In the previous post, we discussed three common problems observed in acetylene plants. The following are some more areas that should be looked into during an acetylene plant audit.
Some common issues observed in acetylene plants are listed below to help you quickly identify the ‘problem areas’ in your plant:
1. Problem: The generator drain valve was leaking.
Solution: The entire unit needs to be replaced.
How to Avoid It: While replacing the generator drain valve, the pilot valve should be replaced as well.
2. Problem: A hole has been drilled in the snubber of the water inlet instrument. The hole in the snubber allows more water to enter the system. This creates more waste like lime slurry.
Solution: The snubber has to be replaced.
How to Avoid It: The water inlet instrument should not be modified without professional help.
3. Problem: The high pressure drier was jammed and could not be opened. Hence, no calcium carbide was being added to the system. Without adding calcium carbide, water could enter the acetylene cylinders.
Solution: The drier should be replaced immediately.
How to Avoid It: Service the high pressure drier daily to help prevent moisture from entering the cylinders. Additionally, the drier cap should be lubricated periodically to prevent it from seizing.
4. Problem: The vent piping of the relief valve located on the compressor has been removed. With removal of the vent piping, an extremely hazardous situation has been created in the acetylene plant. High pressure acetylene can be released in the generator room. If the acetylene reacts with static electricity, it could lead to a combustion or fire.
Solution: New vent piping needs to be installed.
How to Avoid It: It is imperative to verify that the vent piping is installed on each compressor.
5. Problem: The relief valve present on the compressor is corroded. This valve keeps high pressure acetylene from entering the generator room. As stated above, this could create a hazardous situation.
Solution: The relief valve has to be replaced.
How to Avoid It: Relief valves should be replaced on an annual basis. Contact Rexarc to learn about its relief valve exchange program to save money and minimize unexpected downtime to service the machinery.
6. Problem: A part of the surface of the purifier is corroded.
Solution: The corrosion needs to be removed. An anti-corrosion material needs to be applied to the surface of the purifier.
How to Avoid It: Since the corrosion was identified in the initial stages, the entire drier didn’t need to be replaced. Hence, early detection will help in reducing costs to a great extent.