1. 1
SMPV (U) RULES, 1981 AS AMENDED IN 1999 .
Pressure Vessel
A : Unfired B : Fired i.e. Boiler
A1: Storage A2: Transport A3: Process Vessel
Vessel Vessel e.g. Autoclave,
Digesters, Reactors,
heat exchangers, Air
receiver
SMPV (U) Rules Covers : A1 + A2 Only
> 1000 Ltrs. Water
Capacity
2. 2
FABRICATION
• BY APPROVED FABRICATOR
• UNDER STAGE WISE INSPECTON OF
• APPROVED INSPECTOR
• WELD JOINS 100% RADIOGRAPHED
• HYDOTESTED AT THE DESIGN TEST PRESSURE
3. 3
Backfire and flashback
• Backfire and flashback
– A backfire (a single cracking or 'popping' sound) is when the
flame has ignited the gases inside the nozzle and extinguished
itself. This may happen when the torch is held too near the work
piece.
– A flashback (a shrill hissing sound) when the flame is burning
inside the torch, is more severe. The flame may pass back
through the torchmixing chamber to the hose.
• Reasons
– •When the blow pipe becomes hot.
– •Nozzle blocked.
– •Nozzle close to the job.
– •Pressure difference between flame pressure and the hose
pressure.
• COMPRESSED GASES HAZARDS
– 1.2
4. 4
If Flash back occurs ,
– The blowpipe valves shall be shut off, oxygen first and then the
fuel gas;
– Oxygen and fuel gas cylinder valves shall be shut off;
– The blowpipe shall be cooled with water, if necessary;
– The equipment shall be checked for damage or faults, particularly
the nozzle.
– Cylinder valves of both fuel gas and oxygen shall be closed
immediately.(If it is safe to do so.)
– Check any acetylene cylinder which has been exposed to
heat/flash back. If it starts to vibrate or becomes warm ,call
emergency services immediately.
– Do not attempt to move an unstable cylinder. Direct water supply
to it (if it is safe to do same)
– Replace damaged Hoses, Blow pipe, Flash back arrestors &
regulators before reuse.
5. 5
Flash Back Prevention
• Training
• Use the correct lighting-up procedures
• Before lighting the blow pipe, purge the hoses by
opening the gas supply for a few seconds
• Use a spark igniters to light the flame.
• Flashback arresters shall be provided at both
ends of the hoses to prevent backflow of gas
towards cylinders
• Correct gas pressure for the nozzle size shall be
used
• Keep nozzles in good condition
6. 6
FIRE ON CYLINDERS
• FIRE ON CYLINDERS
–Try to extinguish the fire from far away.
–Do not stand in the direction of fusible
safety valve fixed at the bottom of the
cylinder.
–Clear the site and raise the alarm.
8. 8
CYCLICAL NATURE OF EMERGENCY MANAGEMENT
GOVERNMENT
REGULATION
LIABILITY MEDIA
EMPLOYEES
HEALTH & SAFETY
PUBLIC
PRESSURE
INSURANCE
EMERGENCY
PREPAREDNESS
SYSTEM
10. 10
Steps in Emergency Planning
• Identify Hazards and Assess risk
• Assess Capabilities And resources
• Review Existing plan
• Define Plan objective and scope
• Choose Appropriate type of plan
• Determine Responsibility
• Determine Emergency Response operation
• Write and edit the plan
11. 11
Emergency Notification procedure should be
designed in the following ways :
• What happened
• To whom did it happen
• How did it happen
• What help is needed
• Where did it happen
• When did it happen
• To what extent.
• (Where, When, How, What )
12. 12
To Control:Specially Trained persons to be
assigned in the following functional area during
emergency:
Policy, Situation analysis, Operation,
Communication, Hazard monitoring,
Meteorological monitoring, Technical support,
Clerical and administrative service, Press and public
information.
Provision to be established for communication
between the following group:
Emergency operation center and response group.
Emergency operation center and all off-site
agencies
Onsite response team and off-site response team
13. 13
Emergency operation center and support personnel
including
Press,public relation and technical support.
Type of drill:
Orientation exercise
Table top
Orientation
Full scale
14. 14
Table top: Table top exercise involve presenting to
key emergency personnel
A simulated emergency situation in an informal
setting to draw out constructive discussion so that
the participants examine and resolve problem in
connection with the plan.
Functional Drill : This is the practical exercise
designed to test the capabilities of personnel to
perform a specific function
( like Communication, First-aid, Rescue etc)
Full scale Drill: Full scale exercise are intended to
evaluate the operational capabilities.
15. 15
MANAGEMENT CONTROL
ELIMINATE UNSAFE
CONDITION
DISCOVERING CAUSES ELIMINATE UNSAFE
ACTIONBY MEANS OF
SAFEGUARDING ALL
MACHINES,EQUIPMENT
WORK SPACE ETC
RECTIFYING OR PREVENTING
DEFECTIVE CONDITION
SUITABLE AND SAFE DESIGN
AND CONSTRUCTION.
SAFE ARRANGEMENTS
PROCESSES,METHOD OF
WORK ETC.
ADEQUATE AND SUITABLE
ILLUMINATION.
ADEQUATE AND SUITABLE
VENTILATION
SAFE DRESS AND PERSONAL
PROTECTIVE EQUIPMENT.
BY MEANS OF
JOB SAFETY ANALYSIS
INSPECTION OF PLANT AND
EQUIPMENT
RECORDING AND TABULATION OF
DATA
INVESTION OF ACCIDENTS
ANALYSIS OF DATA
PERSONAL ADJUSTMENT
SUPERVISION
SAFETY EDUCATION AND
TRAINING.
DISCIPLINE
BY MEANS OF
19. 19
FLASH BACK ARRESTOR
•Check valves allow
gas flow in one
direction only
•Flashback arrestors
are designed to
eliminate the
possibility of an
explosion at the
cylinder.
•Combination
Check/ Flashback
Valves can be placed
at the torch or
regulator.
28. 28
DURING SHUTDOWN FIVE KEY PARTIES ARE INVOLVED
1. THE CLIENT/PRINCIPAL EMPLOYER.
2. THE DESIGNER
3. THE PLANNING SUPERVISOR
4. THE PRINCIPAL CONTRACTOR
5. CONTRACTOR AND THE SELF EMPLOYED.
The principal employer should ensure that the planning supervisor,the
designer,the principal contractor and contractor are competent.
The designer should ensure that so far as possible structure on
building site are designed to avoid or minimise risk to health and
safety while they are being built or maintained.Where risk cannot
be avoided,adequate information must be provided.
29. 29
The planning supervisor has overall responsibility for co-ordinating the
health and safety aspects of the design and planning phase of a shut
down. They are also responsible for developing a health and safety
plan and notify the HSE about the shut down.
The principal contractor should take into account health and safety
issues when preparing tenders or similar documents.They also have
duties to develop the health and safety plan and co-ordinate the
activities of all contractors.Principal contractor should also check that
employees who are involved in the shutdown job are given adequate
information and training.
Contractor and the self employed should co-operate with the principal
contractor and provide relevant information on the health and safety
risk created by their work and steps they will take to control and
manage the risks.
30. 30
THE HEALTH AND SAFETY PLAN:
The pre tender health and safety plan should include:
• General description of the work.
•Details of timings with in the shutdown
•Details of risks to workers at the pre-tender stage
•Information required by potential principal contractors to
