1. ISSHR2015 - Bio-data of speaker
Name:
VIJAY KUMAR
Designation:
Jt. General Manager (FS&PD)
Organisation:
MECON LIMITED
Work Experience:
32 years of experience in Design & engineering of Gas pipelines, Gas cleaning Plants & other gas related facilities
Awards/ Achievements:
Certificate from MECON, CMD for excellence in the field of knowledge sharing in BOF gas cleaning plant
Papers published/ presented:
Paper on disaster management presented in Institution of engineers

2. GAS SAFETY IN STEEL PLANT Jt.General Manager, FS&PD
WELCOME TO
PRESENTATION ON
GAS SAFETY IN STEEL PLANT BY
VIJAY KUMAR
Jt.General Manager, FS&PD

3. WHY SAFETY CHECKS BEFORE CHARGING OF GAS NETWORK?
IN STEEL PLANTS INHOUSE GENERATED FUEL GASES ARE
BF GAS
LD GAS (BOF GAS)
COKE-OVEN GAS
MIXTURE OF ABOVE GASES
THE ABOVE GASES ARE HIGHLY HAZARDOUS AND TOXIC IN NATURE.
THIS REQUIRES STRINGENT SAFETY BEFORE CHARGING TO ENSURE SAFE & RELIABLE OPERATION.

4. CHARACTERISTIC OF BLAST FURNACE GAS (BF GAS)
Typical composition:-
Constituent
% by Volume
Carbon Monoxide (CO)
22.2
Carbon dioxide (CO2)
19.2
Hydrogen (H2)
4.0
Nitrogen (N2)
54.4
Oxygen (O2)
0.2
BF GAS GENARATION RATE FROM BF
Nm3/t of hot metal
(1.32 G.cal/t of hot metal)
Properties:-
Gross calorific value
Kcal/Nm3
Dust Content (Before GCP)
10-15 g/Nm3
Dust Content (After GCP)
5 mg/Nm3
Water vapour
0.5 gm/Nm3
Density
1.33 to 1.35 kg/Nm3

5. CHARACTERISTIC OF BASIC OXYGEN FURNACE GAS (BOF GAS)
Typical composition:-
Constituent
% by Volume
Carbon Monoxide (CO) 65
Carbon dioxide (CO2)
17.8
Hydrogen (H2)
1.5
Nitrogen (N2)
15.5
Oxygen (O2)
0.2
RECOVERABLE BOF GAS GENARATION RATE
80 Nm3/t of hot metal
(0.16 G.cal/t of hot metal)
Properties:-
Gross calorific value
2000 Kcal/Nm3
Dust Content (Before Scrubber)
g/Nm3
Dust Content (After Scrubber)
50 mg/Nm3
Dust Content (After ESP)
5 mg/Nm3
Density
1.33 to 1.35 kg/Nm3
GAS GENERATION AT CONVERTER MOUTH
1.8 to 1.9 X O2 blowing rate

6. CHARACTERISTIC OF COKE OVEN GAS (CO GAS)
Typical composition:-
Constituent
% by Volume
Carbon Monoxide (CO)
7.1
Carbon dioxide (CO2)
2.4
Hydrogen (H2)
58.4
Nitrogen (N2)
3.6
Oxygen (O2)
0.4
Methane (CH4)
25.7
Ethane (C2H6)
COKE OVEN GAS GENARATION RATE
Nm3/t of dry coal charge
(1.32 G.cal/t of dry coal charge)
Properties:-
Gross calorific value
Kcal/Nm3
Tar fog
0.005 gm/Nm3
Density
kg/Nm3
Hydrogen Sulphide
3.40 gm/Nm3
Ammonia
48.0 mg/Nm3
Naphthalene
92.0 mg/Nm3

7. Physiological effects of CO on human body
Poisoning effect of CO is based on the fact that it combines easily with the haemoglobin of the blood forming carboxy-hemoglobin. The affinity of “CO” for haemoglobin is 300 times that of oxygen. When oxygen is replaced by “CO” in the haemoglobin of the blood capacity of hemoglobin carrying O2 to the tissues cannot function properly because of oxygen hunger and more and more accumulation of CO in the haemoglobin of blood at a certain stage stops the function of body. The symptoms of CO poisoning are headache, weakness, dizziness, vomiting, fainting, collapse, coma, respiratory failure and death.

8. EFFECT OF CO ON HUMAN BEING
CO CONTENT IN PPM
EFFECTS ON HUMAN BEING 50
None (Maximum level of exposure for 8 hours working per day)
100
Tightness across forehead, headache within 1-2 hours
200
Severe headache, throbbing sensation in the head, dizziness caused within 1 – 2 hours
600
Severe headache, weakness, shortness of breath, dizziness, dimness of vision within 1-2 hours
800
Unconsciousness, depressed heart action and respiration, death is possible within 2 hours
1000
Weak pulse and slower respiration, respiratory failure and death within 2 hours
1600
Headache, dizziness and nausea in 20 minutes, collapse, unconsciousness, possibly death in 2 hours
6400
Headache, dizziness in 1- 2 minutes, unconsciousness and danger of death in 10 – 15 minutes
12800
Immediate effect, unconsciousness and danger of death in minutes

9. SAFETY CHECKS REQUIRED BEFORE CHARGING
CHECKING OF PURGE POINT WITH CONNECTION DETAILS
VENT ASSEMBLY OF ADEQUATE HEIGHT WITH SAMPLING POINTS
GAS CONDENSATE DRAINS USING SEAL POTS
POSITIVE ISOLATION SYSTEM (U-SEAL)
ISOLATION VALVES
APPROACH LADDERS/STAIRCASES FOR MAINTENACE PURPOSE
PLATFORMS, CROSS OVERS AND WALKWAYS WITH HAND RAILS & TOE GUARDS

10. SAFETY CHECKS continued….
MEDIA PIPES FOR ISOLATION AND PURGING NEEDS
LAYING OF FUEL GAS PIPES WITH OTHER PIPES CAUSING HAZARD
CONNECTIONS OF HOSES
NRV AT T.O.P. OF EACH SHOP FOR PIPES HAVING INTERFACING WITH FUEL GAS PIPES
GAS DETECTION AND ALARM SYSTEM & AVAILABILITY OF PORTABLE CO MONITORS
HAZOP STUDY

11. SAFETY CHECKS continued….
VISUAL INSPECTION
RE-TESTING OF PIPELINES FOR LEAKAGES
PROPER DRAINAGE OF DRAINS FROM GAS LINES
VALVE REVISIONING & HOLDING TEST
EXPANSION JOINTS
CHECKING OF SUPPORT TYPE AND ITS WELDING
HEAT PROTECTION SHEILDS

12. SAFETY CHECKS continued….
FAIL SAFE POSITIONS OF CONTROL VALVES
DEDICATED VESSELS FOR UNINTERUPPED AIR SUPPLY TO VALVES & INSTRUMENTS
SAFETY POSTERS

13. WHAT IS HAZOP STUDY?
HAZOP is a very useful technique for hazard evaluation.
The basic assumption in HAZOP is that the process will work well safely as long as it is operating under design conditions.
The objective is to identify the problems which might arise when deviations from design conditions occur.
HAZOP is also called “what if” method.
HAZOP study highlights the hidden operability problems and identifies hazards.
HAZOP is a brainstorming approach which stimulates Creativity and procedure for generating ideas.
HAZOP study is generally undertaken for units involving process controls and not applicable to units where the process and operations are mechanical in nature.

14. IMPORTANT TERMS & GUIDE WORDS USED IN HAZOP STUDY
Meaning
Comments
None / No
No Action
No part of the intention is achieved; e.g. No flow, No Pressure.
More
Quantitative Increase
More of any relevant physical property than there should be; e.g. higher flow, higher temperature, higher pressure,
more heat, etc.
Less
Quantitative Decrease
Less of any relevant physical properly than there should be; e.g. lower flow, lower pressure, less heat etc.
IMPORTANT TERMS
Intention
Deviation
Causes
Hazards
Consequences

15. HAZARD & ITS ANALYSIS
Hazard is a physical situation, which may cause human injury, damage to property or the environment or some combination of these.
The hazard may be created by a chemical and is indicated by fire, explosion, toxicity, corrosiveness etc.
The potential of different chemicals to create hazard varies.
Type of HAZARD are as follows;
1. Flammable substance
2. Oxidising substance, reacts with reducing agents.
3. Emits a toxic gas or vapour
4. Emits an irritating gas or vapour
5. Emits a narcotic gas or vapour
6. Gas or vapour not dangerous other than displacing air
7. Causes skin irritation or burns
8. Toxic substance
9. Explosive material under certain condition

16. THANK YOU