1995-06-15 sIL:43

Safety Information Letter

The Hazard of Adiabatic Compression

Heat from adiabatic compression in oxygen system causes many oxygen fires. Preventive
measures should already start at the oxygen systems design stage by selecting the correct
materials and by using good engineering practice. Acetylene will start decompose when ex-
posed to heat above 300 C which involves special risks that may result in serious accidents.
By correct handling and operation of systems under pressure the risk of ignition caused by
adiabatic compression can be reduced.

In the enclosed document, the physics of adiabatic compression is explained. There are also
different experiments described which would make it easier to make people understand and
follow the instructions.

AGA AB, Lidingo

Safety and Quality

Sune Sandstrom
B. Gerlach 1995-06-15 Encl. SIL:43

Adiabatic Compression

Gaseous Physics

When gas is enclosed in a cylinder or another type of container, any pressure change will
result in a temperature change - i.e. increasing the pressure increases temperature,
decreasing pressure decreases temperature.

A Simple Example - The Bicycle Pump

A simple way to demonstrate compression heat is to pump air into a bicycle tyre. You
have to do some work to compress the air, therefore increasing the internal energy ofthe air
inside the pump. You can feel, by hand, the pump being heated-up.

Compression Heat

However, if the pump was perfectly heat insulated so that you would not feel any increase in
temperature, despite pumping air, then most of the heat remains in the air inside the pump.
In this case, we approach the condition that is known as adiabatic compression.

The word adiabatic originates from the Greek adiabatos, which means not penetrating. If
there is no heat transfer during compression or expansion of a gas, either because of perfect
insulation or because the change in pressure was so rapid that there was simply insufficient
time for any flow of heat, then this process is called adiabatic.

On the other hand when the pressure of a gas is changed (compressed or expanded), but its
temperature is kept constant (e.g. by cooling) this process is said to be isothermal.
A Practical Example - The Diesel Engine

You encounter adiabatic compression in everyday life, a good example of this being the
diesel engine. Diesel engines work as follows: Air is sucked into a cylinder and is
adiabatically compressed to about one sixteenth of its original volume, therefore increasing
both its pressure and temperature. A fine spray of diesel fuel is now injected into this heated
air. Because of the high temperature generated in the air in the cylinder, the fuel is immed-
iately ignited, further increasing both the temperature and pressure. This moves the engine
piston down the cylinder, during which a measured quantity of fuel continues to be injected,
keeping the pressure constant throughout the ignition of the fuel. After the fuel supply is
shut-off, the gas will continue to expand adiabatically to the end of the piston stroke.

The diesel engine is an example of how to make use of adiabatic compression in a

controlled and safe way. However, if an adiabatic compression occurs in an uncontrolled
manner then this presents a number of dangers: Piping systems, valves, vessels, instruments,
etc., which are not designed for such high pressures and high temperatures will represent
a considerable risk!

The Risks
In this technical world we live in, there are many applications which use gases. Some very
common applications are welding and cutting, shielding gases, medical gases or simply
compressed air. Steady development ensures that the field of gas applications is widening,
with the implication that more and more people are handling gases.

When gases are stored in cylinders the gas pressure may be considerable - 200 bar or even
300 bar. Therefore if you open a valve very quickly the connected piping system, instrument
or other appliance will be very rapidly pressurised. This may enter the danger zone of
adiabatic compression! You can create such high temperatures downstream of the valve that
the ignition temperature of many types of materials may be easily reached. These might be
O-rings, seal material, membranes and also even dust, lubricants, metallic powder from
wear and tear, which can ignite and start a combustion.

It is dangerous to hurry

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Oxygen
Oxygen is a gas which in the conditions described above will add greatly to the risk. By
itself oxygen does not bum, but it will increase combustion of other materials tremendously.
Even metal will burn violently. Such combustion is often accompanied by personal injury,
because the person opening the valve would be standing close by.

Preventive Measures
To avoid the risks of adiabatic compression the following preventive measures can be taken:

l Correct technique
0 Correct choice of material
0 Correct handling
0 Correct information / training

Correct Technique

Beginning at the design and development stage, steps should be taken to avoid the risks of
too rapid pressurisation from occurring.

Correct Choice of Material

All components in a system should be selected so that they can withstand the temperatures
and pressures which are expected to occur, even during exceptional circumstances. Oxygen
systems should especially be treated according to safety recommendations. This also extends
to maintenance and repair!

Correct Handling and Correct Information and Training

Every person who handles gases or use gases should be aware of the risks involved and
know how important it is to handle gases in a correct and cautious way.

When opening valves, this must always be done in a cautious manner. Gas pressure must
only be allowed to build-up gradually. Ball valves represent a hidden danger, as their
simple design may tempt operators to open the valve too quickly by flipping over the handle.

Never, never . . . . . . . . . do it that way ! lr

Acetylene

Acetylene gas requires special attention, due to its particular properties: At only even
slightly elevated temperatures, around 300 C (542 F), a violent reaction may be initiated,
known as a decomposition of the gas. Therefore, when using acetylene welding gear, it
must be especially remembered to open the acetylene valve very softly.

Acetylene - Be cautious: Handle it the soft way

Calculating Temperatures

If a gas is compressed so that its volume is reduced to half its original volume, its pressure
will be doubled. This is according to Boyles law and assumes that during the compression
the temperature of the gas remains constant, i.e. there was perfect heat transfer to ambient
matter.

If the gas is again compressed to half its original volume but this was done adiabatically,
then the resulting pressure will be more than double the original pressure. This is because
the increased temperature of the gas will further increase the pressure. By applying
Poissons law we can calculate this final temperature (TJ, when starting from a temperature
T,, at a pressure Pi, assuming a final pressure P,.

P q/c- 1
T,=T, [$I' f=
1 CL&
Where:

T= Absolute temperature (Kelvin)

P= Absolute pressure (atmospheric pressure = 1)
c, = Heat capacity at constant pressure
c, = Heat capacity at constant volume

f= 0.286 for gaseous oxygen.

Using the above equation we can easily calculate the final temperature in the example of
adiabatic compression shown below:

At start: 20C and

atmospheric pressure

Resulting temperature at the end of the tube (pipe) when the gas in
the tube is so rapidly compressed that any heat loss does not occur
and the pressure rapidly rises to 200 bar = approx. 1 OOOT!!

A Simple Example of Adiabatic Compression

0 Rapidly pressurising a section of a gas supply piping system will lead to

extremely high temperatures. Ball valves, in particular, may contribute to the
onset of high gas pressures. As stated earlier, the consequences could become
very serious if pure oxygen gas is present. Using the equation above it can be
seen that a temperature in the range of 1000 C (1832F) may easily occur.

The examples on the following pages illustrate the consequences of adiabatic compression,
from various causes.

Example 1 Adiabatic Compression Involving Unsuitable Materials

(see photograph 1)

This is an experiment of a special kind, which shows the result of adiabatic compression
occurring under poor conditions - i.e. where unsuitable materials have been used,
unfortunately an not unlikely combination of careless or ignorant actions. This is
especially the case when oxygen may be involved, where the use of oxygen compatible
materials is mandatory.

A tube, which is connected to the valve outlet of a cylinder containing oxygen gas at 200
bar, is purged with oxygen then closed gas tight at its outer end by a sealing disc and a steel
plate. Initially the oxygen in the tube is at atmospheric pressure. Both the disc and plate are
held in place by a cap nut with a large opening. The sealing disc is made of ordinary engine
gasket material, while the steel plate is made of normal mild steel. The steel plate has a
small hole (+ 1 mm) drilled through its centre to simulate a leak in the piping system and
to act as an ignition starter.
 (gasket) Mild steel disk,
/ \
4mm
\

mm leak
hole

A Demonstration of the Violent Consequences of Adiabatic Compression

Consequence - Violent Reaction

When the valve is opened, there will be a violent reaction. Oxygen escapes from the
cylinder into the tube, where the pressure rises from atmospheric to 200 bar. The resulting
temperature rise is so high that the gasket burns through and oxygen is then forced through
the small leak hole (setting the bum away direction) in the steel plate. The steel plate
immediately ignites and during a fraction of a second the steel plate and part of the brass nut
bum away.

Photograph 1 clearly shows the burning metal forcefully leaving the end of the tube, the
molten metal flying a long way. All this was started by a simple adiabatic compression.

Personal Injury

In this example there is no doubt how seriously a person could get hurt if they were standing
in the path of the jet.

Therefore always open valves carefully and slowly and even then stand away and behind the
outlets of valves. Keep your head away from cylinder regulators and other equipment when
the gas pressure is being turned on.

6
Example 2 Ageing Equipment (See photographs 2 & 3)

Photograph 2 shows a pressure regulator, an old-timer, which has been exposed to a

temperature shock and a burn-out.

This is an important reminder of another important item:

0 Even if material and equipment from the start have been approved as OK and are
also oxygen compatible, the effect of ageing must still be considered. Each time the
equipment is subjected to extreme temperature the materials resistance will be
weakened. In addition, over long periods of use, traces of dust or other impurities or
even also worn-off metal powder may accumulate and subsequently facilitate
ignition.

Photograph 3 shows an example of such an accumulation. This is what can happen when
small particles collect and accumulate inside the Teflon lining of a high pressure hose.

The tubing shown in the photograph was used to connect gas cylinders to a manifold in a gas
supply station of a large workshop. For many years and after many cylinder changes all had
worked well.

However when, after a new oxygen cylinder had just been connected, the operator handling
the gas supply opened the cylinder valve he saw to his horror that the tubing became red hot.
In less than a second the hose burst and the brass armature started burning. Fortunately he
had the presence of mind to be able to safety shut-off the gas supply, preventing any further
damage to the equipment.

This example demonstrates the importance of good preventive measures, to avoid such risks,
including regular inspections and maintenance. Worn and old components must be
exchanged for new items. Equipment may have to dismantled at scheduled intervals for
checking, cleaning, repair and testing for safe function.
Example 3 A Simple Method of Demonstrating Temperature Increase by
Adiabatic Compression (See photograph 4)

It is not necessary to stage difficult experiments involving molten metal to demonstrate the
effects of adiabatic compression. A good and lasting impression can be gained by showing
how oil can be ignited merely by manually compressing air.

Photograph 4 shows an instruction kit) for this demonstration, which can be conveniently
used indoors for gas handling training or safety lectures.

Start : 20C (293K)

and atmospheric pressure

Compression to approx. 50 bar

Resulting adiabatic temperature:

approx. 600C

The Operating Principle of the Adiabatic Compression Instruction Kit

1) Further details and ordering information for the Adiabatic Compression Kits can be
obtained from:

GERLACH & SON

BJGRKEBYGGET
S - 260 70 IJUNGBYHED

Tel.: +46 (0)435 - 77 03 92

Fax.: t 4 6 (0)435 - 77 00 63