GAS LINE MAINTENANCE

&
SAFETY PRACTICES
IN
BOKARO STEEL PLANT
 PRESENTED BY:

VINOD KUMAR

MANAGER

ENERGY MANAGEMENT DEPARTMENT

BOKARO STEEL PLANT

 BOKARO STEEL PLANT
BF, CO & CONV. GAS NETWORK

LRSII
MIXER
4/37 SMS-II CCD
30
GH-2 24 26/24
RSRS
IMY
43/11
43/28
SL. MILL HSM
GH-1 43/45 SMS I 195/7
RGBS
MIXER
IMF GMBS
158/63 202 234 253
69 85 126 158
172 186 195 222
144
FORGE
SHOP HCl
65/11 BMS RRS
144/9
HRCF
M/C PGP
ICF SHOP

65/42
202/12
DSU
202/14 RRHS
202/15
126/40

STEEL CRM
FDY
STRL. 144/40
SHOP
 GAS LINES IN BSL

We at Bokaro Steel Plant to follow the

basics:

• DESIGN IT RIGHT

• OPERATE IT RIGHT AND,

• MAINTAIN IT RIGHT
 Safety by Design in Existing
Gas Lines
• Russian Design as per GOST Codes,
Standards and Specification
• There are no explosion flaps in the ODPL
network
• Expansion joints are provided to take up a
maximum compensation of 40mm per
compensator
• Condensate drain points are provided at
regular interval to take up the load of
condensate from the gas line
• Purging points and bleeders are designed for
steam (media)
Contd.
 Safety by Design in Existing
Gas Lines
• For large dia. Pipelines, supports are designed
with high factor of safety (four legged rigid and
two legged swinging type flexible supports)
• Smaller dia. pipelines (up to 1000mm) have
sliding / rolling type flexible supports
• Slope of the gas lines is maintained at a rate
5mm per meter.
• All the branch lines emerging out of main gas
line are provided with rising stem type gate
valves as isolation valves.

Contd.
 Safety by Design in Existing
Gas Lines
Limitations
• All the branch lines emerging out of main gas line are
provided with rising stem type gate valves as isolation
valves. No provision of U seals for quick & safe
isolation of Branch lines.
• No provision for partial isolation of main gas
network
• No alternate gas line
• No provision of continuous online CO monitoring
facility at potential hazard area.
• No provision of gas holders for BF & CO gas.
 Improvement in Original Design

• Action initiated to include provision of Water U-seals

at strategic places for isolation purpose.
• Provision of U seals has been included in all the
upcoming gas lines under modernization.
• Continuous online CO monitoring facilities has been
installed at potential hazard area.
• Provision of Nitrogen purging has been introduced at
many places. ( 5 locations)
 The individual components of Gas
line system are

• Pipe
• Piping fittings
• Valves
• Expansion joints
• Bolts and gaskets (fasteners and sealing)
• Accessories such as bleeders, purging
points, Drains, pipe supports etc.
 Safety of Gas lines by
Maintenance Practices
Good, effective and safe maintenance of the
gas lines can be ensured by:
• Proper understanding of the design of gas
lines and its equipments
• Proper understanding of the Gas safety
aspects involved in the job each time
• Use of the latest applicable codes/ standards
like IPSS, IS, ASME, etc.
 Safety of Gas lines by
Maintenance Practices

Maintenance practices for gas lines is can

be divided into two categories:

• Preventive (both in charged and isolated

conditions) and,
• Corrective (both in charged and isolated
conditions
 Safety of Gas lines by
Maintenance Practices

Preventive maintenance practices in BSL

include:
• Schedule maintenance of gas line
equipments with emphasis on keeping Drain
pots in healthy condition
• Thickness measurement of gas lines at
identified critical locations
• Cladding of the gas lines and painting
 Safety of Gas lines by
Maintenance Practices
Corrective maintenance practices in BSL
include:
• Regular leakage detection, corrosion detection &
control, of critical areas
• Twice a year, members of a dedicated task force
walk every foot of the pipeline –with digital CO
monitor which can detect extremely low
concentrations (Parts Per Million) and to look for
physical condition of the pipeline and the
structures.
 Safety of Gas lines by
Maintenance Practices

• Immediate control of gas leakage by

temporary means like clamping, cold
welding with steel putty or M-seal etc.
• Permanent repair of the defect either by
welding or replacement of the part as the
case may be
• Proper Gas Safety protocol is followed for
every case irrespective of method of
rectification (online or isolated condition)
 Safety of Gas lines by
Maintenance Practices
Effective and extensive use of gas safety tools/
equipment like:

• Closed circuit self contained Oxygen Breathing apparatus (Gas

masks)
• Artificial Breathing Apparatus (ABA)
• Fresh Air Breathing Apparatus (FABA)
• Compressed Air Breathing Apparatus (CABA)
• Digital CO detector
• Explosimeter
• Oxygen Analyzer etc.

in both preventive and corrective maintenance

practices
 Safety of Gas Lines by
Operational Practices

At BSL some of the operational measures

adopted towards safety of gas lines include:

• Adhering to SOPs
• On-line monitoring and control of gas net
work pressure and flow round the clock.
• Control room operators are highly skilled at
responding to emergency situations
 Safety of Gas Lines by
Operational Practices

The massive task of safe handling of the gases

can be gauged from Production of gases in
BSL

• BF Gas -1000x103 Nm3/hr

• CO Gas - 125-130x103 Nm3/hr
• LD Gas - 10-12x103 Nm3/hr (this is being flared
currently)
 Safety of Gas Lines by
Operational Practices
Network pressure maintained by Gas Control
through :
• Diverting / Reducing gas to Buffer Consumer
(Power plant)
• In extreme cases, Pressure is maintained by
• Releasing Surplus gas through Flare stacks / bleeders.
– BF Gas - 2 x 120000 Nm3/hr.
– CO Gas - 2 x 30000 Nm3/hr.
• Restricting gas to the low priority customers in case of
shortage.
 Safety of Gas Lines by
Operational Practices

Process Safety Management is further

ensured by:

• Training programs for the new staff

• Refresher courses for the existing staff
• Checking of safety interlocks as per schedule
• Mock drills for emergency situations like
Power Failure, Gas Leakage etc.
 SAFETY RELATED INCIDENT –
A CASE STUDY OF NEAR MISS
Job Description:
Cladding of a leaking double disc compensator
installed in the BF gas line of Dia. 3000mm
The Job involved cutting & welding and had to be
carried out online as it was on main gas network
which cannot be shut down
Challenges:
• A Coke Oven Gas Gland Compensator just below
this BF gas compensator at a gap of about 1.5m
• The CO concentration on the working platform was
more than 1500PPM
• The height of the gas line 14m and large pipe dia.
 SAFETY RELATED
INCIDENT
Potential Hazards in the job;
• Gas Exposure hazard
• Fire hazard
• Explosion Hazard
• Working Height Hazard
All the related risks were considered and a
proper protocol was prepared to carry out
the job safely
 SAFETY RELATED INCIDENT
As per Plan
• Two welders to work from both side of Gas line.
• One supervisor to supervise the job.
As per protocol
• No additional worker was allowed on working platform
• Arrangement to use Compressed air masks by all
three.
• Arrangement of Standby fire tender.
• Arrangement of Rescue Van equipped with all
accessories at site.
• Two air blowers from both side to disperse gas from
platform.
• Arrangement of running steam hose on either side.
 SAFETY RELATED INCIDENT

The incident
• Supervisor noticed that one welder on
opposite side had stopped welding.
• Supervisor tried to contact by shouting.
• No response from welder.
• Supervisor immediately crossed over the
Gas line.
• The welder found talking on mobile phone
without mask.
 SAFETY RELATED INCIDENT
Action taken
• The welder was immediately instructed to wear the
mask and leave the job.
• The welder got down the stairs on his own along with
the supervisor and was apparently appearing to be
normal.
• However, as a precautionary measure he was given
Oxygen with the help of Artificial Breathing
Apparatus
Though the incident did not result in any
kind of gas exposure to the welder due to
alertness of supervisor but this could have
been serious.
THANK YOU