Recommended Lubricants for Acetylene Plants and Important Maintenance Checklists
Acetylene is an industrial gas with several beneficial properties, which makes it easily popular over other industrial gases such as methane, propane, and so on. Though all these gases are hydrocarbons, the acetylene differs from them in terms of its chemical bonding. The chemical formula of acetylene is C2H2 that suggests the presence of two carbon atoms and two hydrogen atoms in the molecule. In this molecule, the carbon items are joined by a triple bond. This additional bond in acetylene lends several typical properties to it, which is being beneficially exploited across various industries.
Nowadays, various types of acetylene plants are being used to ensure its continuous supply. These industrial acetylene plants, like any other compressed gas equipment or industrial equipment, demand regular lubrication. The earlier discussed molecular bond also makes acetylene a sensitive gas, which means extra care must be taken for choosing the right type of lubricant. Are you interested to know the different types of lubricants used in acetylene plants? Read the post to know more. Here Rexarc, the manufacturer of industry-grade acetylene plants, recommends popular lubricants that can be used in these plants.
Different Types of Lubricants Used in Acetylene Plants
The following is a list of the parts and recommended oils for lubricating them.
1. Acetylene Compressors: It is one of the integral parts of the acetylene plant that requires regular lubrication. Normally, non-detergent hydraulic oils of SAE20W (ISO 68) are recommended for lubrication. The viscosity of the oil used must be 315-SSU-68 cSt at 100°F (37.7°C). These are some of the recommended lubricant oils:
- Arco Duro S-315
- Mobil DTE Oil, Heavy Medium
- Texaco Regal Oils R & O-(PC) 68
- Shell Tellus Grade 33, Code 65211
- Sunvis 931-1431-00
- Sohio Factovis – 52
- Exxon Terrestic 52, Alternate Exxon Nuto 53
- Union 76 – Turbine Oil XS Grade 315
2. Air Compressors and Screwfeed Oilers: These parts must be lubricated using any SAE 30W (ISO 100) non-detergent hydraulic oils having viscosity 158 SSU, 30 cSt at 100°F (37.7°C). The following are a few lubricating oils that meet the aforementioned requirements:
- Arco Duro S-150
- Texaco Regal Oils R & 0-(A) 32
- Mobil DTE Oil, Light
- Sohio Factovis – 43
- Exxon Terrestic 43 or Nuto 43
- Sunvis 916-1429-00
- Shell Tellus Grade 27, Code 65208
3. Gear Reducers: These must be lubricated using AGMA #7 (ISO 460) gear oil with viscosity 2337 SSU, 437 cSt at 100°F (37.7°C). The following are a few oil lubricants meeting this specification:
- American Worm Gear Oil #5EP
- Citco Compounds L-3-X
- Gulf Senate 145D
- Gulf EP
- Gulf Lube 150
- Mobil Gear Oil 634
- Hector S-150
- Philube Gear Oil 140
- Chevron Gear Compound 140
- Son Gear Lub GL-4
- Sunep EP-130
- Union Gear Compounds #130
4. Hoist, Residue Pumps, Acetone Pumps, and Screwfeed Hydraulic Systems: These parts should only be lubricated using SAE 10W (ISO 32) non-detergent hydraulic oils.
It is important to check the oil levels in all the above-mentioned components before starting your acetylene plant. The components should be opened after ensuring that all gauges are set at zero pressure. Also, it is recommended to use the oil listed for that particular component. Along with this timely lubrication, it is also important to conduct daily, weekly, and monthly inspection and maintenance of various components in the acetylene plant to ensure their proper functioning. These activities will be covered in the next few sections.
Daily Acetylene Plant Maintenance Checklist
It is important to conduct a daily inspection of certain components before starting the acetylene plant. This inspection can be accomplished in the following steps:
- Starting with the agitator, ensure that it runs 2 out of every 10 minutes.
- Examine the stuffing box of the agitator for leaks. Make the necessary adjustments to avoid leaks.
- Check hydraulic pipes and ensure there is no leakage.
- Clean the monitor filter.
- Clean control tubes of the slurry pump.
- Check temperatures of the screw feed gearbox and the agitator gearbox.
- Next, move on to the generator equalizer manifold by draining its condensate.
- Check carbide hoist cable and control ropes for any wear and tear.
- Check residue drain valve for leaks.
- Grease agitator shafts every couple of hours.
- Check the level of water in a purifier scrubber.
- Drain or filter oil condensate from acetylene compressor.
- Check oil level in the acetylene compressor.
- Refill high-pressure drier with calcium chloride.
- Check the water temperature of the compressor.
- Check the gas temperature of the cooler condenser.
- Check the oil level in the air compressor.
- Check water to carbide ratio. It should be maintained at 1:1 ratio such as 1 pound carbide to 1 gallon water.
- Check the purity of acetylene, if being purified.
- Check moisture level at the inlet of the purifier.
Weekly Acetylene Plant Maintenance Checklist
Conducting a weekly inspection and maintenance of the acetylene plant helps it running longer. The following steps will ease this process:
- Lubricate hopper fill cap and lugs.
- Check oil level in both screw feed oilers and add if required.
- Check oil level in both screw feed reservoirs and add if required.
- Check screw feed oil pressure at both reservoirs.
- Drain water from both generator flashback arrestors, then refill them.
- Check generator safety valves for any leaks.
- Check low-level water alarm.
- Fill the medium pressure drier with anhydrous calcium chloride.
- Drain the water from purifier scrubber, and then refill.
- Check the size of cooling tank anodes, and replace them if necessary.
- Check high-pressure filter cartridge and replace if required.
- Check condensate valves for leakage.
- Check manifold pigtails for damage.
- Check manifold and station vales for leakage.
- Check and clean the cylinder sprinkling system.
- Lubricate the acetone pump by oiling it.
- Check the scale for accuracy with weights.
- Check the fire equipment.
Monthly Acetylene Plant Maintenance Checklist
The monthly acetylene plant inspection becomes easier when you follow the steps mentioned below:
- Check the operation of high water level alarm.
- Check the sensitivity of the residue drain valve.
- Check the operation of temperature safety instrument.
- Check hopper vent valves for leakage.
- Add oil to the agitator drive gear, if required.
- Add oil to both screw feed gear reducers, if required.
- Drain the water from acetylene compressor cooling tank, clean, and refill.
- Check the condition of drive belts on acetylene compressor.
- Check all piping for general condition and leaks.
- Check the condition of drive belts on air compressors.
- Drain the air compressor oil and refill.
- Drain the acetylene compressor oil and refill. Change the filter too.
Yearly Acetylene Plant Maintenance Checklist
The below-given are a few points that will help you conduct an effective yearly inspection at your acetylene plant.
- Clean and inspect generator tank interior. Replace any damaged paddles.
- Check agitator shaft and packing for wear. If leaking lime, replace shafts and seals.
- Check water inlet spray system. Clean if necessary.
- Check the control diaphragms. They should be flexible and have no holes.
- Check carbide valve seats. Repair or clean if needed.
- Inspect the hopper and its gaskets.
- Check safety relief valves for leaking and set them.
- Check operation of hydraulic cylinders. Specifically check for leaks.
- Check screw feed drive chains and belts.
- Check generator valves and gauges.
- Clean and oil manifold tubes.
- Have hoist inspected by hoist company (or someone local).
- Lubricate acetylene compressor motor.
- Clean medium pressure drier.
Choosing the right oil for the acetylene plant as well as conducting maintenance in the right way will help you maximize the value of its investment. Rexarc is not only involved in designing and delivering innovative and safety-driven acetylene plants but also known to help its clients utilize the acetylene plant in the right way.