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

TAKING MEASURES ACCORDINGLY

AND

CO GAS U-SEAL
AND
SEAL POT

Gas composition
Mixed
Gas(BFG+BOF)

CBM

16.2

22.38

1-2

26.9

69.3

32.4

4-7

46.2

14.5

42.1

% vol

52-59

--

--

--

CH4

% vol

24-28

--

--

--

95-97

Other gases

% vol

1.5-2.5 3.6

--

3.14

2-4

2000

1054

8300
(NCV)

Constituents

Unit

COG BFG BOF

CO2

% vol

3-4

23.3

CO

% vol

6-7

N2

% vol

H2

Calorific Values Kcal/Nm3 4250

914

Gas properties
SN

Source

COG

BFG

Blast furnace gas, a byCoke oven gas, is the gas

product of blast furnaces,
obtained when coal is
is generated when the iron
heated in an air tight
ore is reduced
place
with coke to metallic iron

Hazardous or Categorized as
Not
hazardous/toxic gas

Categorized as
hazardous/toxic gas

Colour
Odour

Yellowish
Pungent

Colourless
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
taken from COG header.
There are one drain-pot
individual boiler.

connected

to

each

lines

U-seal

of

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

U-SEAL facts
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.

CO GAS
SEAL POT

CENTRAL POWER TRAINING INSTITUTE

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.

2000
Mm
WC

When pressure rises above 2000

mm WC, then it throws out the
water from the over flow outlet.
A Category-I & ISO 9001:2000 Certified Institute

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
3. Near
4. Near
5. Near
6. Near

Boiler Area
DM Plant
Cooling Tower
Cooling water Pumphouse

Safety in cabale galleries & trenches

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.

ADDITIONAL MEASURES TO BE TAKEN

THROUGH SOPS & SMPS
Always ensure overflow in the Drainpot 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

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

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

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 unauthorized 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

SAFETY RULES DURING AN

EMERGENCY
Never
Always
Never fail to
Always study
anticipate
every
emergencies.
conceivable
Do not wait
emergency and
until something
plan exactly
happens to
what moves to
start the
make.
thinking

SAFETY RULES DURING AN

EMERGENCY
Never
Always
Never start to
Always proceed to
manage
proper valves or
emergency
switches rapidly but
without
without confusion in
understanding time of emergency.
what exactly
You can better
has happened
walking than
running.

Thank You