosions.
It is, therefore, necessary to understand the basic safety principles in
handling,
and equipment such as pipe lines, lighting up and shutting down of furnaces,
However," the following general safety
precautions are given as a guldeiine to understand the safety aspect better.
(l)
at Gas pistrlbution Svstem
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 fell below 100 mmwo.

(ii)
if the pressurefalls below the above mentioned safe limit, there are chances of

air enteringinto thegas,:;rnai_n_. and causing backres 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 beclosed ifthe pressure-tails below the safe limits and Energy
Centre should be informed.
Water Drainers :- Water drainers of standard type are to be provided in gas
mains. The water drainers with their water inlet, drain and overow valves-and
connections should regularly be inspected and should be in a condition to be
lled up at" a short notice. The valve should be of gate or cook type in good
operating condition and easily approachable. Low pressure water drainerlHigh
pressure water drainer should be used depending upon the gas line network
pressure. i
Bieeders and Steammltrggan purging cognection 1- The steamiblitrogen
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 suiticlentiy 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. Bleeciers 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.
l lnsggction 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
EMD 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.
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 bieeder.
b) Deblank gas line as per standard gas safety practices.
cl Charge the gas line with inert media uptc the end breeder.
cl) Stop steamlnitrogen and purge the gas from end bleeder till oxygen
content comes below 1%. e) Finally close the end bleeder, and disconnect steaminitrogen hose
connections.

Pnocgourte or= siiutoowu or: arms MAINS ANg_ouIPM___rg_nT FOR l3r_e1;Ig

wgnk iNc;__u_ome gyrrme rwg_L_r_:>iNo age
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. 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

a) No two goggle valves should have common hydrauliclelectrical system.

b) After goggle valve operation the power supply must be switched off and
fuses should be removed to prevent the malfunctioning of it.
c) For maintenance of goggle valve an isolating ange should be provided
before the goggle valve.
\_Cl
All branch pipes on the portion of the pipe to be isolated, should be cut oii by

putting blanks at the nearest flanges.

PURGING
1.
All steamlbiitrogen 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.
2. As soon as blanking is over, the purging points and the end bleeder should be
opened and the condensate should be drained out.
3. Progress of purging shouid be recorded. The aim shouid be at complete
replacement of combustible gas from the point of blanking up to end of the pipe.
4. 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 wili 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 bieeder/open
manholes. '
VENTILAIION
Alter proper purging, all the manholes and end anges, if necessary should be
opened, so that circulation of atmospheric air is welt established from one end
to the
other. Duration of ventilation will depend on size and total iength of pipe to
be ventilated
and purpose of work.
SAMPLING AND CLEARANCE FOR THE JOB

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

* KEEP CHIMNEY DAMPER OPENED.

5. GUIDE LINES FOR PROTOCOL FOR GAS HAZAR@US WORK I
_ All gas line jobs should be done on a protocol in order to assign
responsibility
and effective co-ordination among various agencies involved and also to provide
check
listsfpoints to ensure that no important step is over looked. The format is as
foliows :
SHOP
Approvedby
Heading :- (Write down the main heading for which the hazardous gas job is
planned).
DATE:
TlME :
A. Brief Description :- (Mention in short the necessity of the above job).

8. 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. Overali Coordinator of the job :S.NO. i DESCRIPTION )RE8PONS!BiLlTlES
| - I (By Name)
A. PREPARATORY JOBS : (With names and designation of persons
responsible for Execution)
i)
ii)
iii)
E3. ACTUAL JOBS :- (Details of operation in sequence with name and designation
of persons respcnsibielsection responsible).
5)
ii)
iii)
iv)
C. SAFETY PRECAUTKDNS :- (Ail safety precautions including fire prevention &
rescue steps taken).
l) ?
ii)
iii)
SlGNATORiES :- Oral! the rsonsco nected fit 0 to be mentioned here
(with namgg. desiuna ton and eoanr'rleR. _
I

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.

No smoldering objects should be left at the work spot on stoppage of work. it

should be extinguished before leaving the spot.
Proper scafioidinglplatforrn should be made with escape route for carrying out
the job safely.
A protocol should be made for all gas line jobs, listing all the safety
precautions
required for it. .
Clearance from gas safety to be taken for the start of work.
Open steam hose ShOUld be made available near the pO|Ilt 01' WOFK.

14.
15.
16.
17..
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.

12.
l3
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.

Wher'e"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 claols, saddle supports should be repositioned.
While positioning of clads at the temporarily plugged leakage point, steam
nipple should be welded to the clads for supply of steam. This will help in
"avoiding re. ~
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 clads.
As experienced, if more number of clads are tack welded gas travels from one
clad to another, therefore less number of clads should be first completely
welded and then others should be positioned.
Places where complete welding is not possible, clads should not be positioned.
Not less than two rounds of welding should be done on clads.
After the completion of job, all temporary supports should be removed and
scrap should be properly stacked for disposal and disposed.
All welding/earthing connections should be removed from the spot on
completion of the work.
Open steam hose should be made available near the place of work
Welding work on charged gas line should be done very cautiously and without
any haste.
Welding transformer should preferably have the return cable lines.

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 dilferent consumers is made up of mild steel
quality
of thickness" 8-10 mm.. Gas line of dia. 1600 mm. And above shall be provided
with
stiffening ribs normally 3 metres apart. These stilfenirrg ribs takes care of
circumferential
load on gas line caused due to gas pressure. These are also used for welding the
suboortsfor auxiliary vibes and walk wave alone 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 :
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 -.

3. No moving parts, hence no maintenance. (Except for

maintenance of water drainer)
4. Very less manpower required to create water seal.
6. 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 due 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, orice plates are installed. To
both side of orice 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 I PRESSURE RELIEF VALVE
Rupture disc are made up of 3 mm. Aluminium sheet, tightened between two
anges 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 tire source is suspected. 8. MANHOLES I HAND!-IOLES
Manhoies are given on gas line to facilitate work man to enter
during shut down and also for ventilation purpose. This can be
into a
gas line tapping by a special deblanking process. Manholes are
near
gate valves, compensators or at locations where gas pocket can

into the gas line

also converted
generally located
form.

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

BLAST FURNACE GAS I

heat and reducing gases. B.F.gas
B.Fce. 6.0. L.D.
Explosive 40-70% 630/o 20-70% (By Volume)
I
- - V: H; .
Density 1.33 ll<g/nrn3 ' . U.46Kgl'Nm3_ , 1.37 l<grNm"
Caloric 800 l<.calrl\lm 4300 l<.calll~lm 1300 l<.calrNm"
Value '
Very poisonous Slightly Poisonous, Deadly poisonous
Colourless Highly explosive, colourless, Odourless
Odourless Cclourless Typical
smell of hydrogen
sulphide and
Naphthalene
l ems with _ Blue ame _ Yellow ame Blue flame
Heavier than T Lighter than Heavier than
air air air
SOURCES OF GASES :
E3.F.gas is generated in Blast Furnace where Coke is burnt to produce
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
: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

it is a byproduct of Coke Ovens and the percentage of Carbon

\a) Coke Oven cellars
b) Coke Oven top
Monoxide ranges from B to 7%. Following are the areas where this gas may be
present
C) Old as weli as New ByProduct Plants
Main Boosters and Exhauster Houses
Area close to CO. gas lines, drip pot, goggle valves etc.
Ail instrument control cabins in the Coke Oven and By-Product Piant
) All GO. gas consumers in piant
\
ICONVERTOR GAS 1
This gas is generated at Converter Shop in the LD. Converter during the
Steel Melting Process. it contains about 65 to 87% 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 :
................_...-..-...............FRE
EXPLOSION
GAS POISONING
Fire is a controiled burning reaction of gas mixture.
Action to be taken in case of fire in Gas Main 2
i. if gas catches fire during work or through some crack, or because of

some leakage, it should be extinguished with ciay, steam, CO2

extinguishers, water, Dry Chemical Powder etc. The portion of the gas
main should be ccoied down with water and only after the re is
extinguished, should the main valve be closed completely for carrying
out repairs.
ii. it should be remembered that the valve is not to be closed when tire is
still there and the pressure in the main should not go down below 100
mmwc
THE TETRAHEDRON OF FIRE
Heat
Oxygen
Fuel
Chain of reaction
J-.W!\7.
EXPLOSION
Explosion is a fast rate of reaction of explosive mixture releasing energy
form of sound,
in the
pressure and heat.
The following two conditions can cause explosions 1
ii.
The gas and air mixture must be within their explosive range.
The heat must be sufficient enough to ignite the resuitantrnixture 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 EXFLOSIVE UPPER EXPLOSIVE
LiMiT OF GAS iii! LIMIT OF GAS IN
THE MIXTURE THE MIXTURE
(% By Volume) (% By Volume)
with resgect to air '
CARBON MONOXIDE 12.5 74.2
METHANE 5 fl 5,__
HYDROGEN 4 75
ACETYLENE 2.5 92
COKE OVEN 6 ' 30
BLAST FURNACE 40 70
CONVERTER 20 70
L.P.(3. 1.9 9.5
CONDITIONS WHICH CAN CAUSE EXPLOSION
. . M The following
. . formation of an explosive mixture and causing explosion.
e"ene

operating conditions in handling gas are conducive to the

lrnproper purging of gas lines and equipment.
improper charging of a gas main.
Adopting the wrong procedures in lighting a furnace.
Esieeder discharging gas into a space where gas is likely to come
contact with a source of ignition.
ignoring the dead pockets (Trapped explosive mixture) in the shut oif
gas lines.
Gradual and unexpected gas leakage from broken or cracked
valveslgas lines (specially coke ovens gas) into closed and semiclosed
spaces which may include pockets under the furnace platforms,
underground or overground galleries, or unauthorised sheds around or
near the furnaces.
Delay in applying ignition source while lighting up a furnace.
Leakage of unburnt gas into furnace
in to