10 SafetyProcedures inAcetyleneManufacturingPlants

- R E X A R C I N T E R N A T I O N A LW W W . R E X A R C . C O M

IntroductionIncorporation of methods ensuring safety of employees and equipment isextremely important in any plant. This becomes even more importantwhen dealing with acetylene manufacturing plants due to the presence ofvolatile gases. Two main reasons for employing safety procedures are: # To ensure physical safety of all plant employees as well aspeople located around the plant.

# To protect the plant and its physical components likemachinery, raw materials, etc.

The job of ensuring overall safety of the plant by looking into the tiniestdetails is the responsibility of acetylene plant owners. Extra precautionshave to be taken to ensure safety with equipment handling criticalprocedures.

Safety Procedure #1: QUALITYPRODUCTS

i. The easiest way to ensure safety is to use quality products.Collaborating with an acetylene plant manufacturer of positive reputationwill allow you to rely on your product.

ii. Choose an acetylene plant manufacturer who: # Uses exceptional raw materials # Employs best practices in terms of manufacturing and componentselection # Ensures that the overall construction of the product is robust # Has rigorous quality and testing procedures in placeiii. Collaborating with industry experts will ensure use of technologies andprocesses that are well-known and dependable. The products developedby them have been able to stand the test of time ensuring increasedreliability.

Safety Procedure #2: COMPATIBLEPRODUCTS

i. Product compatibility is of immense importance. Only the machinerythat has been designed to handle acetylene should be used. This is aprecautionary step that will keep acetylene from reacting with parts of themachine. Using the right machinery, components, and raw materials willensure a safer working environment.

Safety Procedure #3: MAINTENANCE

i. Regular maintenance of all equipment is mandatory for safe operationon a day-to-day basis.

ii. The best maintenance practices dictate that an organization shouldconduct regular maintenance procedures.

iii. Consider incorporating proactive as well as reactive maintenanceprocesses.

Safety Procedure #4: HEAT

i. The overall temperature of the generator should never cross 175 ºF.Cooling systems can be used to ensure safe operating temperatures.

ii. To mitigate risk, cylinder storage areas should be placed far enoughfrom the plant to be unaffected by an explosion, excess heat, leak, or fireresulting in the acetylene manufacturing plant.

iii. Follow manufacturer guidelines in terms of optimum operating andenvironment temperatures.

Safety Procedure #5: SET-UPCONSIDERATIONS

i. Acetylene plant explosions have caused major destruction to life andproperty. Hence, most acetylene plant owners will/ should set up theiroperations far from developed areas.

ii. This precautionary step could help in saving lives in the event of adisaster. It is important to take this into consideration irrespective of thenumber of safety procedures and systems employed in an acetyleneplant.

Safety Procedure #6: SAFETYEQUIPMENT

i. Safety equipment and gear should be made available to all employees.

ii. Safety and regulatory equipment should be installed throughout theacetylene plant operations. Several safety products related to acetyleneproduction are available in the market.

iii. For example, in acetylene plants, there is a high chance of an explosionor fire being caused by a spark resulting from a flashback. This can beavoided by installing a flashback arrester.

iv. Pressure relief devices are also good examples of safety equipment used in acetylene plants to prevent an explosion. These devices helpreduce pressure build-up.

Safety Procedure #7: SAFETYMETHODS

i. The NFPA, EIGA, JIGA, and other global standards have outlined severalsystems to help prevent fire as well as procedures to be followed in caseof a fire.

ii. Acetylene production plants should stock the equipment needed tofight fire in plain view of all employees.

iii. Systems should be in place to alert employees of a fire as well as guidethem to a safe location.

iv. For example, fire alarms, sprinklers, fire extinguishers, etc. should beinstalled at convenient locations throughout the plant. Emergency exitsshould be marked clearly.

Safety Procedure #8: TRAINING i. Regular training sessions should be conducted on safe use ofoperational systems.

ii. Employees should also be educated about the best practices toadhere to during regular operations as well as in emergency situations.

iii. Dealing with emergency situations like evacuation protocol,firefighting methods, usage of firefighting equipment, etc. is extremelyimportant for employees working in acetylene plants.

Safety Procedure #9: SAFETY WITHACETYLENE CYLINDERS

i. Acetylene cylinders should always be handled with extreme care andcaution.

ii. Any damage to the outer body of the cylinder could result in potentiallylife threatening situations. Even the components of the cylinder like thefuse plug should be intact at all times.

iii. If an acetylene cylinder is dropped or gets dented, it could result inleaking. Since acetylene gas is extremely flammable, it is importantto separate and store the cylinders in a safe location that is away from theplant operations immediately.

Safety Procedure #9: SAFETY WITHACETYLENE CYLINDERS

iv. Empty acetylene cylinders could contain some residual acetylene inthem. Hence, the above-mentioned precautions should be followed evenwhen transporting or storing empty acetylene cylinders.

Safety Procedure #10:TRANSPORTING ACETYLENE

CYLINDERS i. When transporting acetylene cylinders, ensure that they remain inthe upright position at all times.

ii. This will keep the possibility of the gas leaking out to a minimum.

iii. Acetylene cylinders should never be stored in damp conditions.

Summary

Setting up and running an acetylene plant is a complex and detailoriented process. It is best practice to seek out experts in the field ofacetylene equipment supply, safety, and operations.

Some organizations that can provide guidelines include OSHA, ISO, NFPA,EIGA, etc., but there is no substitute for having qualified personnelcomplete field training. Implementing and enforcing safety procedureswill not only help the plant run properly, it will also provide assurance tocustomers and investors.

Contact Us

Rexarc International, Inc.

35 East Third StreetWest Alexandria, OH 45381

www.rexarc.com

Phone: 1-937-839-4604Fax: 1-937-839-5897Email:info@rexarc.com