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UPGRADATION OF GAS SAFETY PRACTICES IN BHILAI STEEL PLANT

UPGRADATION OF GAS SAFETY PRACTICES IN BHILAI STEEL PLANT. P. K. SINGH DGM (Gas Safety) Energy Management Dept Bhilai Steel Plant Steel Authority of India Ltd pksmargam@gmail.com

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UPGRADATION OF GAS SAFETY PRACTICES IN BHILAI STEEL PLANT

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  1. UPGRADATION OFGAS SAFETY PRACTICESINBHILAI STEEL PLANT P. K. SINGH DGM (Gas Safety) Energy Management DeptBhilai Steel Plant Steel Authority of India Ltd pksmargam@gmail.com M: 09407981597

  2. OBJECTIVE • To analyze Gas Safety Practices of the plant • Challenges in handling of by product gases in steel plants • Enforcement of best safety practices to minimize the effect of gas hazards भिलाई इस्पातसन्यंत्र स्टील आथारिटी आफ इन्डिया लिमिटेड

  3. GAS NETWORK-CONSTRAINTS • Most complicated gas network • Difficult to take shutdowns • Maintenance of gas line is challenging • Manpower oriented Total length of the gas line is approx 64 KM भिलाई इस्पातसन्यंत्र स्टील आथारिटी आफ इन्डिया लिमिटेड

  4. RING MAINS IN GAS NETWORK • Ring main helps in isolating a segment of gas line without affecting other units. • It minimizes fluctuations in gas pressure due to feeding from two ends. भिलाई इस्पातसन्यंत्र स्टील आथारिटी आफ इन्डिया लिमिटेड

  5. GAS LINE INSPECTION & NDT • As per IPSS: 1-06-038-01 (Inspection of Utility pipelines) gas line inspection once in three months and ultra-sonic thickness testing once in two years is carried out. • Based on visual inspection and reduction in thickness of the gas line (40% from its original), repair/replacement is planned. भिलाई इस्पातसन्यंत्र स्टील आथारिटी आफ इन्डिया लिमिटेड

  6. USE OF IS-2062 GRADE-B PLATE IS-2062 Grade “B” MS Plate is used for new gas lines which are long lasting and resistant to corrosion. The heat with Copper content 0.2% to 0.35% is developed in the Converter shop and SLAB is rolled in the Plate Mill for usage in gas line. भिलाई इस्पातसन्यंत्र स्टील आथारिटी आफ इन्डिया लिमिटेड

  7. TIMELY REPAIR/REPLACEMENT OF GAS LINES BSP has replaced majority of gas lines safely & successfully in a phased manner. भिलाई इस्पातसन्यंत्र स्टील आथारिटी आफ इन्डिया लिमिटेड

  8. INTERCONNECTION OF GAS LINES AT CRITICAL LOCATIONS Interconnection of Blast Furnace and Coke Oven gas line at critical locations are highly useful in maintaining positive pressure in the network with the available gas during emergencies. On SIX occasions, interconnections have saved BSP during major gas emergencies. भिलाई इस्पातसन्यंत्र स्टील आथारिटी आफ इन्डिया लिमिटेड

  9. USE OF FIBRE SHEETS FOREXTERNAL CORROSION External corrosion of pipe lines due to phenolic spray (near Quenching tower of COB) is eliminated by using FIBRE SHEETS. भिलाई इस्पातसन्यंत्र स्टील आथारिटी आफ इन्डिया लिमिटेड

  10. INTRODUCTION OF PHA PHA and CA is an excellent tool to methodically identify, evaluate, and develop systems to control significant hazards in a process. Started in COB and RSM. In most of the shops HAZOP study has been carried out and risks are identified for time bound mitigation. भिलाई इस्पातसन्यंत्र स्टील आथारिटी आफ इन्डिया लिमिटेड

  11. GAS PIPELINE INCLUDED IN ERM BSP has included ageing of gas line in the “Enterprise risk management” (ERM). Threats of gas line can have major impact on the business of the plant hence, it risks needs to assessed properly for determining a response strategy and monitoring progress. भिलाई इस्पातसन्यंत्र स्टील आथारिटी आफ इन्डिया लिमिटेड

  12. U-SEAL ISOLATION IN GAS NETWORK • U-seal is the best methodology for isolation of gas line. • Safe and easy to operate. • Required less manpower • Surrounding areas are not affected • No gas hazard भिलाई इस्पातसन्यंत्र स्टील आथारिटी आफ इन्डिया लिमिटेड

  13. PROVISION OF NITROGENPURGING SYSTEM In extreme emergencies, nitrogen can be injected immediately (from three identified locations) in the gas network to maintain positive pressure all the time, thus safety of the gas network is ensured. भिलाई इस्पातसन्यंत्र स्टील आथारिटी आफ इन्डिया लिमिटेड

  14. SCHEDULE WATER DRAINER MAINTENANCE • Average frequency of water drainer inspection is once in a fort night. • Critical drainers (Drainers which are connected at Valley or bottom portion of U-seal of gas line) are checked once in a week. भिलाई इस्पातसन्यंत्र स्टील आथारिटी आफ इन्डिया लिमिटेड

  15. GAS SAFETY EQUIPMENTS भिलाई इस्पातसन्यंत्र स्टील आथारिटी आफ इन्डिया लिमिटेड

  16. CONCLUSION The real enemy of Gas Safety is not non-compliance but non-thinking. Rules are parts of systems and systems serve humans. Awareness regarding potential hazard and required safety norms to abide by should be step towards gas safety. भिलाई इस्पातसन्यंत्र स्टील आथारिटी आफ इन्डिया लिमिटेड

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