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Acetylene Plant Case Study

 
Hole Drilled into High Water Alarm

Problem Identification

Hole has been drilled into high water alarm eliminating the alarm

Solution

New restriction tee is needed

Maintenance Tip

A major cause of the high level alarm on old plants is leaks in the aluminum tubing from corrosion or wear. Replacing all of the tubing from the generator controls to the motor control panel with stainless steel tubing will remedy this problem of leaks.


Air Fitting Leak

Problem Identification

The air fitting connections have leaks and the restrictors have been drilled out to compensate for this problem

Solution

Replace the aluminum tubing with ¼” (.250) stainless steel tubing. All leaks in this tubing must be stopped for the controls to operate correctly


Control Tube

Problem Identification

Control tube has been hit with a wrench multiple times to unstick movement

Solution

Replace complete control tube as it has been made oval due to being hit, now it is frozen

Maintenance Tip

Only used approved replacement parts. Usingnon approved parts can reduce the life of the plant.


Generator Drain Valve Leak

Problem Identification

Generator drain valve has a leak

Solution

Replace unit

Maintenance Tip

Pilot valve should be replaced at the same time


Water Inlet

Problem Identification

Water inlet instrument has been modified. Hole has been drilled in the snubber

Solution

New G snubber is needed

Maintenance Tip

With the hole in the snubber water is added at all times using more water than is needed and producing extra lime slurry.


High Pressure Drier Set

Problem Identification

High pressure drier cannot be opened

Solution

Replacement of the set of driers is strongly recommended

Maintenance Tip

Without the addition of calcium chloride daily, water will enter the acetylene cylinders.


Vent Piping Relief Valves

Problem Identification

Vent piping from relief valves has been removed on the compressor

Solution

Install vent piping

Maintenance Tip

High pressure acetylene will be released into the generating room which could ignite from static electricity to start a fire.


Badly Corroded Relief Valve

Problem Identification

Relief valve is corroded badly and does not work

Solution

The relief valve must be replaced

Maintenance Tip

This relief valve keeps high pressure acetylene from entering the room.


Flashback Relief Valve Handle

Problem Identification

Handle is broken on the flashback relief valve

Solution

Replace handle

Maintenance Tip

Handle can be removed and replaced without effecting the pressure setting of the relief valve.


Corrosion in Purifier

Problem Identification

Corrosion on purifier

Solution

The corrosion needs to be removed and a anti–corrosion agent applied.


Pressure Drier Corrosion

Problem Identification

Corrosion at the base of the medium pressure drier

Solution

The corrosion needs to be removed and a anti–corrosion primer and paint used to protect the metal from further corrosion.


Acetylene Leakage

Problem Identification

1. Acetylene leaking from the top of the control.
2. Lime slurry leaking from between the control unit and the generator

Solution

New diaphragm needed

Maintenance Tip

When replacing unit make sure diaphragm is in good condition. Use bolts, not screws, to mount the control.


Empty Oiler

Problem Identification

Empty oiler shows lack of proper maintenance

Solution

Fill oiler with proper oil

Maintenance Tip

Follow proper maintenance schedules listed in the plant operators manual for all lubricants.


Leakage of Lime Slurry

Problem Identification

Lime slurry leaking from the agitator shaft

Solution

Keep agitator shafts lubricated

Maintenance Tip

Leaking lime slurry accelerates shaft wear causing premature failure. Change the packing and lubricate the shafts with grease several times daily.


Warning Sign

Problem Identification

There are no signs warning people that calcium carbide is stored in this area of the building

Solution

Post signs stating that this is a calcium carbide storage area and no water is to be used in the area


Rexarc Acetylene Plants

Many Rexarc acetylene plants have been in operation for over 50 years. It is important to follow all procedural manuals and maintenance guidelines and utilize only approved replacement parts.

As a result of this audit Rexarc has assured the safe and efficient operation of this plant, thereby optimizing the investment of the plant owner.

To schedule an audit of your plant please donʼt hesitate to contact Rexarc at This email address is being protected from spambots. You need JavaScript enabled to view it. or call us at 1-937-839-4604

Copyright © 2019 Rexarc International, Inc. All Rights Reserved.