training safety gas

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Gas SafetyLegal Compliance

OHSAct Vessels Under Pressure Regulation v/s Pressure Equipment RegulationsConstruction Regulation ANSI Z223.1SANS 10227 – Criteria for the operation of inspection authorities performing inspection i.t.o Pressure Equipment Regulations

SANS 347 – Categorisation and conformity assessment criteria for all pressure equipment in dangerous service

SANS 329 – Industrial thermoprocessing equipment. Safety requirements for combustion and fuel handling systemsMajor Hazardous InstallationOther

Air Quality BillEnvironmental & Pollution Acts

Gas Reticulation System (Suppl ier)

Main Transmission LineDistribution Lines (HP & LP)Pressure Reducing Station (PRS)Customer Metering Station (CMS)

Gas Reticulation System (Customer)Internal Line

Gas Train

Emergency Procedure

Commissioning Procedure

Operational Procedures

Start-up

Shut-down



Legal Compliance

• Section 7 – Health and Safety Policy

– Any employer may be directed in writing

– Category of employers may be directed by

notice in the Gazette (Problem!)

• to prepare a written policy concerning the

protection of the health and safety of his

employees at work

• Accompanied by guidelines – contents of the

policy

• Display copy(where?)

of the signed policy(By who?)

OHSAct



Legal Compliance

• Section 8 – General Duties of Employers

– Every employer shall provide and maintain as far as reasonably practicable aworking environment that is safe and without risk to the health of his employees

• Serverity and scope of the hazard or risk concerned

– do risk analysis

– SHE Plan

• State of knowledge reasonably available and any means to remove/mitigatethat hazard or risk

– SOP / SWP

– Toolbox sessions

– Safety Training

• Means to remove/mitigate the hazard or risk

– Engineering methods

– PPE / PPC

• The cost of removing/mitigating that hazard or risk in relation to the benefitsderiving therefrom

– Cost Analysis

OHSAct



Legal Compliance

• Section 8 – General Duties of Employers

– The matters to which the duties refer to include

• Maintenance of systems of work, plant and machinery

• Eliminate/mitigate any hazard or potential hazard before resorting to PPE

• Production, processing, use, handling, storage or transport of articles or substance

– Ensure safety when executing these duties

– Identify risks attached to these duties

– Establish precautionary measures• Provide information (section 13 – “Duty to inform), instructions, training and

supervision

• Prohibit working in areas where risk have been identified until correctiveactions have been taken

• Ensure compliance of the act by every person• Enforce matters concerning the health and safety

OHSAct



Legal Compliance

• Section 9 – General Duties of Employers – Ensure that other persons who may be affected by his activites are not exposed

to hazards

• Section 10 – General Duties of Manufactures – Any person who design, manufactures, imports, sells or supplies, erect or

supplies any article for use at work place shall ensure that it is safe and withoutrisks to health when properly used (How?)

– Undertaking in writing to take specified steps to ensure safe use – this will relievethe supplier from the duty imposed on him

OHSAct



Legal Compliance

• Section 14 – General Duties of Employees – Every employee should take reasonable care for the health and safety of himself

and other persons who may be affected by his acts or omissions

– Co-operate with employer in carrying out duties assigned to him – Carry out any lawful order given and obey the health and safety rules and

procedures laid down by his employer

– Report any unsafe or unhealthy situations as soon as possible to the employer or the health and safety rep.

– If involved in any incident which may affect his health and safety or hassustained injuries, he must report this to the employer not later than the end of the particular shift during which the incident happened

OHSAct



Legal Compliance

• Section 18 – Functions of Health and Safety Reps – Review the effectiveness of health and safety measures

• SOP / SOW

• SHE Plan• Health and Safety Policy

– Identify potential hazards and potential incidents

– Examine the causes of incidents

– Investigate complaints by employees to their health and safety

– Rep in the Health and Safety Committee and the inspector – Inspect the workplace with the view to the health and safety of employees at

specified intervals, with a prior notice to his intentions

– Participate in consultation with the inspector

– Visit the site of an incident and carry out investigations

– Inspect any document which the employer is required to keep i.t.o this act – Participate in internal health and safety audits

– The health and safety rep, shall not incur any civil liability by reason of the factonly that he failed to do anything which he may do or is required to do i.t.o thisact

OHSAct



Legal Compliance

• ‘gas fuel’ means any liquefied gas, coal produced gas or natural gas

• ‘gas fuel system’ means an assembly of tubes, pipes or similar ducts,

fittings and valves for the process and conveyance of a gas fuel, excludinga boiler, pressure vessel or portable gas container connected to the system

• ‘pressurised system’ means an assembly of vessels under pressure andincludes connections by pipes or similar ducts, fittings and valves whichoperate under gauge pressure equal to or greater than 40 000 pascal for

the process and conveyance of a flammable liquid, hazardous chemicalsubstance, saturated steam or superheated steam

• ‘vessels under pressure’ means a vessel which operates under pressureand includes a boiler, pressure vessel, pressurised system or portable gas

container

Vessels Under Pressure Reg



Legal Compliance

• Design, Construction and Manufacture

– designed and constructed in accordance with a health and safety standard (where?

Which?)

incorporated into these regulations in terms of section 44 of the Act – manufactured under the supervision of an approved inspection authority (AIA)(How? – SABS 0227 (SANS 10227); SANS 347)

– the user is in possession of a certificate of manufacture issued by themanufacturer

• Appurtenances

– pressure vessel must be provided with all the appurtenances as required by thehealth and safety standard used in the design, construction and manufacture (eg.SANS 329)

– fitted with at least one pressure gauge and the maximum operating pressureshall be indicated

– fitted with at least one safety valve (What’s a safety v/v?)

• Automatic controls and indicators – Automatic controls and indicators of vessels under pressure should be arranged,

installed, maintained and operated in accordance with the provisions of thehealth and safety standard (eg. gas train SANS 329)

• Access

– Vessels under pressure to be erected so that access to and exit from anychamber, flue, manhole, inspection opening, control or appurtenance is safe andunobstructed.




Legal Compliance

• Gas fuel Use, Equipment and SystemsNo person shall:

– handle, store or distribute a gas fuel in any manner other than in accordance with a

health and safety standard under section 44 of the Act – install a fixed appliance, equipment or system in accordance with a health and safety

standard incorporated under section 44 of the Act

– install a fixed appliance, equipment or system for gas fuel , unlesssuch person is a holder of a certificate of registration issued by anorganisation approved by the chief inspector (SAPGA)

• Inspection and test – pressure vessel including the appurtenances and automatic controls and

indicators, to be subjected to an internal and external inspection and a hydraulicpressure test to 1,25 times the maximum permissible operating pressure9 by an AIA; before commissioning; after installation, re-erection or repairs

9 by a person appointed in writing by the user and who is competent to do suchinspections and tests by virtue of their training, knowledge and experience in operation,maintenance, inspection & testing




Legal Compliance

• Record keeping – Any user of a vessel under pressure shall keep on the premises a record of the

results of all inspections, tests, modifications and repairs. Signed by the

competent person

• Maintenance – Pressure Vessels must be maintained in a safe working condition and the

efficiency thereof is proved by regular testing

– The equipment must be free from carbonised oil or flammable material which

may ignite; substance which may cause corrosion or liable to chemical reactionwhich cause an uncontrolled rise in pressure

• Modification and repair – to be carried out under the supervision of an approved inspection authority

– Any modifier or repairer shall issue a certificate clearly describing workperformed (always refer to the health and safety standard)

• Offences and Penalties – Anyone contravening or fails to comply, shall be guilty of offence and liable on

conviction to fine or imprisonment




Legal Compliance

• Notification of installation (permanent or temporary installations)

– Chief inspector, provincial director and relevant local gov. in writing

• Major hazard installation means an installation- – where more than the prescribed quantity of any substance is or may be kept,

whether permanently or temporarily; or

– where any substance is produced, processed, used, handled or stored in such a

form and quantity that it has the potential to cause a major incident;• Major incident means an occurrence of catastrophic proportions (How?), resulting fromthe use of plant or machinery, or from activities at a workplace;

Major Hazard Installation Regulations



6

Phoenix

Richardsbay

Pretoria

Benoni

Ressano Garcia

MPUMALANGA

GAUTENG

SWAZILAND

KWAZULU-NATAL

MAPUTO

MAGUDE

GAZA

INHAMBANE

MOAMBA

3

2

15

4

Avo ca

Sabie

Nigel

Guija

Maputo

Temane

Durban

Motaze

Mahele

ErmeloBethal

Alb erto n

Chokwe

Muabsa

Talofo

Jofane

Rosslyn

Chigubo

Verulam

Mandini

Panjane

Secunda

Witbank

BreytenLenasia

Springs

Meginge

Babelegi

HendrinaBadplaas

Malelane

Carolina

Meyerton

Componde

Empangeni

Barberton

Nelspruit

Volksrust

Ams terd am

Sasolburg

Lyttelton

Magandene

Camo-Camo

Rumbacaca

New Castle

Middelburg

Standerton

Vilanculos

Kemptonpark

Komatipoort

Vereeniging

Randfontein

Mabuiapanse

Produced by:

SASOL GAS GIS TEAM Alro deMarch 2005

SASOL GAS NETWORK

SASSEC Product Pipelines

Petronet Pipeline

MSP Transmission Gas PipelineLow Pressure Pipeline

High Pressure Pipeline

A

E

F

LEGEND

NO LOCATION X_COORD Y_COORD

SECUNDA - SSP START 29.15 -26.55

RANDFONTEIN - END 27.75 -26.13

BABELEGI - END 28.28 -25.34

SASOLBURG - END 27.83 -26.82

SECUNDA - PRODUCT LINES - START 29.15 -26.55

SASOLBURG - END 27.83 -26.82

SECUNDA - PPP START 29.14 -26.55

DURBAN - ALLIANCE PEROXIDE END 30.90 -30.03

TEMANE 35.06 -21.75

RESANO - TAKE OFF 32.00 -25.46

SECUNDA - MSP END 29.19 -26.55

SECUNDA - SWM START 29.15 -26.55

MIDDELBURG - END 29.50 -25.79

SASOLBURG - SEP - START 27.84 -26.82

LANGLAAGTE - SEP - END 27.98 -26.21

5

6

1

2

3

4

B

C

D

ADDRESS

A ALRODE DEPOT CNR CLARKE & GARFIELD, ALRODE

B NELSPRUIT DEPOT PTN 13 GRANITE HILL KAAPSCHEHOOP AVE

C MAPUTO BAIRRO TRIUMFO, 5A AVENIDA, RUA 4505, CASA 380

D PINETOWN SUZUKA RD PINETOWN

E PRETORIA DEPOT 117 INDUSTRIAL RD PRETORIA WES

F ARNOLD STR DEPOT ARNOLD STR ALRODE

DEPOTS

S l G T i i & Di t ib ti Pi li N t kR 5 0

N 1 7

N 17

ERMELO

DIEPDALE BETHALERMELO



Sasol Gas Transmission & Distribution Pipeline Network KwaZulu Natal

R74

R 6 1 4

R 3 4

R 3 3

N 2

R 6 6

R 6 0 3

N 3

R 6 2 2

M35

M 4

M37

M27

R 7 4

R 3 3

R 6 6

M 7

MANDINI

N 3

R 6 2 4

R5

6

R 3 3

N 2

R 3 4

N 2

R 7 4

R 1 0 2

N 2

N 2

R 1 0

2

AVOCA

NEWCASTLE

R 5 4

6

R 3 8

R 3 5

R 3 9

R 2 3

R 2 3

R 5 0 R

5 4 7

0

N 1 1

N 2

R 5 4 3

R 3 3

N 2

R 3 4

R 3 3

R 6 9

R 6 1 8

R 6 9

R 6 6

R618

R 6 6

R 6 2 1

R 68

R 6 0 2

R 3 3

R 6 8

R 34

N 1 1

R 1 0 3

R616

N3

R 1 0 3

R74

R 6 0

0R 1 0 3 N

3

N 3 R

1 0 3

R 6 1 7

R 6 1 2

EMBALENHLE

STANDERTON

VOLKSRUST

PAARDEKOP

AMERSFOORT

SIVUKILE

ERMELO

PIET RETIEF

DUMBE

VRYHEID

UTRECHT

DUNDEE

LADYSMITH

MOOI RIVER

GREYTOWN

SAINT LUCIA

MTUBATUBA

KWA MBONAMBI

ESHOWE ESIKHAWINI

GINGINDHLOVU

ONGOYE

ZINKWAZI BEACH

STANGER

BLYTHEDALE BEACH

TINLEY MANOR BEACH SHAKASKRAAL

MONA

DURBAN CATO RIDGE

PIETERMARITZBURG

UMNGENI

ESTCOURT

AMSTERDAM

SHEEPMOOR

MARTHINUS

SECUNDA

RICHARDS BAY

EMPANGENI

DURBAN

VERULAM

PHOENIX

STANDERTON

INGWAVUMA

UBOMBO

UBOMBO

NONGOMA

NGOTSHE (LOUWSBURG)

NKANDLAMSINGA

UNDERBERG (HIMEVILLE)

KLIPRIVIER (LADYSMITH)

ESHOWE

MAPUMULU

NDWEDWE

RICHMOND (KZN)

IXOPO

UMVOTI(GREYTOWN)

VRYHEID

HLABISA

LOWERUMFOLOZI (EMPANGENI

MTUNZINI

LOWERTUGELA (STANGER)

NEW HANOVER

MOOI RIVER

DUNDEE

WAKKERSTROOM

BABANANGO

NQUTU(VERULAM)

DANNHAUSER

KLIPRIVIER (LADYSMITH)

ESTCOURT

MAHLABATINI

ESHOWE

MTUNZINI

KRANSKOP

HLABISA

SIMDLANGENTSHA

PAULPIETERSBURG

BULWER

IMPENDHLE

UNDERBERG

RICHMOND

CREIGHTON

CORONATION

DIRKIESDORP

FORT NOTTINGHAM

OKHAHLAMBA

BALLITO

AMANZIMTOTI

PINETOWN

BOLATA

HIMEVILLE

WARTBURG

YORK

G S



Supplier’s Reticulation System

TRANSMISSION LINE

P = 125 bar

PRS

Poutlet = 625 kPa

TRANSMISSION LINE

P = 50 bar

CMS

Poutlet = 100 kPa

INTERNAL PIPELINE

Pinlet = 100 kPa

METHANE-RICH GAS

IS ENVIRONMENTALY

FRIENDLY

PPS

IN SECUNDA

CUMSTOMER’S

PREMISES

DISTRIBUTION

NETWORK

Keep

>40bar

Pop = 40 –

50 bar

HP – same trans

LP – 6.26 bar

Pop = 40 – 50 bar

Quality – Jacobs

Bamboo –

Prospecton

Athlone -

Umbongintwini

Transnet Pipelines

Supplier’sresponsibilityCustomer’sResponsibility

Gas Supply

SCADA S stem



SCADA System

SCADA System



SCADA System

S li ’ R ti l ti S t



CMS


Components

• Safety shut off valve

• Filter

• Meter & Mercury Index

• Two regulators

• Emergency service shut

off valve• Pressure relief valve

• (Customer Valve)

S li ’ R ti l ti S t



Dispersion Model


C t ’ R ti l ti S t



Customer’s Reticulation System

Steel • Steel: ASTM A 106 Grade B, seamless pipe

API 5L Grade B, seamless pipe

• Schedule 40 pipe

• Above ground pipelines - secured to structures• Welded joints are preferable to screwed joints

– Coded welder should be used

• Flanges can also be used

Underground

• Protect against corrosion• Apply insulating material around undergroundpipe

• Thin inner wrapping and thick outer wrappingshould be applied

• Bury pipe to depth of at least 1 meter

• Fine soil should be used to backfill around the

pipe

HDPE (High Density Polyethylene)• HDPE: PE 80 ; 50 yrs 8MPa ; P ≤ 5.5 bar

PE 100 ; 50 yrs 10MPa; P ≤ 7 bar

• Can only be used as buried pipes

• Minimum depth = 1 meter • Fine soil should be used to backfill around thepipe

Internal Line

C t ’ R ti l ti S t



Flexible hoses• Fixed clamps

– Screw joints – Flanged joints

• Wire brazed hoses

• Flexible tubing shall be compatible with the type of gas used andthey must be – As short as possible

– Suitable for maximum and minimum operating temperature

– Suitable for pressure 1.5 times maximum operating pressure(MOP), Have an accessible, upstream shut-off valve

– Be mounted in such a way as to avoid distortion, whiplash anddamage

– Have end fittings as integral parts of the tubing

Internal pipeline


C stomer’s Retic lation S stem



Manual isolation valves• Main shut off valve on the connecting flange of the customer meter station

• Valves should be at reachable height

• Good practice to install valves on branch lines in order not to interrupt of the wholeplant in the case of an emergency

Unconnected pipework • All unconnected live pipework shall be plugged, capped or blank flanged by a metallic

part

Marking • The pipework shall be easily identifiable as a gas pipework

• Where colour coding is used it shall be in compliance with SANS 10140-3

Testing • After assembling the gas reticulation system, it shall be tested for

– Leak tightness (e.g Foam generating liquids, pressure decay monitoring)

– Ability to withstand the internal test pressure of 1.5 times the MAOP, with anallowance made for ambient condition flactuations

– The frequency of testing shall be determined prior installation and it shall not beless than 36 months


Internal pipeline

Gas Spec



• Energy content @ P=101.325 kPa 0oC 15oC – Gross energy content MJ/m³ 35.97 34.05

– Net energy content MJ/m³ 32.35 30.69

• Density kg/m³ 0.75

• Relative density (RD) 0.58

• Wobbe index (WI) EC/√RD 47.23

• Lower explosive limit (LEL) % gas in air volume 5

• Higher explosive limit (LEL) % gas in air volume 15.7

• Auto ignition temperature ºC 630

• Theoretical flame temperature ºC 1925

• Stoichiometric air to gas ratio 8.57:1

• Sulphur mg/m³ ≤ 9

MRG

Gas Spec

Combustion



Auto Ignition Temp 1200° C

Combustion

700° C

15° C

Re-heat furnaces

Melting furnaces

Incinerators

Boilers

Baking ovens

Drying & Curing

ovens

( M e t h an eR

i c h G a s )

650° C

( N a t ur al G a s )

620° C

Fact file!



American Stats

• 50% during start-ups

• 40% during burner firing• 10% re-lighting after flameout

When do burners fail?

Fact file!

Combustion



• will include:

complete burner start / stop sequence, controls and flame supervision

• it will:

9 Verify proper conditions for combustion

9 Pre-purge any accumulated fuel

9 Sequence a controlled ignition

9 Monitor the combustion process

• it will:

9 Shut down on flame failure

9 Shut down on system interlock failure

9 De-energize on power failure

9 Monitor all burners

9Monitor operating parameters (P & T)

Properly designed combustion system

Combustion

Low flame

High flame

•Prove flame at

all times

•Confirm proper

conditions at all

times

Combustion



Prove all system interlocks

Purge combustion chamber

Trial for pilot ignition

Prove pilot flame

Power main fuel valves

Prove main flame

Interrupt pilot

Combustion System Operating Sequence

Combustion

Combustion



System Failures

Combustion

EXPLOSION

• Fuel leakage during shut-down• Loss of burner during operation without shut-down

• Re-lighting after flame out without prepurge

• Repeated piloting attempts without prepurge

• Poor air:fuel ratio control

• Unstable air or fuel supply

• Flame blow-off caused by excess mixture pressure

• Flame quenching caused by extreme excess air

• Defective or bypassed safety interlock

• Failure to shut-down burner if flame not present

• Mechanical or electrical failure• Human error

Combustion



System Failures

Combustion

EXPLOSION

Combustion



Combustion

Elements of combustion /

explosion

Fail Safe

Systems

Combustion



• The ultimate aim of safety is to have fail safe

equipment. This is achievable when correctsafety devices are used to:-

9detect flame,

9detect gas and air failure,9 response fail safe immediately

When a power failure occurs, the burner equipmentmust also be shut down to a fail safe position.

• After every failure the proper light-up sequence

should be adhered to.

Fail Safe Systems

Combustion

Combustion



CABLECONNECTION

CERAMIC INSULATOR

ELECTRODE

THREADED COUPLING

Fail Safe System – Flame Rod Property Sensed: Ionization in flame

Application: Gas flame

Placement: 1. Upper 2/3 of flame

2. Ground ratio 4:1

Advantages: 1. Low cost

2. Steady signal

Limitations: 1. Ambient temperature = 500° F

2. Furnace temperature = 2600° F

3. Low signal

4. Do not use with oil burners

5. Precise placement in nozzle mix burners

6. Must be kept clean

Combustion

Combustion



Fail Safe System – Flame Rod

Combustion

Flame Rod

C. CorrectB. No Ground Surface in Flame

X X

upper 2/3

of flame

Combustion



ELECTRICAL CONNECTION

VIEWING WINDOWOR MAGNIFYING LENS

COOLING AI

Fail Safe System – UV Scanner

Combustion

Property Sensed: Ultraviolet radiation

Application: Gas and oil flame

Placement: First 1/3 of flame

Advantages: 1. High output2. Signal can be magnified

Limitations: 1. Can detect ignition spark

2. Detector tube life limited

3. Temperature sensitive

4. Can fail in a conducting mode

5. Must have a clear sight path

Combustion



Fail Safe System – UV Scanner

Combustion

U.V. SCANNER

AS INLET

COMBUSTION AIR

first 1/3of flame

Combustion



Safety interlocks

Combustion

m

1 2

3

4

5 6

7

8

3

pilot gas vent

ain gas

1. Low gas pressure switch

2. High gas pressure switch3. Valve closed position switches4. Combustion air proving switch5. Burner low fire start switch6. System fan proving switch7. Exhaust fan proving switch

8. High temperature limi t switch9. Dampers open

9

Combustion



Burner Lighting

Combustion

Start

Purge

Low

High

Time

Purge

4 AirChanges

Combustion

Air Valve

Ignition

10seconds

Pilot valve open Main valve open

Flame must be

detected

Flame

Failure

Shutdown

in 1 sec

10seconds

Burner

Start

Signal

Low fire

proven

Safe Start

Check

Purge

Limits

Made

Safety!



• Do not take short cuts

• Do not disable any safety devices

• Use common sense when working with gas fired equipment

• Repair all gas leaks when detected

• Maintenance• …

• …

• …

• Safety is your responsibility!

Things to remember…

Safety!

training safety gas

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