reply / response to eac committee recommendations ... · m/s bhilai steel plant project...

Reply / Response to EAC Committee Recommendations / Observations

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M/s Bhilai Steel Plant project "Modernization-cum-expansion of Bhilai Steel Plant (CrudeSteel capacity from 4MTPA to 7.0 MTPA; Captive Power Plant - 76 MW; TRT -14 MW &CDCP – 4 MW; Total Power Generation: 94 MW) at Bhilai, Chhattisgarh by M/s SteelAuthority of India Limited [Online proposal No. IA/CG/IND/67974/2017; MoEFCC File No.J-11011/28/2007- IA-II(I)] for Environmental Clearance, was appraised before EAC in the1st meeting of the Re-constituted EAC (Industry-I) held during 26 to 28 November, 2018,under Agenda point 1.2 of the EAC meeting. The reply / response to EAC committeerecommendations / observations is given hereunder in Table A.

Table A : Reply / Response to EAC Committee Recommendations / ObservationsEACObservationNo.

EAC Recommendations /Observations

BSP's Reply

1. Revised HazardIdentification and RiskAssessment report alongwith the action plan specificto the project addressing allpossible hazards / risks.

Subsequent to the accident held at Bhilai Steel Plant& as per the above recommendation of EAC,MoEFCC. BSP has undertaken the following safetymeasures.

a. All the Hazard Identification and RiskAssessment (HIRA) documents of the criticalshops have been revised with special emphasison Gas Safety during operational andmaintenance activities pertaining to Gas line.

b. Revision in the SOPs has been carried out inview of the changes in HIRA documents.

c. Engineering measures have been taken forensuring safety in plant operation andmaintenance activities.

d. Decision has been implemented not to carry outon-line gas maintenance and repair activities.

e. SAIL is in advance discussion with worldrenowned Consultant M/s. DuPont, for seekingtheir services for organizing safety audit ,review & provide recommendations for theimprovement of existing safety managementsystem/ The focus areas during the study shallbe “Gas Safety, Iron making & Steel making”

A copy of the “Revised Hazard Identification andRisk Assessment (HIRA) report along with the actionplan specific to the project addressing all possiblehazards / risks is enclosed for kind reference asAnnexure I


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EACObservationNo.


BSP's Reply

2. Revised time bound actionplan including budgetaryprovisions for the issuesraised during the publicconsultation.

Revised time bound action plan including budgetaryprovisions for undertaking developmental activitieswith respect to the issues raised vis-a-vis BSP'scommitments made during public consultations /public hearing is given in Table 2. The details ofissues raised during public hearing, BSP'scommitments and developmental activities finalisedalong with budgetary provisions and time fame isattached as Annexure II.

3. Revised CER as per theguidelines issued by theministry vide OM dated 1stMay, 2018.

The CER for the proposed project have beenrevised as per MoEFCC Office Memorandum (OM)F.No. 22-65/2017-IA.III dated 01st May, 2018.

The Capital cost for the proposed project is Rs. 273Crores and the CER for the proposed project inview of MoEFCC OM dated 1st May 2018, comes toabout Rs. 2.3 Crores as shown in Table 1.

Table 2 shows the time bound action plan alongwith budgetary provisions for the developmentalactivities to be undertaken by BSP in response tothe issues raised vis-a-vis BSP's commitmentsmade during public consultations / public hearing.

Table 1 :CER Calculation as per MoEFCC OM Dated 01.15.2018SN Capital Investment

/ Additional CapitalInvestment (in Rs)

Brown Field Project- % of Additional

Capital Investment

CER for the Proposed Project (CapitalCost Rs. 273 Crores)

Project Cost (Rs.) CER Amount (Rs.)1. ≤ 100 Crores 1% 100 Crores 1 Crore2. > 100 Crores to ≤

500 Crores0.75% 173 Crores 1.2975 Crores

Total 273 Crores 2.2975 CroresSay 2.3 Crores

Table 2 :Action Plan (Schemes) Planned as CER Project - Based on Issues Raised DuringPublic Hearing

SN. Village CER Project : Schemes Finalised / PlannedBased on Issues Raised During Public Hearing

BudgetProvision

(Rs. Lakhs)

CompletionYear

1 Selud New Bore well fitted with Solar operated pump withstorage tank at three places shall be provided

15.00 2021-22

Four Seater Sulabh Shauchalya at Bazar Chowkshall be constructed.

6.00 2020-21


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BudgetProvision

(Rs. Lakhs)

CompletionYear

2 Khapri(Kuatelabhata)

Boundary wall of Panchayat Bhavan with treeplantation all around the periphery shall beconstructed.

10.00 2021-22

New Bore wells at 2 locations fitted with Solaroperated Pumps shall be provided.

10.00 2020-21

Two extra rooms in Govt. Primary School shall beconstructed.

10.00 2020-21

Dustbin for 10 villages shall be provided 0.50 2020-21Beautification and tree plantation around ShitalaTalab shall be provided.

2.00 2020-21

3 Dhumardhi Service road from main road to cremation groundapprox..700 meters shall be cemented

10.00 2021-22

Pipeline for drinking water pipeline shall be extendedfurther by 1000 m approx.

7.00 2020-21

4 Pauwara Sanitary Pad Machine to women group shall beprovided

3.00 2020-21


7.00 2020-21

Tree plantation at new talab shall be provided 1.00 2020-21Tree plantation at unused land shall be done. 1.00 2020-21

5 NGO(Muskan) Garage for School Bus at Muskan School shall beconstructed.

1.00 2020-21

6 Pathora Four Seater Sulabh Shauchalya at Govt. Middleschool for boys shall be constructed.

3.00 2019-2020

Boundary wall at high school of length 165 metershall be constructed.

15.00 2021-22

State government is already taking up theseactivities

7 Dhuarabhatta Four seater Sulabh Shauchalya at Khadan Talab forboth men and women shall be constructed.

12.00 2020-21

Additional 2 class rooms at High school premiseshall be constructed.

10.00 2021-22

Boundary wall of approx. - 380 meters shall beconstructed at high school premise.

20.00 2021-22

Construction of separate toilets for both boys andgirls shall be constructed.

5.00 2020-21

8 Mahakakala -Mudpaar

Pipeline for drinking water pipeline shall be extendedfurther by 1000 m approx. meters in ward no01,06,04

7.00 2020-21

C.C. road shall be constructed at ward no 05 forapprox. 250 meters.

4.00 2020-21

C.C. road shall be constructed at ward no 04 forapprox. 250 meters.

4.00 2020-21

Four seater Sulabhh Shauchalya for boys and girlsshall be constructed.

12.00 2020-21

Will be taken up through CSR department of BSP10 Aundhi Pipeline for drinking water pipeline shall be extended 7.00 2021-22


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BudgetProvision

(Rs. Lakhs)

CompletionYear

further by 1000 m approx.C.C. road shall be constructed from Ward No 14 toWard No 20Will be taken up through CSR department of BSP

10.00 2021-22

12 Pahandor New Bore wells at required location fitted with solaroperated Pumps shall be provided.

10.00 2021-22


7.00 2020-21

13 PariyavaranMitra Mandal,Bhilai

One E-rickshaw shall be provided to facilitate theplantation activities

3.00 2020-21

One Power driven portable drilling machine tofacilitate the plantation activities

1.00 2020-21

14 Mahakakurd New Bore well fitted with Solar operated pump withstorage tank at one place shall be provided

5.00 2021-22

Four seater Sulabhh Shauchalya for men andwomen shall be constructed

12.00 2020-21

Total 232.25


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Table A Contd. : Reply / Response to EAC Committee Recommendations / ObservationsEACObservationNo.


BSP's Reply

4. Standard OperatingProcedures (SOP) forreporting of non-compliance/infringementsto the Board of Directors atperiodical interval inter aliaincluding in case ofoccurrence of emergency /accident.

Bhilai Steel Plant has well laid-out procedure forreporting of non-compliance / infringements withrespect to environment management to the Boardof Directors at periodical interval inter alia includingin case of occurrence of emergency / accident.

The safety related issues are addressed by SafetyEngineering Department. The Standard OperatingProcedures (SOP) for reporting non-compliance /infringements to the Board of Directors atperiodical interval inter alia including in case ofoccurrence of emergency / accident is given below.a.Environmental non-compliances are reported to

EMD Kolkata on quarterly basis.b.Occurrence of emergency / accident – safety

department sends First Priority Flash Reportto –i. Chief Inspector of Factories cum Labour

Commissioner, Naya Raipur,ii. Secretary, Ministry of Steel, New Delhi,iii. Chairman SAIL, New Delhi,iv. Director SAIL (Technical), New Delhiv. Director SAIL (Personnel), New Delhi,vi. Executive Director (Safety), SSO Ranchivii. Dy. Director, Industrial Health and Safety,

CG Govt.viii. Collector , Durgix. Superintendent of Police , Durg

5. Action plan for 100%utilization / disposal ofsolid waste

The expected generation of Solid Wastes & theaction plan for 100% utilization of solid wastes afterthe stabilization of expansion units is given inTable 3.


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Table 3 : Action Plan for 100% utilization of Solid Wastes (Including Wastes generated from the units to be phased-out after3 Years i.e BF-1, SMS-1,BBM & RMP-1)

SN. Solid Wastes EstimatedGeneration

(t/yr)

Utilisation/ ProposedDisposal

Action for utilization % Utilization afterStabilization of

MODEX projects1. BF slag 2,239,800 Sold to Cement Plants and

utilized in JV Cement Plant.100%

2. BF sludge 52,500 To be used in the SinterPlant.

A scheme for installation of Sludge handling &recycling is under finalisation. Implementation ofthe scheme envisages the recycling BF-Sludge,BOF Sludge after blending & subsequentbriquetting.

Some quantity also to be sold to local recyclers.

100%

3. BF flue Dust 120,008 Sold to cement plant. 100%4. SMS/BOF Slag 747,000 To be used as flux in Sinter

plant/in construction androad making.

Efforts will be made for the utilization of slag alsofor road making

100%

5. SMS sludge / Dust 102,000 To be used in the Sinterplant after briquetting.

A scheme for installation of Sludge handling &recycling is under finalisation. Implementation ofthe scheme envisages the recycling BF-Sludge,BOF Sludge after blending & subsequentbriquetting.

Some quantity also to be sold to local recyclers.

100%

6. Refractory Bricks 20,000 Sale & recycling. - 100%7. Fly Ash 15,000 100% Utilisation as per Fly

Ash Rules.- 100%

8. Unprocessed/aircooled slag fromBF-1

2,75,000 Sold to Slag woolmanufacturers.

Efforts will be made enhance the sale throughaggressive marketing.

100%

9. Sludge from BF-1 6000 To be used in the SinterPlant/Sold to outsideagencies.

A scheme for installation of Sludge handling &recycling is under finalisation. Implementation ofthe scheme envisages the recycling BF-Sludge,BOF Sludge after blending & subsequent

100%


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SN. Solid Wastes EstimatedGeneration

(t/yr)

Utilisation/ ProposedDisposal

Action for utilization % Utilization afterStabilization of

MODEX projectsbriquetting.

Some quantity also to be sold to local recyclers.10. BF flue Dust 10,000 Sold to cement plant. - 100%11. THF- Slag (SMS-1) 1,25,000 Used in leveling & Road

Making.- 100%

12. Sludge from SMS-1 28,000 To be used in the Sinterplant / Sold to outsideagencies.

- 100%


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BSP's Reply

6. Concrete action plan fordisposal of hazardouswaste.

As per Hazardous Waste (Management andHandling) Rules 2016, for the 7.0 MTPAmodernisation-cum-expansion, BSP has beenauthorized by Chhattisgarh EnvironmentConservation Board (CECB) for the specifiedquantity of disposal of Hazardous waste (Table 4).The guidelines of MoEFCC / CPCB are followed inthe handling, storage (temporary) and transportationof Hazardous waste.

The expected generation of Hazardous Wastes afterthe stabilization of expansion units & the action planfor disposal of hazardous waste is given at Table 4.


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Table 4 : Action Plan for Disposal of Hazardous WasteSN. Hazardous Wastes

(HW)Hazardous

Wastes(HW)

Category#

GenerationUnit

Estimated Generationafter Stabilisation of7.0 MTPA Project /Authorisation from

CECB

Storage Mode of Disposal / Recycle / Reusevis-a-vis Action Plan for Disposal

1. Benzol Acid Sludge 13.3 By-productPlant

2,500 TPA 2 Tanks of 10 m3 each Is being sent for co-processing tothe CPCB / CECB authorized co-processer. (M/s. Ambuja Cements)

2. Tar Storage tankresidue

13.5 By-productPlant

1,500 TPA NA Recycled back into in to coke ovensalong with coal.

Sold to authorised recyclers.3. Decanter Tank Tar

Sludge13.4 By-product

Plant4,000 TPA NA Recycled back into in to coke ovens

along with coal. Sold to authorised recyclers.

4. Used / Spent oil 5.1 Rolling Mills /Other shops

500 KLA Storage capacity 10m3 container

Re-used internally after treatment -for lubrication purpose.

Sold authorised recycler.5. Spent Solvent 20.2 By-product

Plant500 TPA Storage capacity 50

m3 container Recovered and reused. Sold to authorised recycler.

6. Discarded containers /barrels with Hazardouswaste / chemicals

33.1 All shopsPlant

275 TPA NA Sold to authorized recyclers

7. Residues, dusts or filtercakes (from sulphuricacid plant)

17.1 By ProductPlant

500 TPA Stored in coveredearmarked area

Recycled back into the process.

8. Copper compounds A-66 Shops 400 TPA Stored in DisposalStores 400 T capacity

Recycled back into the process. Sold authorised recyclers.

9. Lead and Leadcompounds

A-5 Shops 50 TPA Stored in DisposalStores - 400 T capacity

Sold authorised recyclers.

10. Asbestos B-1 Coke Ovens/ Other

80 TPA Earmarked room withConcrete Floor

Presently there is no generation asasbestos ropes have been replaced


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SN. Hazardous Wastes(HW)

HazardousWastes

(HW)Category#

GenerationUnit

Estimated Generationafter Stabilisation of7.0 MTPA Project /Authorisation from

CECB

Storage Mode of Disposal / Recycle / Reusevis-a-vis Action Plan for Disposal

shops asinsulatingmaterial

by ceramic ropes.

BOD Plant Wastes11. Oil & Grease Skimming

Residues35.4 BOD Plant 100 TPA NA Recycled / reused.

Sold to authorised recycler.12. Chemical / Biological

Sludge from ETP ofCOCCD

35.3 BOD Plant 2,500 TPA NA Recycled back into in to coke ovensalong with coal.

TPA : Tonnes Per Annum; KLA = Kilo Liters Per Annum;# : Hazardous Waste Category - Schedule I / II of Hazardous and Other Wastes (Management and Tran-boundary Movement) Amendment Rules 2016


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BSP's Reply

7. Action plan forperformance monitoring ofpollution controlequipment.

Regular inspection is being carried out byEnvironment Department representative and shoprepresentative. ISO 14001:2015 has beenimplemented in BSP. Regular audit is being doneby internal and external auditors. All shops havedesignated officer for monitoring the environmentalparameters and taking corrective actions. CAPAmeeting is also carried out regularly as per EMSsystem by HOD. BSP has also carried-outperformance monitoring of pollution controlequipment with respect to statutory compliance inthe year 2015-16.

BSP shall also carry-out the performance monitoringof pollution control equipment through aCPCB/MoEFCC certified agency at least once in 3years.

8. Details of land utilizationfor plant, green belt andcolony shall be provided.

Land utilisation for plant, greenbelt and colony isgiven in Table 5a.

Land Utilisation for Green Cover / PlantationThe total tree plantation carried out by BSPin plant,township and surrounding areas of plant area, asgiven in Table 5b.Action Plan for Improving Green Cover /PlantationAction Plan for further strengthening the green cover/ plantation in BSP Project area and in surroundingareas is given in Table 5c.

Table 5a :Land Utilisation of Plant Area, Greenbelt and Township - With assumptionsSN. Details/Description Plant Area (ha.) Township (ha.) Total (ha.)1 Plant Proper / Infrastructure /

Buildings596.42 1063.92 1660.34

2 Water Bodies / Cooling Pond 1100 73 11733 Roads and Rail Tracks 440 207.33 647.33

4 Parking Area / RecreationalParks/Play Grounds

465.68 818.2 1283.88


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SN. Details/Description Plant Area (ha.) Township (ha.) Total (ha.)5 Slag Dump Area 183.26 183.266 Green Belt / tree plantation area 407 839.55 1246.557 Area for future development 92.39 92.39

Total 3284.75 3002 6286.75

Table 5b : Existing Green Cover / Plantation in and Around BSP ProjectYear Area (ha) No. of Plants PlantedTotal Planted up to 2016-17 1,711.33* 41,92,1442017-18 14 35,190Total up to 2017-18 1,725.33 42,27,334*Out of 1711.33 hectares, 464.78 hectares of green belt planted/developed through

community plantation, areas adjacent to Township & Roadside plantation

Table 5c: Action Plan for Improving Greenery in BSP Project and Surrounding AreasYear Area Location No. of

PlantsArea Covered(ha)

Cost (Rs. InCrores)

2018-19ProjectArea

Waste Dump, Mills Area,BF Complex, Coke OvenComplex, Steel MeltingShop complex etc.

3000

6.25InternalResources

2019-20 10002020-21 20002020-22 20002022-23 20002018-20 Township - 97500 39 6.72 Crores

Total 107500 45.25


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BSP's Reply

9. Consolidated waterbalance of the plant forexisting and expandedcapacity shall be provided.

There will be no increase in the hot metalproduction, crude steel production, finished steelproduction, coke production, lime and doloproduction due to the proposed associated /additional projects envisaged under the presentproposed project. However, only the sinterproduction is envisaged to increase throughoperational optimisation.

No additional water requirement is envisaged for theproposed additional / associated projects under thepresent proposal of revised configuration of 7.0MTPA Modernization-cum-Expansion from that asrequired for the 7.0 MTPA modernisation-cum-expansion (EC 2008).

The existing total water requirement at 7.0 MTPAModernisation-cum-expansion of BSP is 15981m3/hr(5.0 TMC ft/y). The water is being taken fromChhattisgarh Water Resource Department throughTandula Canal to Maroda-II reservoir of BSP. Thewater requirement of BSP is met from Maroda-I andMaroda-II reservoirs.

Consolidated Water Balance for the Plant is given inTable 6. The overall water Balance for BSP isshown in Fig. 1.

Table 6 : Consolidated Water Balance for 7.0 MTPA Project After StabilizationSN Units Make-up Water Requirement (m3/hr)

Plant Units 4.0 MTPAStage

Additional for 7.0MTPA Stage

Total AfterStabilisation

1. CO & CCD 103.13 -2. CO Bat 11 including CCD - 390Total Coke Oven Complex & CCD 103.13 390 493.133. Blast Furnaces (1-7) 293.3# -4. BF-8 - 1230Total Blast Furnaces 293.3 1230 1523.35. PP-1 137 -6. Power & Blowing Station-II - 865Total Power Blowing Station 137 865 1002


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SN Units Make-up Water Requirement (m3/hr)Plant Units 4.0 MTPA

StageAdditional for 7.0

MTPA StageTotal After

Stabilisation7. Sintering Plant-2 64.1 -8. Sintering Plant-3 24.2 -9. SP-3 ( M/c-2) - 150Total Sinter Plant 88.3 150 238.310. Steel Melting Shop-1 61.24* -11. Steel Melting Shop-2 119.3* -12. SMS-III - 1530Total SMS 180.54 1530 1710.5413. Blooming Mil 73.5* -14. Billet Mill 66.6* -15. Rail & Strl. Mill 48.3 -16. Merchant Mill 45.1 -17. Wire Rod Mill 32.2 -18. Plate Mill 128.9 -19. URM - 20520. BRM - 395Total for Rolling Mills 394.6 600 994.621. Refractory Material Plant-1 9.35* -22. Refractory Material Plant-2 6.45 -23. RMP-3 - 15Total for RMP 15.8 15 30.824. Ore handling facilities - 705 70525. Utilities, Firefighting &

Miscellaneous349.3 515 864.3

Total 1562 6000 7562#BF 1 to be phased out after 3 years; *Units to be phased out after 3 yearsAfter 3 years on phasing out of the units indicated above, the water requirement will be reduced.

Note: The make-up water consumption in 4.0MTPA units is being brought down through:a. recycling of effluents from the plant outlets (Outlet-A, B & C),b. Recycling of treated sewage water from Sewage treatment plant set-up in the Township.c. The total recycled water will be to the tune of 10,000 m3/hr.


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Fig 1 : Overall Water Balance Flow Sheet for Modernization-cum-Expansion Plan for 7.0MTPA of BSP


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ANNEXURE I :

REVISED HAZARD IDENTIFICATION AND RISKASSESSMENT (HIRA) REPORT AND PROJECT

SPECIFIC ACTION PLAN ADDRESSING ALLPOSSIBLE HAZARDS / RISKS

REPORT

ON

“REVIEW OF HAZARD IDENTIFICATION ANDRISK ASSESSMENT (HIRA)”

AND

OTHER

“CONTROL MEASURES FORSTRENGTHENING SAFETY MANAGEMENT”

AT

BHILAI STEEL PLANT

ऑफ़STEEL AUTHORITY OF INDIA LIMITEDBHILAI STEEL PLANTISPAT BHAWANBHILAI, DIST. DURGCHATTISGARH, PIN - 490001

REPORT

ON


AND

OTHER


AT

BHILAI STEEL PLANT


REPORT

ON


AND

OTHER


AT

BHILAI STEEL PLANT


STEEL AUTHORITY OF INDIA LIMITEDBHILAI STEEL PLANT

REPORT ON “REVIEW OF HAZARD IDENTIFICATION AND RISK ASSESSMENT (HIRA)” ANDOTHER “CONTROL MEASURES FOR STRENGTHENING SAFETY MANAGEMENT” AT

BHILAI STEEL PLANT

(i)

Report Index

SN. Content Page No1. Introduction 12. Summary of the Major Revisions 23. Other Actions Undertaken for Strengthening the Safety Management

in View of the Accident Occurred on 09.10.20183

4. Fuel Management : Gaseous and Liquid 45. Revised SOPs / EMPs for De-blanking / Blanking of Gas Pipeline 46. Revised HIRA Documents of BFs 47. Revised HIRA Document of SMS-1 48. Revised HIRA Document of BBM 59. Revised HIRA Document of RMP-1 510. Revised HIRA Document of EMD 5

List of Annexures

Annexure No. Details No of PagesAnnexure I Revised Hazard Identification and Risk Assessment (HIRA)

Report and Project Specific Action Plan Addressing All PossibleHazards / Risks - Covering Annexure IA to IG

1-257

Annexure IA Fuel Management : Gaseous and Liquid 1-12Annexure IB Revised SOPs / EMPs for De-blanking / Blanking of Gas Pipeline 1-6Annexure IC Revised HIRA Documents of BFs 1-33Annexure ID Revised HIRA Document of SMS-1 1-9Annexure IE Revised HIRA Document of BBM 1-32Annexure IF Revised HIRA Document of RMP-1 1-64Annexure IG Revised HIRA Document of EMD 1-23



BHILAI STEEL PLANT

(i)

Report Index




List of Annexures



1-257




BHILAI STEEL PLANT

(i)

Report Index




List of Annexures




1-258


REPORT ON “REVIEW OF HAZARD IDENTIFICATION AND RISK ASSESSMENT (HIRA)”AND

OTHER “CONTROL MEASURES FOR STRENGTHENING SAFETY MANAGEMENT” ATBHILAI STEEL PLANT

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1. INTRODUCTION

Hazard identification and risk assessment and control are ongoing processes. Regularreviews of the HIRA are being undertaken on periodical basis and also after an incidentto avoid repeat of such incidents at the place of incident but also prevent similaroccurrences at all other process areas for making the work place safer.

Apart from the above, all people involved are informed about the changes and, whennecessary, provided with the appropriate information, instruction, training andsupervision to ensure that each worker is safe from injury and risk to health. Adequaterecord keeping of the risk management process is also being done. This informationinclude:

• Hazards identified.• Assessment of the risks associated with those hazards.• Decision on control measures to manage exposure to the risks.• How and when the control measures are implemented.• Evidence of monitoring and reviewing of the effectiveness of the controls.

The unfortunate accident occurred at BSP on 09.10.2018 has also automatically resultedin the thorough review of the HIRA documents pertaining not only to that of the activitiespertaining to “Gas Line Maintenance” but also all other related activities in other processareas.

In this report the revisions carried-out in the following shops/areas are included

I. Blast Furnace-1 (BF-1)II. Steel Melting Shop-1 (SMS-1)

III. Blooming & Billeting Mill (BBM)IV. Refractory Material Plant-1 (RMP-1)V. Energy Management Department (EMD)

A brief on Energy Management Activities at Bhilai Steel Plant is also incorporated in thereport for understanding on the nature of different gases and Fuels being handled atBSP but also on overall structure &activities of Energy Management Department.




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1. INTRODUCTION












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1. INTRODUCTION












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2. SUMMARY OF THE MAJOR REVISIONS

In this section summary of the major revisions in the HIRA documents of EnergyManagement Department, subsequent to the unfortunate accident occurred on09.10.2018 is given hereunder.

Changes in HIRA document of Energy Management Department (EMD) in comparison toearlier version:

S.No SECTION OLDDOCUMENT

NEW DOCUMENT CHANGES MADE IN REVISEDDOCUMENT

1

GASSAFETY

ISOLATION OFLIVE GAS LINEBY BLANKING

GAS LINEBLANKING/DE-BLANKING JOBAFTER GATEVALVE

GAS LINEBLANKING/ DE-BLANKING JOBAFTER FILLING U-SEAL WITHWATER

Earlier the Job of isolation orrecommissioning (i.e. blankingor de-blanking) was being doneeither in zero gas condition or inpositive pressure condition(Maintaining low pressure in thegas line).

In the revised document, theisolation job will be done in nogas condition i.e. byA) Closing the gate valve,

or,B) Filling the U-seal

2 REPAIR OFISOLATEDGAS LINE

REPAIR OFISOLATED GASLINE

1. Purge the isolated headercompletely, ensure safesample and keep slightnitrogen charged in theheader.

2. Extinguish the fire (if anyduring repair) in the depositusing water, steam etc.

3. Keep CO monitor3 CLADDING OF

LIVE FUELGAS LINE

CLADDING OF GASLINE

1. Provide Guy line withproperly anchoring at theends

2. Clads to be matched gentlywithout excessive




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1

GASSAFETY












LIVE FUELGAS LINE

CLADDING OF GASLINE






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1

GASSAFETY












LIVE FUELGAS LINE

CLADDING OF GASLINE






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hammering3. Welding to be done at low

current only4. Welding of clads to be done

after adequate monitoring ofarea.

5. Keep fire extinguisher/steam/nitrogen nearby tomeet any exigency

6. Job to be done in G shift only

3. OTHER ACTIONS UNDERTAKEN FOR STRENGTHENING THE SAFETYMANAGEMENT IN VIEW OF THE ACCIDENT OCCURRED ON 09.10.2018

a. BSP is in advance discussion with world renowned Consultant M/s. DuPont, forseeking their services for organizing safety audit , review & providerecommendations for the improvement of existing safety management system/The focus areas during the study shall be “Gas Safety, Iron making & Steelmaking”

b. BSP has stopped all live line gas jobs.c. BSP has appointed consultant CET to prepare a Feasibility Report for installation

of additional U seals in the Gas lines to enable positive isolation.d. Special Safety Audit is being conducted as per IS:14489, in 18 departments, by 6

Committee comprising of DSOs & Safety Officers of BSP, based on the learningsfrom the in-plant training by M/s NSC, Mumbai.

e. Workshop on ‘Rising Bhilai - 7 MT’ organised at HRDC, Bhilai on 18.12.2018 withfocus on ‘Safety’ was organized for union officials of BSP. 44 union officials fromrecognized unions (CITU, INTUC & Ispath Shramik Manch attended and sharedtheir suggestions to enhance safety at worksite. CEO, BSP and other Seniorofficials were present during the occasion.

f. A new Safety window has been opened at BSP Home Page. Any BSP employeecan log in through their e-Sahyog pass word and enter their safety suggestions,near miss cases & unsafe act / conditions, along with relevant photographs.

g. CEO, BSP inaugurated the ‘Safety Excellence Centre – Suraksha Kawach’,located near Main Gate on 29.11.2018 for briefing safety guidelines, during plantvisit of VIPs / other dignitaries.




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h. LEO (Learning from Each Other) Workshop is being organized at Bhilai, on 16th& 17th Jan 2019 for all Steel Plants, on the theme: “Steel Plant By-Product FuelGas Pipelines – Gas Safety Practices and Gas Management”

i. In-Plant Safety Training Programme on “Behavioral Based Safety Management”by Shri. G R Behra, Ex DGM (Safety), Rourkela Steel Plant was organized forSenior Officials of BSP at BMDC, Bhilai during 16.11.2018 to 17.11.2018.GMs/HODs (31 Nos.) attended the programme.

j. In-Plant Safety Training Programme on “Safety Leadership” by Mr. GeoffreyDean Curie, Chief (Health, Safety & Environment), Vedanta, Korba wasorganized for Senior Officials of BSP at HRDD, Bhilai on 29.11.2018. GMs/HODs(26 Nos.) attended the programme.

k. In-Plant Safety Training Programme on “Occupational Safety & Health Audit forStatutory Compliance” by M/s National Safety Council, Mumbai was organizedfor DSO’s, ZSO’s and Safety Officers at BMDC, Bhilai during 03.12.2018 to05.12.2018. 29 participants attended.

4. FUEL MANAGEMENT : GASEOUS AND LIQUID

Various liquid and gaseous fuel is used in the BSP plant operations and are managed byEnergy Management Department (EMD). The deatils of Fuel Management is given inAnnexure IA.

5. REVISED SOPS / EMPS FOR DE-BLANKING / BLANKING OF GAS PIPELINE

The SOP / EMP of De-blanking / blanking has been revised in view of theaccident held on 09.10.2018. The same is attached as Annexure IB.

6. REVISED HIRA DOCUMENTS OF BFS

The HIRA for BFs was revisited post accident dated 09.10.2018 and the RevisedHIRA Documents of BFs have been revised and attached as Annexure IC.

7. REVISED HIRA DOCUMENTS OF SMS-I

The HIRA for SMS-I was revisited post accident dated 09.10.2018 and theRevised HIRA Documents of SMS-I have been revised and is attached asAnnexure ID.




Page 4 of 5
















Page 4 of 5
















Page 5 of 5

8. REVISED HIRA DOCUMENTS OF BBM

The HIRA for BBM was revised in view of the accident dated 09.10.2018 and theRevised HIRA Documents of BBM have been revised and attached as AnnexureIE.

9. REVISED HIRA DOCUMENTS OF RMP - 1

The HIRA for RMP-1 was revised in view of the accident dated 09.10.2018 andthe Revised HIRA Documents of RMP-1 have been revised and attached asAnnexure IF.

10. REVISED HIRA DOCUMENTS OF EMD

After the accident dated 09.10.2018 the HIRA for Energy ManagementDepartment was reviewed and the revised HIRA document of EMD is attachedas Annexure IG.




Page 5 of 5










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ANNEXURE IA : ENERGYMANAGEMENT DEPARTMENT

ENERGY MANAGEMENT DEPARTMENT, BSP

(Preliminary Information for M/s DUPONT on GAS MANAGEMENT SYSTEM by EMD)

Energy Management Department (EMD) manages the distribution of various liquid and gaseous

fuels in the plant. The department comprises of following sections:

1. Energy Centre

2. Gas Cleaning Plants

3. LD Gas Holder

4. Gas Mixing & Booster Stations

5. Liquid Fuel Stations

6. Gas Safety Section

7. Maintenance (Mechanical & Electrical).

1.0 Brief Description of each section of EMD is as follows:

1.1 Energy Centre The Energy Centre is responsible for proper distribution of available fuel gases viz. B.F., C.O. and

L.D. gas to all consumers. It closely monitors and controls all energy parameters in the plant. Since

there are no gas holders for storing C.O. gas and B.F. gas, the network pressure is maintained by

balancing the "Gas Make" and the consumption, continuously. During periods of surplus

availability, the gases are burnt in high-pressure boilers. During shortages, restrictions are imposed

on consumers, as per priorities approved by management from time to time.

1.2 Gas Cleaning Plant

1.2.1: Gas Cleaning Plants # 1 TO 6: Each Blast Furnace has its own gas cleaning plant. The raw B.F. gas from Blast Furnaces carries a dust load of 25-40 gm/M3. More than 50% of

the dust gets separated out of the dry dust catcher. The raw B.F. gas contains about 10-15 gm/M3 of

dust at the inlet of the scrubber. At the scrubber, gas travels from bottom to top and water spray to

the extent of 800-1200 M3/hr is given through nozzles located at four levels. From the scrubber, the

gas passes through a set of parallel venturi-atomizers. Water spray is given at the venture-throat

where again the dust is entrapped. In the final phase of gas cleaning the gas passes through two

parallel electrostatic precipitators. The clean B.F. gas contains dust less than 10 mg/M3. In the gas

cleaning plant the temperature of B.F. gas is brought down from about 180°C-250°C at the inlet to

about 35 ± 5°C at the outlet.

1.2.2: Gas Cleaning Plant # 7 : B.F.No.7 gas cleaning plant is different from GCP # 1 to 6 in the following respect:

a. It has three Paul-worth gas boosters which supply high pressure semi-clean B.F. gas to

Furnace top equipment for cooling the BLT gear box, in case of non-availability of

Nitrogen.

b. It is PLC operated and all GCP equipment’s are installed in a single tower.

c. Septum valve is replaced by Annular gap Element.

d. Water consumption is reduced by installing water recirculation pump.

e. Water level is controlled by Hydraulic valves.

f. In-addition to mechanical controlled throttle, there is also a provision of hydraulic

Operated valves to maintain pre-scrubber & AGE scrubber water level

1.2.3 Cleaning of Raw B.F. Gas at: G.C.P. No.1 - about 130 x 103 M3/hr.

G.C.P. No.2 - about 130 x 103 M3/hr.

G.C.P. No.3 - about 130 x 103 M3/hr.

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ANNEXURE IA

G.C.P. No.4 - about 190 x 103 M3/hr.

G.C.P. No.5 - about 190 x 103 M3/hr.

G.C.P. No.6 - about 190 x 103 M3/hr.

G.C.P. No.7 - about 260 x 103 M3/hr.

The quantity of Blast Furnace gas generated is 130-230 X 10³ Nm3/Hr depending on the size of the

Blast Furnace

1.3 L.D. Gas Holder A wet type of Gas Holder with working design capacity of 40,000 Nm3 to sustain a pressure of 350

mmWC is provided for recovery and storage of L.D. gas, of CV 1700-2000 Kcal/Nm3, which is

produced during steel making in Converter. The gas is cooled, cleaned and then collected in the

Gas Holder. The yield of converter gas is 85-90 Nm3/T of liquid steel. Five boosters of 12000

M3/hr each are provided to draw the gas from gas holder and pump to CO Gas Network at two

injection point. Before injection, the gas is cleaned by Three Electrostatic Precipitators.

The injection of L.D. gas in CO Gas network has duel advantage. Apart from checking the

atmospheric pollution, L.D. gas meets and maintains the supply of CO gas to consumers, whenever

yield from Coke Oven Batteries fluctuates.

The LD gasholder is a telescopic, wet type consisting of three shells that can collapse one into the

other and all the shells being kept immersed in an outer water tank. The gas is led into the gasholder

by a U shaped pipe (U seal), which has an expansion joint. Gas leakage is prevented from the

expansion joint by water sealing system to which make up water is added continuously. In order to

prevent accumulation of water in U-pipe, drainers are provided.

After the structural problems that occurred in 2016, the outer shell was kept locked at down

position and now only the inner and middle shell are working. Because of this the holder

volume has decreased to 24,000 Nm3

LD Gas is being stored in Water Sealed Gas Holder as per factory act under Section 31 rule 67 A.

1.4 Gas Mixing & Booster Stations:

1.4.1 Rolling Mill Gas Mixing & Booster Station: In this station blast furnace gas is mixed with coke oven gas in the desired proportion for supply to

mills as gaseous fuel. Initial gas pressure for mixing is maintained 450 mmwc to 480 mmwc as per

requirement and desired calorific value is 1850 Kcal/Nm3. Part of this mixed gas goes to Soaking

Pit after further enrichment with Coke Oven gas. This is termed as Low pressure mixed gas( 450-

480 mm WC ) with calorific value of 2000-2200 Kcal/Nm3 approx is fed to soaking pits of

Blooming and Billet mill.

The Reheating furnaces of Rail & Structure Mill, Merchant Mill and Wire Rod Mill requires high

pressure gas suited to injection type burners installed at those furnaces. The mixed gas is boosted to

a pressure of 1800 mm WC from 450 mm WC. There are 6 boosters, and each has a capacity of

40000 M3/hr; they are fitted with 350 KW squirrel cage type drive motors. The boosted gas is supplied to Rail Mill, Merchant Mill & Wire Rod Mill as fuel at a CV of around 2000 Kcal/Nm

3.

All these mills are supplied with injection type of burner where high pressure gas is required for

sucking air from atmosphere for the furnace.

1.4.2 Plate Mill Gas Mixing & Booster Station: The Reheating furnaces of Plate Mill are supplied with mixed gas at a pressure to 750-850 mm WC

and calorific value of 2500 kcal/ Nm3 (approx.). The mixing and boosting of pressure of the mixed

gas is done at Plate Mill gas booster station. There are total 6 nos. of boosters, out of which 3 nos.

are of 12000 M3/hr & 3 nos. are of 40000 M3/hr each. Two By-pass valves have been installed for

maintaining suction & delivery pressure.

1.4.3 Normalising Gas Mixing & Booster Station: The Normalising furnaces of Plate Mill are supplied with mixed gas. Mixing of gas takes place at

Gas Mixing Station no. 3 (GMS # 3), located near Plate Mill booster station. Boosting of mixed gas

Page 2 of 12

ANNEXURE IA

with the help of boosters are done near Normalising furnace. There are 3 nos. of boosters of

capacity 18000 M3/hr each. The gas pressure is boosted form 400 mmwc to 650 mmwc in these

boosters.

1.4.4 Gas Mixing Stations: Gas Mixing Stations are automatic mixing stations where B.F. gas and CO gas are mixed in a

desired ratio, based on the principle of ratio controller (proportional mixing) in-order to achieve the

desired calorific value of mixed gas.

1.5 Liquid Fuel Stations:

1.5.1 Liquid Fuel Station (G): this station is also called LF (G) and it handles Pitch Creosote Mixture (PCM). There are two underground storage tanks of 500 KL capacity each, for

storing pitch creosote mixture (Liquid Fuel produced at the by-products plant). Three electric

pumps are provided for pumping liquid fuel to twin hearth furnaces and to boilers of Power Plant-1

and Rotary kilns of Refractory material plant-1.

The liquid fuel is kept circulating in the network all the time. Surplus quantity of liquid fuel comes

back to the tanks by the return line. Steam heaters have been provided in the storage tanks, and in

the unloading channels, electrified heat tracing in the pipe line network is also provided to keep the

liquid fuel in hot flowing condition (with proper viscosity).

1.5.2 Liquid Fuel Station (P)& (R ): these stations are also called LF (P) and LF (R) respectively and it handles Furnace Oil. Petroleum based Furnace oil (FO) is procured from the

refineries and is stored in tanks, located in Liquid Fuel Station (P) & Liquid Fuel Station (R).

LF (P) caters to the requirement of Reheating Furnace of Plate Mill. There are two storage tanks having a capacity of 2000 KLs each. Liquid fuel is pumped from this station

continuously to the Plate Mill furnaces. This station has been re-commissioned on

13.10.2011, in order to tide up for the shortage of coke oven gas and thus to provide an

alternate fuel to RH Furnaces of Plate Mill.

LF (R) caters to the requirement of Lime Kilns of RMP -2. There are two storage tanks

having a capacity of 2000 KLs each Liquid fuel is pumped continuously to RMP-II.

1.6 Gas Safety Section: The objectives of Gas Safety Section are as follows:

Prevention of hazardous conditions leading to gas poisoning; fire and explosions in gas lines, equipment and connected accessories.

Updating maintenance method to avoid hazardous conditions in the gas network and gas hazardous aggregates.

To create awareness among all working people about the basic principles of gas safety.

Quick liquidation of hazardous conditions.

Scheduled and emergency monitoring of gas hazardous places in the plant for presence of Carbon Monoxide in the atmosphere. (The safe limit of carbon monoxide is 50 ppm for all

works ).

Maintenance and repair of Oxygen Breathing Apparatus / Gas Mask.

Standby duties and giving job clearances at the shop floor level.

1.7 Maintenance (Mechanical & Electrical): This section looks after the maintenance of all mechanical and electrical equipment provided in the

gas network, gas cleaning plants, gas mixing stations, gas booster station, gas safety station, liquid

fuel station and L.D. gas holder.

In addition to above, repair and maintenance work on gas line and equipment’s is carried out by this

section, as and when needed.

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ANNEXURE IA

2.0 Additional Information

2.1: Operating Parameter of By Product Gases: a) BF Gas pressure : 800-850 mm WC b) Coke Oven Gas pressure: 550-650 mm WC c) LD Gas pressure: 300 -310 mmWC d) Mixed gas Pressures:

Rolling Mill Gas Booster Station: 1650-1800 mm WC Plate Mill Gas Booster Station : 650-850 mm WC Normalising Gas Boosters : 650-700

2.2: Typical Analysis of Gases

2.3: Properties of Gases

S.NO.

PROPERTIES

B.F.GAS

COKE OVEN GAS

L.D.GAS

1.

Explosive range

43%-74% 6-30% 20%-70%

Explosive Highly Explosive Explosive

3.

Density

1.33 Kg/Nm3

Heavier than air

0.46 Kg/Nm3

Lighter than air

1.38 Kg/Nm3

Heavier than air

4. Calorific value 775 to 800

KCal/NM3

4250 to 4300

KCal/NM3

1800 TO 2000 KCal/NM

3

5. Toxicity Toxic Slightly Toxic Highly Toxic

6. Colour Colourless Colourless Colourless

7.

Odour

Odourless

Having smell of H2S

and Naphthalene

Odourless

8. Flame colour Blue Yellow Blue

S.NO.

CONSTITUENTS

B.F.GAS

COKE OVEN

GAS

L.D.CONVERTER

GAS

Combustible part

1. Carbon Monoxide 22-23% 7-8% 65-70%

2. Hydrogen 2-3% 55-60% 2-3%

3. Methane 0.3-0.5% 25-28% -

Non combustible part

1. Nitrogen 53-55% 2-3% 15-20 %

2. Carbon dioxide 18-20% 3-4 % 15-20 %

3. Oxygen Less than 1 % 0.5% 0.5 %

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ANNEXURE IA

2.4: Toxic Gas Release-Carbon Monoxide (CO) CO is colourless, odourless and tasteless, making it almost impossible to detect. The symptoms of

CO poisoning can be very vague, and they involve many of the body's systems. But immediate

diagnosis is critical.

2.5: Sources of Carbon Monoxide in Steel Plant

Coke Oven gas - 6% to 7%

Blast Furnace gas - 20% to 22%

L.D. Convertor gas - 65% to 72%

Mixed gas - 16% to 32%

Foundries - Cupola Section 13% to 17%

3.0: Sources of By product Fuel Gases in Bhilai Steel Plant

3.1: BLAST FURNACE GAS

B.F. gas is generated in Blast Furnace where Coke is burnt to produce heat and reducing gases. B.F.

gas contains 22-23% by volume of Carbon Monoxide. People engaged in the concerned areas can

get exposed to its hazards. Following are the gas hazardous areas where B.F. gas is generally found:

Blast Furnace Cast House, Hoist House and Dust Catcher

Stoves Area

Blast Furnace Top

Gas Cleaning Plant

Gas Boosting Station

Areas close to B.F. gas lines and BF gas equipment’s such as drip pot,

goggle valves etc.

Power Plant No. 1&2

All B.F. gas consumers

All BF gas line drainers

PBS-2 area

All instrument control cabins in the BF area

3.2: COKE OVEN GAS

It is a by-product of Coke Ovens and basically a mixture of Hydrogen and Methane which ranges

from 80 to 88 %. Following are the areas where this gas may be present

Coke Oven cellars

Coke Oven top

Old as well as New By-Product Plants

Main Boosters and Exhauster Houses

Area close to C.O. gas lines, drip pot, goggle valves etc.

All instrument control cabins in the Coke Oven and By-Product Plant

All C.O. gas consumers in plant

All C.O. gas line drainers

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ANNEXURE IA

3.3: CONVERTOR GAS

This gas is generated at Converter Shop in the L.D. Convertor during the Steel Melting Process. It

contains about 65 to 70 % 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.

Converter Shop: - I.D. Fan room, Valve changing station etc.

L.D. Gas Holder

Entire Converter Gas piping and its accessories.

Gas Mixing and gas booster station.

All LD Gas line drainers

All instrument control cabins in the Converter and Gas Holder area

3.4: MIXED GAS

This is a mixture of C.O. gas and Blast Furnace gas, which

contains Carbon Monoxide about 12 to 16%. This is used throughout the plant.

Following are the important areas where this gas may be present: -

Soaking Pits, Sintering Plant-II, III, Plate Mill

All Reheating furnaces of R & S Mill, Merchant Mill, Wire Rod Mill, Plate Mill, Coke Oven and Blast Furnaces

Gas Mixing and Boosting Stations at following places. I. Sintering Plants Mixing Station

II. Rolling Mill Booster Station III. Plate Mill Booster Station

Entire mixed gas piping and its accessories

All instrument Control Cabins

All Mixed Gas line drainers

4.0 : Identification of Major Hazard Potentials

4.1 Major Installations of EMD

S. No. Installations

1 Rolling Mill Booster Station

2 Plate Mill Booster Station

3 Normalising Booster Station

4 LD Gas Holder

5 Gas Cleaning Plants 1 -7

6 Entire Gas Network Line

4.2 Major Hazard Potentials Assessment

Process Hazards:

Hazards Gas

Fire Possible due to Coke Oven Gas, Blast Furnace Gas, L.D. Gas & Mixed Gas Toxic Release

Explosion

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ANNEXURE IA

4.3: Hazard-wise Area Identification

Fire Hazard Area All EMD installations and Entire Gas Network of the plant.

Explosion Area

Toxic Release Area

4.4: Safety Precautions Taken for Safe Operation (Inbuilt or otherwise):

1) Safety inter-locks are provided for safe operations of all units. They are periodically tested

and recorded.

2) Gas sampling/monitoring carried out prior to any maintenance job.

3) Protocols are prepared for all gas line jobs.

4) Shut down procedures are available for each unit.

5) Developed gas network Ring mains which helps in isolating segment of pipeline easily without affecting other units

6) U-Seal Isolation in the gas lines which is the safest way of isolating gas pipelines

7) Nitrogen purging system for entire pipe line for quick and easiest way of purging gas mains.

8) Timely repair of gas network based on gas line inspection.

9) Schedule Water Drainer (approx 500 nos.) inspection and maintenance in order to supply uninterrupted gas to the consumers

10) Interconnection of BF and Coke Oven gas network at critical locations to safe guard the gas network during emergencies.

11) Availability of Portable Gas Monitors to all gas consuming units

12) Fixed CO gas monitors installed at critical location.

13) Availability of three numbers of BF gas excess gas burners and one Coke Oven gas bleeder to meet any eventuality to save the gas mains. These burners are installed in the respective

gas netwroks.

5.0: Probable On-Site Emergencies Identified at EMD:

SN. Emergency

1 Uncontrolled massive release of toxic/poisonous gases due to

leakages in the gas networks

2 Extremely low pressure conditions in the gas lines.

3 Fire in the gas line.

4 Explosions in gas lines.

5.1: Situational Emergencies

SN Emergency Situations

1 Emergency in Plate Mill Booster / Normalising Gas Booster

In case of compressed air/Nitrogen failure In case of Power Failure

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ANNEXURE IA

2 Emergency in Rolling Mill Gas Booster In case of compressed air/Nitrogen failure In case of Power Failure

3 Emergency in LD Gas Holder Interlock failure Low pr & high pr in gas holder High oxygen percentage in the incoming gas

4 Emergencies in Gas Cleaning Plants When circulating. water pumps get tripped in pump house. When water seal of scrubber/Atomiser gets broken.

When water seal of scrubber gets increased/ Over flow throttles

6.0: Interlocks in System for Gas Management in EMD

Various Interlocks are provided in LD Gas Holder for safe LD gas recovery system , Gas Cleaning

Plant for safe handling and cleaning of BF gas, Gas boosters for safety of process and equipment’s.

All the interlocks aim at process, personnel and equipment safety.

7.0: Safety System in EMD

SN Jobs being done 1 Ensure healthiness of gas line network

NDT once in two years and Inspection once in three months of gas line

Action plan for repair

Eliminations of defect (if any) 2 Safe working of LD Gas Holder, BF Gas Cleaning Plants & Gas Booster

Stations

Testing of interlocks

Monitoring of operating parameters

Adherences to SOP’s

Round the clock monitoring 3 Ensure Safety in Maintenance of Gas Boosters, GCPs, Liquid Fuel Stations

and Gas Holder

Strict adherence to SMP’s

All jobs with protocol

Scheduled maintenance of equipment

Monitoring of maintenance jobs 4 Ensure Safety in contractual jobs of the department

Job specific training to various groups

Ensuring usage of PPEs

Monitoring of contractual works

Page 8 of 12

ANNEXURE IA

8.0: Major Repairs in last three years:

S.No Duration/Date Equipment Nature of

Repair

Major Jobs Done

1. 06/February to

13/March-2016

LD Gas holder Scheduled

Repair

Repair of Internal & External

Rollers, Brackets, Columns

2. 08/March to

25/March-2018

LD Gas holder Scheduled

Repair

Repair of Internal & External

Rollers, Brackets, Columns

9.0: Activities for shutdown of gas mains for repair work and its

commissioning

Protocol: Protocol is made as per IPSS. For eg.

Protocol For Gas Hazardous Work (Refer IPSS:1-06-044-08)

Laying Of New Gas Lines (Refer IPSS:1-06-014-02)

Gas Line Inspection Guidelines (Refer IPSS 1-06-038-01

Positive Isolation: It is basically done by either

a) U-Seal

b) Google Valves

c) Isolation Valves

EMD has installed 148 U seals so far in Gas Network and this has facilitated in Isolation of

gas line for work as well as for emergency conditions. More such facility needs to be

installed in the gas network, especially for Coke Oven Gas Line.

Purging

Ventilation

Sampling and Clearance for the Job

Execution of Job/ Supervision

Gas Charging and Lighting Up

10.0: Any Other Point: A. There is only one bleeder in Coke Oven Gas network as mentioned in 10.4 (13) and this was

provided in original design of CO gas network in 1958. The probability of introducing

another bleeder in the CO gas main network needs to be worked out to overcome any

emergency situation in CO gas network.

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ANNEXURE IA

11. EMD Equipment Status

1. Rolling Mill Station Gas Booster

- Number of boosters: 06

- Volume: 40,000 M3/hr

- Pressure (outlet) 2250 mmWC

- Pressure (inlet) 450-500 mmWC

- Lub Oil Pr. 0.8 – 1 Kg./cm2

- Bearing clearance 0.22-0.3 mm

- Axial play 0.22-0.28 mm

- Type: Centrifugal Type

Motor Details: - Type: Induction motor.

- Capacity-350 KW

- Voltage- 6600 V.

- RPM 2975

Lubrication System Motor Details

- Power-1.5 KW

- RPM-1500

- Current-3.7 A

- Voltage-415 V.

- Capacity of the surge tank is 25 KL

2. MODEX (7 MT) Gas Booster Details for URM/BRM

- Number of Gas Boosters- 04

- Type- Centrifugal,

- RPM: 1450

- Impeller: Backward Curved type

- Flow Rate: 40000 NM3/hr

- Suction Pr. 200-400 mmwc

- Discharge Pr. 1300-1600 mmwc

- Differential Pr. 1100-1200 mmwc

- Power: 415 V AC, 3 Phase, 50 Hz

- Casing: Split Type

- Shaft Sealing: Nitrogen @ 7-8 Kg/Cm2

3. Plate Mill Station Gas Booster - Volume 40,000 M3/hr

- Pressure (outlet) 900-1000 mmWC


- Lub Oil Pr 1.25-1.5 Kg./cm2


Page 10 of 12

ANNEXURE IA

- Axial play 0.75-0.8 mm

- Type: Centrifugal Type

- Mixed gas temperature - 35oC

- Density of mixed gas - 0.85 to 0.9 kg/NM3

Motor: Voltage: 450 V (3 phase)

S.No. Booster Motor Rating

(KW)

RPM Flow(M3/hr) VVVF Drive

1 P-1 55 2970 12000 -------

2 P-2 45 2970 12000 -------

3 P-3 150 2970 12000 -------

4 P-4 132 2970 40000 -------

5 P-5 132 2970 40000 -------

6 P-6 132 2970 40000 YES

4. L.D. Gas Export Boosters: - Volume 10,000-12,000 M3/hr




- Axial play 0-0.05 mm

- Type: Centrifugal



(KW)


1 CB-1 110 2970 12-15,000 -------

2 CB-2 132 1470 8-10,000 -------

3 CB-3 110 1470 12-15,000 YES

4 CB-4 110 1470 12-15,000 YES

5 CB-5 110 1470 12-15,000 -------

5. Liquid Fuel (R): PUMP DETAILS:

- Transfer pump (3 nos.)- Capacity - 8 kl/hr.

- Head- 16 kg/cm2

- Unloading pump(2 nos.) - Capacity - 100kl/hr.

--Head - 5 kg/cm2

- Unloading header - Length - 130 meters

TANK DETAILS:

- Number of tanks - 02

- Diameter - 400 mm

- Tank Capacity - 2050 Kl

- FO Tank temp. - 40-60 ◦ C

- Steam pressure - 6 kg/cm2

- Temperature - 250 ◦ C

Page 11 of 12

ANNEXURE IA

6. Liquid Fuel (G): - Tank capacity 500 KL

- Number of tanks 02

- Oil temp maintained 90 to 95 0 c

- Type of Pump - Triplex titano type (Peroni)

(Safety valve spring type)

- Pumping temperature 60-80 deg C

- Capacity of pump- 20 KL/hr (max)

- Discharge pressure- 15 kg/cm2 (g)

- No. of cylinders- 3

- Pump RPM- 149

- Motor-Power- 15 KW

- RPM- 960

- Voltage- 400 V

- Phase- 3

- Cycle- 50

7. Normalising Gas Booster - Volume 10,000 M3/hr



- Mixed gas temperature - 35oC

- Density of mixed gas - 0.85 to 0.9 kg/NM3



(KW)


1 N-1 75 1470 10000 -------

2 N-2 75 1470 10000 -------

3 N-3 75 1470 10000 YES

1. EMD Manpower Status

Manpower EMD Executives

GM 0

DGMs 6

AGMs 4

Sr. Mgr. 1

Managers 4

Dy. Managers 8

Asstt. Managers 5

Jr. Managers 3

Non -Executives

Supervisors (S-8 & above) 107

Workers ( up to S-7 ) 24

Contract Workers 62

Page 12 of 12

ANNEXURE IA

ANNEXURE IB : SOP / SMPEMD - FOR BLANKING /

DEBLANKING GAS PIPE LINE

ENERGY MANAGEMENT DEPARTMENT

SOP FOR BLANKING/DE-BLANKING OF GAS LINE

The isolation of the gas line is completed by the Goggle valve operation or by inserting blank

plates at pre-determined locations with proper plan. The blanking/De-blanknig of gas line is to

be done under positive isolation which is achieved by:

- U-seal Isolation

- Closing of Gate valve

The SOP is as follows:

(I) Preparatory Jobs for Blanking/De-Blanking:

a) Site inspection with the working group (before execution of job).

b) Identification of preparatory jobs and safety precautions wrt it. Check points are:

- Type of Gas Pipeline (BF/CO/Mixed/LD)

- Nominal Diameter of Gas Pipeline (mm)

- Blank of the right size to be kept ready along with gasket/rope/ring packing. (in

case of Blanking)

- Number of bolt holes in flange, Hole diameter, Size of bolts.

- Revisioning /Replacement of all bolts for ensuring free operation during gas job.

- Suitable Hoist to be made available for blanking/De-Blanking.

- For creating gap between the flanges, jack brackets are required. (minimum

distance 750 mm).

- Condition of working platform, saddle support and freeness of support.

- Approach for the platform.

- Existing gap in the flange.

- Types of tools required for the job, like spanners, scrapper rods, J-Hooks, chain

pulley block, turn buckles, rope packing, ring packing, wedges, hammers etc. All

tools should be of Non sparking type.

- Supporting agencies required like Fire brigade for rescue and firefighting,

Ambulance, SED persons for safety monitoring during job.

- Check for any possible presence of ignition source in the vicinity, if there is any,

it should be taken care of.

- Other Requirements

a) Breathing apparatus

b) CO detectors for area monitoring during the job

c) Respirators for first aid

Page 1 of 6

ANNEXURE IB : SOP / EMP EMD - BLANKING / DEBLANKING GAS LINE

- Making of protocol for the job, which contains three main sections; Preparatory

jobs, Actual jobs, safety precautions and Signatories of executing agencies and

approving authorities. Layout of the planned gas line to be attached.

(II) Actual Job:

During job following sequence to be followed:

1. Isolate the gas line after getting clearance from consumer by filling U-seal or by

closing Gate valve fully.

2. Purge the isolated gas line with nitrogen from the end bleeder to evacuate the

toxic gas from the line

3. Take sample and ensure CO concentration less than 50 ppm.

4. Keep small amount of nitrogen flowing in the isolated gas line in order to have

nitrogen flooding in the gas main

5. Apply plenty of water on the flange joint

6. Opens flange bolts. Remove top half of the flange bolts and keep bottom half of

the flange bolts in open condition.

7. Create gap between the flanges by Jacking.

8. Remove old packing and apply water on the open flange so that deposits get

wet.

9. Insert Blank plate with the help of chain pulley block/Max pull.

10. Insert new rope/ring packing and tighten flange bolts.

11. Check for leakages if any and retighten the flange if required.

12. Stop nitrogen.

Page 2 of 6



SMP’s For Cladding of Gas Line

1. If leakage is observed, it should be plugged and area sample should be ensured for safe

working.

2. Prepare half-clad/patch as per the profile of the gas line.

3. While welding on gas lines low current is preferred, so welding transformers should be

checked for proper regulation of current.

4. Pipe line thickness of defective area must be measured before the start of job; this will

help in arranging proper size of clad/patch/electrodes. Besides this, it will also help in

proper regulation of welding current.

5. Only experienced and trained welders should be allowed to work, as the line will be in

charged condition.

6. As the gas line is charged, job should be done only during day light hours.

7. Clad/patch should be properly positioned and welded without excessive hammering on

gas line.

8. As far as possible clad should be welded to the fully welded ribs.

9. Where 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 clads,

saddle supports should be repositioned.

10. 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 fire.

11. If cladding is done where leakage is there, then all efforts should be made to contain

the leakage and prevent the travel of gas to other clads.

12. 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.

13. Places where complete welding is not possible, clads should not be positioned.

14. Not less than two rounds of welding should be done on clads.

15. After the completion of job, all temporary supports should be removed and scrap

should be properly stacked for disposal and disposed.

16. All welding/earthing connections should be removed from the spot on completion of

the work.

17. Open steam hose should be made available near the place of work.

Page 3 of 6


18. Welding work on charged gas line should be done very cautiously and without any

haste.

19. Welding transformer should preferably have the return cable lines.

Page 4 of 6



SMP’s FOR ISOLATED GAS LINE

1. Purge the isolated gas line from blank to end bleeder of line with steam /nitrogen

for sufficient time as per past experience