Gas Safety

Legal Compliance OHSAct Vessels Under Pressure Regulation v/s Pressure Equipment Regulations Construction Regulation ANSI Z223.1 SANS 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 systems Major Hazardous Installation Other Air Quality Bill Environmental & Pollution Acts Gas Reticulation System (Supplier) Main Transmission Line Distribution 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
OHSAct
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?)

Legal Compliance
OHSAct
Section 8 General Duties of Employers Every employer shall provide and maintain as far as reasonably practicable a working 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/mitigate that 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 benefits deriving therefrom Cost Analysis

Legal Compliance
OHSAct
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 corrective actions have been taken Ensure compliance of the act by every person Enforce matters concerning the health and safety

Legal Compliance
OHSAct
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 without risks to health when properly used (How?) Undertaking in writing to take specified steps to ensure safe use this will relieve the supplier from the duty imposed on him

Legal Compliance
OHSAct
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 has sustained injuries, he must report this to the employer not later than the end of the particular shift during which the incident happened

Legal Compliance
OHSAct
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 fact only that he failed to do anything which he may do or is required to do i.t.o this act

Legal Compliance
Vessels Under Pressure Reg
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, excluding a boiler, pressure vessel or portable gas container connected to the system pressurised system means an assembly of vessels under pressure and includes connections by pipes or similar ducts, fittings and valves which operate under gauge pressure equal to or greater than 40 000 pascal for the process and conveyance of a flammable liquid, hazardous chemical substance, saturated steam or superheated steam vessels under pressure means a vessel which operates under pressure and includes a boiler, pressure vessel, pressurised system or portable gas container

Legal Compliance
Vessels Under Pressure Reg
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 the manufacturer

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

fitted with at least one pressure gauge and the maximum operating pressure shall be indicated fitted with at least one safety valve (Whats 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 the health and safety standard (eg. gas train SANS 329)

Access
Vessels under pressure to be erected so that access to and exit from any chamber, flue, manhole, inspection opening, control or appurtenance is safe and unobstructed.

Legal Compliance
Vessels Under Pressure Reg
Gas fuel Use, Equipment and Systems
No 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 , unless such person is a holder of a certificate of registration issued by an organisation 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 hydraulic pressure test to 1,25 times the maximum permissible operating pressure
9 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 such inspections and tests by virtue of their training, knowledge and experience in operation, maintenance, inspection & testing

Legal Compliance
Vessels Under Pressure Reg
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 reaction which 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 work performed (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
Major Hazard Installation Regulations
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 from the use of plant or machinery, or from activities at a workplace;

SASOL GAS NETWORK

INHAMBANE

Jofane Rumbacaca Temane Vilanculos Talofo Muabsa Componde Chigubo Camo-Camo

GAZA

Mabuiapanse

LEGEND
SASSEC Product Pipelines Petronet Pipeline MSP Transmission Gas Pipeline Low Pressure Pipeline High Pressure Pipeline
MAGUDE

Magandene Meginge

Guija Mahele Chokwe Motaze Panjane

MOAMBA Babelegi Rosslyn Pretoria MPUMALANGA Nelspruit B Malelane Sabie

Komatipoort

Ressano Garcia Barberton MAPUTO

1
GAUTENG Randfontein Lenasia

E Lyttelton
Kemptonpark Benoni Springs A F Nigel Alberton Meyerton

Middelburg Witbank Carolina Hendrina Breyten Bethal Secunda Ermelo Amsterdam SWAZILAND

Badplaas

C Maputo

6
Vereeniging Sasolburg

Standerton

NO 1
Volksrust New Castle

2 3 4 5
Empangeni Richardsbay

KWAZULU-NATAL

LOCATION SECUNDA - SSP START RANDFONTEIN - END BABELEGI - END SASOLBURG - END SECUNDA - PRODUCT LINES - START SASOLBURG - END SECUNDA - PPP START DURBAN - ALLIANCE PEROXIDE END TEMANE RESANO - TAKE OFF SECUNDA - MSP END SECUNDA - SWM START MIDDELBURG - END SASOLBURG - SEP - START LANGLAAGTE - SEP - END

X_COORD Y_COORD 29.15 -26.55 27.75 -26.13 28.28 -25.34 27.83 -26.82 29.15 -26.55 27.83 -26.82 29.14 -26.55 30.90 -30.03 35.06 -21.75 32.00 -25.46 29.19 -26.55 29.15 -26.55 29.50 -25.79 27.84 -26.82 27.98 -26.21

3
Produced by: SASOL GAS GIS TEAM Alrode March 2005 Phoenix

Mandini

Verulam Avoca Durban

A B C D E F

DEPOTS ALRODE DEPOT NELSPRUIT DEPOT MAPUTO PINETOWN PRETORIA DEPOT ARNOLD STR DEPOT

ADDRESS CNR CLARKE & GARFIELD, ALRODE PTN 13 GRANITE HILL KAAPSCHEHOOP AVE BAIRRO TRIUMFO, 5A AVENIDA, RUA 4505, CASA 380 SUZUKA RD PINETOWN 117 INDUSTRIAL RD PRETORIA WES ARNOLD STR ALRODE

N17
R50

BETHAL
N17

ERMELO

DIEPDALE

ERMELO

EMBALENHLE

SECUNDA
R35
N 11
R38

AMSTERDAM SHEEPMOOR

Sasol Gas Transmission & Distribution Pipeline Network KwaZulu Natal

N2

R5 47

R39

SIVUKILE

R546

STANDERTON
R23

VRYHEID

R6

R6 18

R 66

R3 3

R6

02

N1 1

R5 0

STANDERTON AMERSFOORT
WAKKE RSTROOM
3 R2
3 R54

PIET RETIEF
INGWAVUMA

PAARDEKOP

N2

DIR KIESDORP

R33

VOLKSRUST
SIMDLANGENTSHA

MARTHINUS

PAULPIETERSBURG

DUMBE
R6 9

UBOMBO

UTRECHT
CORON ATION

NGOTSHE (LOUWSBURG)

UBOMBO

NEWCASTLE

R34

R34

NONGOMA VRYHE ID
6 R6

R618

HLABISA DANNHAUSER
R6 21
R68

DUNDEE
R33

NQUTU (VERULAM)
8 R6

MAHLABATINI BABANANGO

HLABISA

DUNDEE

KLIPRIV IER (LADYSMITH)

SAINT LUCIA MTUBATUBA

R103

BOLATA

R616
R1 03
N3

LADYSMITH

KLIPRIV IER (LADYSMITH)

KWA MBONAMBI
MSINGA NKANDLA
R3 4

LOWER UMFOLOZI (EM PANGENI

R34

R74

EMPANGENI
R66

N2

ESTCOURT

OKHAHLAMBA
R33

ESHOWE
KRANSKOP
R66

ONGO YE
MTUNZINI

MTUNZINI
N2

R6 00

ESTCOURT
R6 22

R7 4
R74

ESHOWE

GINGINDHLOVU
02 R1 ESHOWE

MOOI RIVER

GREYTOWN

UMVOTI (GREYTOWN) MAPUM ULU

MANDINI
R74

R3 3

MOOI RIVER
N3

LOWER TUGELA (STANGER)

ZINKWAZI BEACH
YORK
NEW HANOVE R
14 R6

STANGER SHAKASKRAAL
M 4R 10

WARTBUR G

UMNGENI

MONA
NDWEDWE

BALLITO

IMPENDHLE

PIETERMARITZBURG
N3

M27

VERULAM

UNDERBERG (HIMEVILLE)

PHOENIX
R 56

HIMEVILLE UNDERBERG
R617

CATO RIDG E
R603

BULWER

RICHM OND (KZN)

N3

DURBAN
M7

AVOCA DURBAN

RIC HMOND
R624

PINETOWN

M35
M37

CREIGHTON

IXOPO

AMANZIMTOTI

N2

FORT NOTTINGHAM

BLYTHEDALE BEACH

TINLEY MANO R BEACH

N2

N2

RICHARDS BAY

ESIKHAWINI

3 R10

N3

R103
R612

R33

Gas Supply Suppliers Reticulation System

Keep >40bar Pop = 40 50 bar METHANE-RICH GAS IS ENVIRONMENTALY FRIENDLY HP same trans LP 6.26 bar Pop = 40 50 bar TRANSMISSION LINE P = 50 bar

TRANSMISSION LINE P = 125 bar PRS Poutlet = 625 kPa

PPS IN SECUNDA

Transnet Pipelines DISTRIBUTION NETWORK

Quality Jacobs Bamboo Prospecton Athlone Umbongintwini

INTERNAL PIPELINE Pinlet = 100 kPa CUMSTOMERS PREMISES

CMS Poutlet = 100 kPa

Customers Responsibility

Suppliers responsibility

SCADA System

SCADA System

Suppliers Reticulation System

CMS
Components

Safety shut off valve Filter Meter & Mercury Index Two regulators Emergency service shut off valve Pressure relief valve (Customer Valve)

Suppliers Reticulation System

Dispersion Model

Customers Reticulation System

Internal Line
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 Protect against corrosion Apply insulating material around underground pipe Thin inner wrapping and thick outer wrapping should be applied Bury pipe to depth of at least 1 meter Fine soil should be used to backfill around the pipe 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 the pipe

Underground

HDPE (High Density Polyethylene)

Customers Reticulation System

Internal pipeline
Flexible hoses
Fixed clamps Screw joints Flanged joints Wire brazed hoses Flexible tubing shall be compatible with the type of gas used and they 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 and damage Have end fittings as integral parts of the tubing

Customers Reticulation System

Internal pipeline
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 whole plant 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 an allowance made for ambient condition flactuations The frequency of testing shall be determined prior installation and it shall not be less than 36 months

Gas Spec
MRG
Energy content @ P=101.325 kPa
Gross energy content Net energy content MJ/m MJ/m

0oC
35.97 32.35

15oC
34.05 30.69

Density Relative density (RD) Wobbe index (WI) 0.58 EC/RD

kg/m 47.23

0.75

Lower explosive limit (LEL) % gas in air volume Higher explosive limit (LEL) % gas in air volume Auto ignition temperature C Theoretical flame temperature C Stoichiometric air to gas ratio Sulphur mg/m 9 630 1925 8.57:1

5 15.7

Combustion
Auto Ignition Temp
Re-heat furnaces Melting furnaces Incinerators

1200 C
(Methane Rich Gas)

(Natural Gas)

700 C
Boilers Baking ovens Drying & Curing ovens

650 C

620 C

15 C

Fact file!
When do burners fail?
American Stats

50% during start-ups 40% during burner firing 10% re-lighting after flameout

Combustion
Properly designed combustion system
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 9 Monitor operating parameters (P & T)

Low flame High flame

Prove flame at all times Confirm proper conditions at all times

Combustion
Combustion System Operating Sequence
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 Failures

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

EXPLOSION

Combustion
Elements of combustion / explosion

Fail Safe Systems

Combustion
Fail Safe Systems
The ultimate aim of safety is to have fail safe equipment. This is achievable when correct safety devices are used to:9 detect flame, 9 detect gas and air failure, 9 response fail safe immediately When a power failure occurs, the burner equipment must also be shut down to a fail safe position. After every failure the proper light-up sequence should be adhered to.

Combustion
CABLE System Flame Rod FailCONNECTION Safe CERAMIC INSULATOR

Property Sensed: Application: Placement:

Ionization in flame Gas flame 1. Upper 2/3 of flame 2. Ground ratio 4:1
ELECTRODE

Advantages:

1. Low cost

THREADED COUPLING 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
Fail Safe System Flame Rod
Flame Rod

upper 2/3 of flame

B. No Ground Surface in Flame

C. Correct

Combustion
Fail Safe System UV Scanner
ELECTRICAL CONNECTION

Property Sensed: Application: Placement: Advantages:

Ultraviolet radiation Gas and oil flame First 1/3 of flame 1. High output 2. Signal can be magnified 1. Can detect ignition spark 2. Detector tube life limited 3. Temperature sensitive 4. Can fail in a conducting mode VIEWING WINDOW 5. Must have a clear sight path OR MAGNIFYING LENS

COOLING AIR

Limitations:

Combustion
Fail Safe System UV Scanner
U.V. SCANNER

first 1/3 of flame

GAS INLET

COMBUSTION AIR

Combustion
Safety interlocks
1. 2. 3. 4. 5. 6. 7. 8. 9. Low gas pressure switch High gas pressure switch Valve closed position switches Combustion air proving switch Burner low fire start switch System fan proving switch Exhaust fan proving switch High temperature limit switch Dampers open

5
pilot gas vent

6 7 8 9

1
main gas

Combustion
Burner Lighting
Purge Limits Made Burner Start Signal Low fire proven Safe Start Check Flame must be detected Flame Failure

Start Purge

Purge
4 Air Changes

Ignition Pilot valve open 10 seconds

Main valve open 10 seconds

Shutdown in 1 sec

High
Combustion Air Valve

Low Time

Safety!
Things to remember
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!