Safety:-

Safety means saving from injury. In industrial context, it is the completion of work
without accident.

Accident:-

Accident is an undesired event. It brings harm to the body and loss of property.

Accident could cause -

i. Physical injury to the workmen

ii. Damage to property

iii. Wastage of raw-materials

Gas Safety
 Causes of
Accident

Unsafe Unsafe
Condition Behavior
(20%) (80%)

Bad Bad Failed

condition house Not using Absent Risk to analyze Improper
of tools keeping PPE mind taking the hazard planning
and tackle

Accident is never desired but 80% of accidents are caused due to Human Errors.

Gas Safety
 Hazard:-

Hazard means the object or condition which causes accident or having potential to
cause accident.

Types of Hazards

Visible Hidden

Hot Surface Electricity Radiation Gas

As information is must for hidden hazards for prevention of accidents.

Gas Safety
 INTRODUCTION TO GAS HAZARDS

GASES-IN-USE:

Name of Gas Source Users Hazards % of CO

Coke Ovens Gas Coke Ovens B.F.Stoves Toxic 9 - 12

CO Battery Inflammable
Boilers, Mills Explosive

Blast Furnace Gas Blast Furnace B.F.Stoves Highly Toxic 19 -25

CO Battery Inflammable
Boilers, Mills Explosive

LD Gas LD Shop Gas is mixed with Extremely Toxic 55 - 70

BF & CO Gas & used Inflammable
in Boilers & Mills Explosive

These gases are poisonous due to presence of Carbon-monoxide.

Other gases used in our Company are Oxygen, Nitrogen, Argon, Hydrogen,
Propane, Ammonia, Acetylene (DA) & LPG etc.

Gas Safety
 TYPICAL ANALYSIS OF BY-PRODUCT GASES

Constituents Coke Ovens Gas(%) Blast Furnace Gas(%) LD Gas(%)

Carbon-dioxide (CO2) 2.5 - 3.2 15.0 – 18.0 10.0 - 15.0

Carbon-monoxide (CO) 9.0 – 12.0 19.0 – 25.0 55.0 – 70.0

Oxygen (O2) 0.6 – 1.0 0.4 – 0.8 1.0 - 1.5

Hydrogen (H2) 52.0 – 55.0 3.0 – 5.0 2.0 – 4.0

Nitrogen (N2) 8.0 – 10.0 52.0 – 55.0 30.0 – 35.0

Methane (CH4) 23.0 – 24.0 Nil Nil

Unsaturated Hydrocarbon 2.5 -3.5 Nil Nil

These gases are burnt to form Carbon-dioxide at the same time is used as fuel to
generate steam, power and used for heating stoves, furnaces even at Canteen in its burner.

Gas Safety
 Danger involved
in handling of
CO, BF & LD Gas

Toxic Release Explosion Fire

(Exposure)

Gas Safety
 What happens in case of Gas Leakage / Toxic Release ?

 Gas comes into the atmospheric air and starts diffusing.

 During our breathing when we breath in such contaminated air, we inhale Carbon-
monoxide along with atmospheric air (21% O2 + 78% N2).

 This air goes to the alveoli of the Lungs where exchange of gas takes place.

 As the hemoglobin having about 300 times more affinity compare to oxygen, even a trace
amount of carbon-monoxide prevent the formation of oxy-haemoglobin and itself produce
carboxy-haemoglobin in the blood.

 So long we will be exposed to such atmosphere more and more carboxy-haemoglobin will
formed in the blood and oxygen deficiency in blood occurs which result the following
symptoms.

 Heaviness of head  Headache  Dizziness  Dimness of Vision

 Loss of Strength and Confusion  Unconsciousness  Finally Death.

Gas Safety
 As such poisonous gas is being generated and used in the company so management has
taken some safety measures.

Management Steps as Safety Measures

1. Depending upon the toxicity of the gas, its area of use is selected.

2. For identification of gas pipe, pipes are coloured with specific colours.

3. In case of excess gas, when gas is released to the atmosphere the system is provided to
burn the gas just after release.

4. Analyzing the hazards the maintenance and checking is done in canteens periodically in
every fortnight.

5. To develop the awareness about gas and its handling, the gas safety training is given to the
company employees, contractor employees and trainees.

Gas Safety
 Eight Steps of Gas Safety

1. Know the area where gas is in use and be alert. While working in these areas keep watch
on gas using gas detector.
Colour Codes for Pipe Line

CO GAS 

BF GAS 

LD GAS 

HP NITROGEN 

MP NITROGEN 

HYDROGEN 

ARGON 

AMMONIA 

OXYGEN 

Gas Safety
2. These poisonous gases either have their own smell (ammonia and chlorine) or gives smell
due to presence of impurities.

 Coke Oven Gas  Give smelling of burning tar

 Blast Furnace Gas  Gives smell of rotten egg or rotten fish

 LD Gas  Impurities is negligible so gives no smell, sometimes

gives smell of lime

 Ammonia  Having smell of urinals

 Chlorine  Having smell of Bleaching powder

Gas Safety
3. Know the symptoms of Gas Exposure (effect of gas poisoning with its saturation in blood)

% of Carboxy hemoglobin Symptom

in blood

5-10 Heaviness of head

10-15 Headache

15-20 Dizziness

20-25 Dimness of vision

25-30 Loss of Strength and confusion

30-40 Above symptoms get intensified

40-50 Unconsciousness

50-60 Death

Gas Safety
4. Don’t work in empty stomach, under sick condition or under intoxicating state in a gas
hazard area.

5. Don’t take rest or sleep in the area where gas is uses. (gas hazard area)

6. Don’t take risk if there is gas leakage, use gas mask and do the job.

7. Before working in the gas hazard area test the area for presence of gas and also take
written permission for working (works permit) in gas area.

8. Do not operate or handle the gas line or gas system without full awareness of system /
layout / job to be done. Don’t do the unplanned job.

Gas Safety
 Summary of Eight Steps of Gas Safety

1. Know the area where gas is in use and be alert. While working in these areas keep watch
on gas using gas detector.

2. These poisonous gases either have their own smell (ammonia and chlorine) or gives smell
due to presence of impurities.

3. Know the symptoms of Gas Exposure (effect of gas poisoning with its saturation in blood)

4. Don’t work in empty stomach, under sick condition or under intoxicating state in a gas
hazard area.

5. Don’t take rest or sleep in the area where gas is uses. (gas hazard area).

6. Don’t take risk if there is gas leakage, use gas mask and do the job.

7. Before working in the gas hazard area test the area for presence of gas and also take
written permission for working (works permit) in gas area.

8. Do not operate or handle the gas line or gas system without full awareness of system /
layout / job to be done. Don’t do the unplanned job.

Gas Safety
 Explosion-

An explosion is a sudden chemical reaction where the product of combustion

produce certain increase of volume and release of energy in violent manner.

Types of
Explosion

Deflagration Detonation Boiling liquid

Electrical
(where shock wave (where shock wave expanding vapour
explosion
is subsonic) is supersonic) explosion (BLEVE)

Gas Safety
 Deflagration;- (where shock wave is subsonic)

 Is a process of subsonic combustion that usually propagate through thermal conductivity,

here hot burning material ignites the next layer of cold material and so on.

 In free air deflagration, the deflagration effect is relative to its flame velocity.

 When flame velocity is low effect of deflagration is release of heat only can be term as flash
fire.

 When a low speed deflagration occurs in a closed vessel, pressure effect is due to
expanding gas so produce damage.

Detonation:- (where shock wave is super sonic)

 Is a process of supersonic combustion in which a shock wave propagate forward.

Gas Safety
For Explosion / Fire:-

Three conditions must be fulfilled for causing fire/explosion.

Combustible Gas Air / Oxygen

Ignition Temperature

The gas air mixture should be within explosive/flammable limit.

Gas Safety
LEL AND EXPLOSIVE LIMITS OF HYDROGEN
Risk of Suffocation
by O2-deficiency
%V/V Gas (Hydrogen) in Air

Hydrogen/Air-mixture too
rich, combustible with
additional air access only
77 Upper Explosive Limit (UEL)

Combustible range,
combustion with self-
content flame propagation

4 Lower Explosive Limit (LEL) 100 %

Measuring range of LEL
flammable gas
detectors Hydrogen/Air-mixture
too lean, not
combustible - not
explosive
LEL AND EXPLOSIVE LIMITS OF PROPANE
Risk of Suffocation
by O2-deficiency

%V/V Gas (Propane) in Air

Hydrogen/Air-mixture too
rich, combustible with
additional air access only
10.9 Upper Explosive Limit (UEL)

Combustible range,
combustion with self-
content flame propagation

1 .7 Lower Explosive Limit (LEL) 100 %

LEL
Propane/Air-mixture
too lean, not
combustible - not
explosive
 Name of Gas LEL % UEL % Ignition Temp °C
Coke Ovens Gas 9 31 605
Blast Fce Gas 35 73.5 680
LD Gas 14.8 71.5
Ammonia 16 27 651
Acetylene 2.5 8.2
Benzene 1.3 7.8 562
Carbon Monoxide 12.5 74 609
Hydrogen 4.0 75.6 585
Propane 2.1 9.5 466
LPG 2.0 9.0 482
Chlorine (non explosive) NA NA
Butane 1.8 8.4
Gasoline 1.4 7.6 280
Methane 5.0 15 537
Toluene 1.2 7.1 533
Carbon Disulphide 100

Gas Safety
AMMONIA

Gas Safety
 OVERVIEW

 Colorless gas and liquid (liquid under pressure).

 Vapor is toxic and irritating to eyes, nose, throat and skin.

 Liquid will burn skin and eyes and cause frostbite.

 Vapor is flammable under limited conditions.

 Use water to control fire and disperse vapors.

 Do not put water on liquid ammonia.

TLV 25 ppm (Threshold Limit Value - for 8 hrs)

STEL 35 ppm (Short Term Exposure Limit - for 15 mins)

IDLH 300 ppm (Immediate Danger to Life and Health)

Gas Safety
 POTENTIAL HEALTH EFFECTS

Primary Routes
of Entry

Skin Contact
Inhalation Visible Eye Contact
/Absorption

Anhydrous ammonia reacts with moisture in mucosal surfaces (eyes, skin, and
respiratory tract) to produce ammonium hydroxide, which may cause caustic injury. The
severity of injury depends upon the concentration and duration of exposure. The extent of
injury ranges from mild cough to laryngeal edema and life threatening pulmonary edema.

Gas Safety
 INHALATION

Acute Exposure:
Ammonia is toxic and a severe irritant of the respiratory tract. It
may cause a running nose, coughing, chest pain, cessation of
respiration and death due to Pulmonary edema.

First Aid for Inhalation:

Move patient to fresh air. Monitor for respiratory distress. If
cough or difficulty in breathing develops, evaluate for respiratory
tract irritation, bronchitis, or pneumonitis. If trained to do so
administer supplemental oxygen with assisted ventilation as
required. Administer artificial respiration if patient is not

Gas Safety
 SKIN

Acute Contact: Ammonia is a severe irritant of the skin. Skin exposure

to high concentrations of the gas may cause burning and blistering.
Contact with liquid may cause

First Aid for Skin: Immediately flush exposed area with copious
amounts of tepid water for at least 15 minutes followed by washing
area thoroughly with soap and water. The patient should be seen in a
health care facility if irritation or pain persists.

Gas Safety
 EYE

Acute Contact:
Exposure to the eyes (>700 ppm) may cause temporary or
permanent blindness.: Eye exposure may result in conjunctivitis,
lacrimation and/or corneal irritation. Total corneal epithelial loss
may occur.

First Aid for Eyes:

Immediately flush eyes with copious amounts of tepid water for
at least 15 minutes. If irritation, pain, swelling, excessive tearing,
or light sensitivity persists, the patient should be seen in a health
care facility and referral to an ophthalmologist considered.
Gas Safety
 ACCIDENTAL RELEASE MEASURES
Spill or Leak Measures:
Stop leak if you can do so without risk. Keep unnecessary people
away, isolate hazard area and deny entry. Stay upwind, , provide
air ventilation, and placing a wet towel or cloth over the face (if
needed). With proper training, self-contained breathing
apparatus (SCBA) and structural firefighter’s protective clothing
used in conjunction with water spray will provide limited
protection in outdoor releases for short-term exposure. Fully
encapsulating, vapor-protective clothing should be worn for
spills and leaks with no fire. Use water spray or foam to control
vapors. Mixing of water and liquid ammonia will increase
vaporization rate. Do not put water on liquid ammonia unless
more than 100 volumes of water are available for each volume
of liquid ammonia.
Small Spill: Flush area with flooding amounts of water.
Gas Safety
CHLORINE

Gas Safety
 OVERVIEW

Place of Use in Tata Steel

a) Cooling Towers b) Water Works
HAZARDS IDENTIFICATION
Main Hazards
Chlorine is toxic, and irritating to the skin, eyes, nose and
mucous membranes. Liquid chlorine causes severe irritation and
blistering of the skin. Oxidiser, may explode or accelerate
combustion in contact with reducing agents.
Adverse Health Effects
Exposure to low concentrations causes a stinging or burning
sensation in the eyes, nose and throat, and sometimes headache,
due to irritation of the accessory nasal sinuses. Inhalation of
chlorine in higher concentrations effects both the upper and
lower respiratory tract, and also produces pulmonary oedema.
Chemical Hazards
Chlorine forms an explosive mixture with hydrogen. Many finely
divided metals will burn in an atmosphere of chlorine. Wet
chlorine is highly corrosive to most common metals.
Gas Safety
 PHYSIOLOGICAL RESPONSES TO VARIOUS
CONCENTRATIONS OF CHLORINE GAS
Effect of Chlorine Gas

Least detectable odour 3.5 ppm

Least amount required to cause irritation to throat 5.1 ppm

Least amount required to cause coughing 30.2 ppm

Least amount required to produce slight symptoms

(of poisoning) after several hours exposure 1.0 ppm

Maximum amount that can breathed for one hour without serious effe

Amount dangerous in 30 minutes to 1 hour 40-60 ppm

Amount likely to be fatal after a few deep breaths 1000 ppm

Gas Safety
OXYGEN

Gas Safety
 OVERVIEW

Physical & Chemical Properties

Appearance/Colour:  Colourless gas

Odour:  Odourless

Molecular Weight:  32

Critical Temperature:  118°C

Boiling Point:  -183ºC

Melting Point:  -219ºC

Relative Density (Liquid):  1.1 (water = 1)

Relative Density (Gas):  1.1 (air = 1)

Vapour Pressure @ 20°C:  Not applicable

Solubility (water):  39 mg/l

Flammability Range:  Oxidiser

Gas Safety
1. Hazardous Properties
Strongly supports combustion. May react violently with combustible

2. First Aid Measures

Inhalation:
Continuous inhalation of concentrations greater than 75%
may cause nausea, dizziness, respiratory difficulty and
convulsions.

3. Fire Fighting Measures

Suitable Extinguishing Media:
All known extinguishants can be used.

Gas Safety
4. Specific Hazards:
Exposure to fire may cause containers to rupture/
explode.
Non-flammable.
Supports combustion.

5 . Accidental Release Measures

Personal Precautions
Evacuate area.
Ensure adequate air ventilation.
Eliminate ignition sources.

Gas Safety
6. Environmental Precautions
Try to stop release.
Prevent from entering sewers, basements and
workpits, or any place where its accumulation can be
dangerous.

7. Handling and Storage

Storage:
Segregate from flammable gases or other flammable
materials in store.
Keep away from ignition sources.
Keep container below 50°C in a well-ventilated place.

Gas Safety
NITROGEN

Gas Safety
 OVERVIEW

Physical & Chemical Properties

Appearance/ Colour: Colourless gas.

Odour: Odourless
Molecular Weight: 28
Melting Point: -210ºC
Boiling Point: -195.8ºC
Critical Temperature: -146.85°C
Relative Density (Liquid): Not applicable
Relative Density (Gas): 0.967 (air = 1)
Vapor Pressure @ 20°C: Not applicable
Solubility (water): 23 mg/l15

Gas Safety
Hazardous Properties Accidental Release Measures
First Aid Measures
Inhalation Personal Precautions
Compressed gas. In
high concentrations
may cause
asphyxiation

In high concentrations may cause

asphyxiation. Symptoms may
include loss of mobility/
consciousness. Victim may not be
aware of asphyxiation. Remove
victim to uncontaminated area
wearing self contained breathing
apparatus Gas Safety