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Safe use and maintenance of acetylene compressors

Safe use and maintenance of acetylene compressors Acetylene compressors are mainly used in petrochemical enterprises and metal cutting processes. They are currently one of the main production equipment for the production of dissolved acetylene stations using calcium carbide as raw materials. Since the acetylene compressor is a kind of equipment that is dangerous from fire and explosion, if it is improperly protected and the use and maintenance are not good, various accidents will occur, and even an explosion will occur. On the basis of extensive collection and collation of data on acetylene accidents, this paper carefully digested relevant safety regulations and operating procedures, analyzed the safe use and maintenance of acetylene compressors, and proposed corresponding problems for some common problems. The solution measures provide some reference for the users of acetylene compressors (hereinafter referred to as compressors) to eliminate hidden dangers and ensure safe production.

 I. Countermeasures against the prevention of compressor design

 (1) Applying frequency conversion technology to prevent safety hazards caused by changes in filling speed

 It is well known that when the cylinder block is full, it is desirable to reduce the gas production of the compressor for safety. Because the pressure of acetylene gas is gradually increased, the speed is reduced, but the intake speed of the compressor is not changed. The increase of the intake and exhaust volume ratio causes the exhaust temperature to rise. When the filling reaches the later stage. Due to the increase in pressure, high-temperature acetylene gas is easily decomposed and emits a large amount of heat. This vicious cycle is highly prone to explosion and has potential safety hazards.

 We apply multi-speed function technology of PLC programmable controller and high-performance inverter, set automatic deceleration interface and explosion-proof speed selection switch, etc., not only reduce the motor speed at the end of filling, but also reduce the gas production of the compressor. To meet the process requirements of filling bottles, the safety is greatly improved, and the power consumption can be reduced and the power consumption cost can be reduced at low speed operation.

 (2) Control the compression ratio to achieve control of the exhaust gas temperature is less than or equal to 90 ° C

 The cooling system of the acetylene compressor must ensure that the temperature causing the decomposition of acetylene does not occur under normal working conditions. For the acetylene compressor using lubricating oil, the maximum compression temperature of the cylinder gas must not exceed 140 °C.

 (3) Set an efficient cooling system to reduce exhaust temperature

 The pressure of the acetylene compressor cooling water (liquid) should be lower than the pressure of the acetylene gas in the chilling unit. The cooler should be equipped with an open tank and a blow-off device. Cooling methods include water cooling, air cooling, and mixed cooling.

 (4) The average speed of the control piston is less than or equal to 1 m/s

 Due to the continuity of acetylene production, the compressor is required to have high reliability. The gas valve is a key component in the compressor that is easily damaged. The length of the valve life is seriously affected by the reliability of the machine operation and the maintenance workload. If the engine speed is low, the impact fatigue and wear can be effectively reduced because Controlling the compressor speed can increase the life of the valve.

 (5) Special requirements for explosion protection and protection systems to improve reliability

 1 The material selected for the main parts of the compressor should be fully considered for its characteristics, such as corrosion, aging, wear, friction, material uniformity, etc., must withstand the expected mechanical, chemical and thermal loads; when they are in contact with acetylene gas There will be no danger.

 2 Use intrinsically safe technology, processes and power sources.

 3 Lubrication system is a component part of lubrication station and oil filter, sub-cylinder lubrication system and transmission lubrication system.

 4 Safety valves shall be provided on all exhaust pipes of all levels.

 Second, hidden dangers in compressor operation

 (1) Compressor equipment with good operation and safety performance is one of the material guarantees for the safety of acetylene production. The normal use and maintenance of compressors is the key to ensuring safe production.

 (2) There should be good natural ventilation conditions in the compressor room, and a signal indicating the storage capacity of the gas cabinet and the device interlocked with the compressor should be provided.

 (3) It must be installed in an open natural air environment, and at the same time pay attention to the separation of the foundation from the foundation of the machine room wall and other equipment.

 (4) The suction pressure of the compressor during operation shall comply with the process requirements.

 (5) Before operation, check whether the safety valve, pressure gauge and various protection pressure limiting devices are installed in place and in good condition.

 (6) Before starting, it is necessary to check the car to prevent serious accidents caused by running the tank.

 (7) Touching various parts during operation to detect the temperature change and vibration of the compressor.

 (8) Look at each indicator instrument.

 (9) Listen to the sound of the machine operation, such as the sound of the valve, piston, crosshead, crankshaft and bearings.

 (10) Timely discharge the waste liquid in the gas-liquid separator.

 (11) When the compressor is running, pay attention to the gas storage capacity of the gas storage cabinet, which shall not be less than the minimum value specified by the process. If it is lower than the specified value, it shall stop immediately.

 (12) The compressor shall not be started or stopped with load except in emergency situations.

 (13) Diligently check whether the working condition of the whole machine and equipment is normal, and find the problem and deal with it in time.

 (14) Compressors connected to the production system shall not be tested with gases other than acetylene or inert gas.

 (15) Regularly check the safety device of the compressor to keep it intact, and keep a record of the operating conditions of the compressor on time.

 (16) When the room temperature is lower than 5 °C in winter, the cooling water must be vented after the compressor is stopped to prevent freezing and freezing.

 Third, the prevention of compressor maintenance

 (1) The compressor station must be well ventilated.

 (2) Fireworks are strictly prohibited in the production area, and the hot fire system is strictly implemented.

 (3) It is forbidden to use copper-containing tools. The amount of copper in the instrument in contact with the instrument should not exceed 70%.

 (4) When the unit is running, do not loosen or remove any parts (covers, joints, fasteners, piping accessories, etc.), otherwise serious personal injury may occur, only to ensure that the compressor unit power supply has been cut off, the entire compressor system The compressor can be disassembled and maintained in the event that the compressed gas inside has been emptied.

 (5) Compressor pressure parts such as: cylinder block, cylinder head, valve cover, cooler, gas pipe parts, etc., must be cleaned regularly due to gas, water erosion and corrosion, and hydrostatic test shall be carried out according to the regulations.

 (6) All the friction parts of the movement (including the accessories) must be regularly refueled.

 (7) Seriously do a good job in the safety and sanitation of the machine room, keep the compressor and the ground clean, do a good job in the handover work; diligently check, diligently investigate, timely handle the fault and record it in the operation diary.

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