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Acetylene
Pure acetylene is a unique gas with hazards that arise from its high energy bonds and flammability. These same prop-
erties give acetylene its value as a high temperature cutting and welding gas with a very wide range of applications.
However, free acetylene can undergo explosive decomposition when compressed or overheated. Decomposition is a
spontaneous reaction forming hydrogen and carbon (in the form of lampblack or soot). A considerable amount of
heat and pressure is generated by this dissociation, which can produce high energy explosions.
Acetylene is normally dissolved in a solvent, typically acetone, at pressures up to 19 barg (275 psig) at 20C (68F). The
dissolved acetylene is packaged in specially designed cylinders filled with a porous material to prevent voids where
gaseous acetylene could collect. The combination of these two features, solvent and porous filler material, allows acetylene
to be contained in cylinders at moderate pressure without danger of decomposition. To prevent decomposition during use,
acetylene gas system pressures must not exceed 1.5 barg (22 psig).
Uses
Acetylene is principally used for oxyacetylene cutting, heat treating, and weld-
ing. Bulk acetylene can be also used as a raw material in the chemicals process-
ing industry for the production of organic compounds, including acetaldehyde,
acetic acid and acetic anhydride.
Health effects
Studies have shown there to be no harmful effects from exposure to acetylene.
While acetylene is classified as non-toxic, it is an asphyxiant gas with slight
anaesthetic properties. The amount of acetylene gas necessary to dilute the
concentration of oxygen in air below levels necessary to support life, is well
above the lower flammable limit, making fire and explosion the primary
hazards associated with acetylene and air atmospheres.
Examples of fusible plugs:
2
This wide flammable range means that Figure 1: Cutaway photo of an Acetylene is normally packaged as a
almost any leak of acetylene will result acetylene cylinder dissolved gas in cylinders ranging in
in a flammable gas mixture. Acetylene size from 3 to 60 litres internal volume
also has a very low ignition energy, (water capacity). Common acetylene
so even low energy sparks such as cylinders are different from all other
static electricity can cause ignition and cylinders in that they contain a porous
explosion. Acetylene must only be used filler material and a solvent (acetone
and stored in well ventilated areas. or dimethylformamide, DMF). By using
Fires which have been extinguished the porous material and solvent, it is
without stopping the flow of gas can possible for a cylinder to contain much
easily reignite with explosive force. more acetylene than could safely be
compressed into the same cylinder
Pure acetylene is odourless, but com- without solvent. The filling parameters
mercial grade acetylene from some of a cylinder or a bundle of cylinders
manufacturing sources can have a dis- depend on the porous material and
tinctively garlic-like smell from impuri- volume and are specified by the cylin-
ties typically present. Odour should not der manufacturer.
be relied on to detect the presence of
acetylene.
Acetylene cylinder shells are made
from welded steel, seamless steel
Materials selection for or sometimes seamless aluminium.
acetylene piping systems Acetylene cylinders may be subjected
Steel and wrought iron are recom- to wear and tear. Prior to every refilling,
mended for use in acetylene piping. the cylinder and valve are inspected
Rolled, forged, or cast steel or mallea- for general integrity (freedom from
ble iron fittings may be used. Cast iron shell defects such as dents, torch burns
is not acceptable for fittings. or corrosion) and to confirm that the
valve is operating properly and that the
Certain materials must be avoided as outlet connection is undamaged and
explosive acetylides can be formed functional. Cylinders are also subject
in acetylene service. Acetylides are to periodic requalification inspections
highly sensitive to shock or friction. by authorized facilities in accordance
Materials that should not be used in with Transport regulations.
direct contact with acetylene include
unalloyed copper, silver, or mercury.
Alloys containing more than 65%
copper or more than 43% silver should
not be used. Aluminium-bronze al-
loys and 7030 (red) brass produce
acetylides with wet acetylene and
must never be used.
3
Figure 2
Valves/outlet connections
Acetylene cylinders are normally
fitted with brass valves that may be
either hand wheel or key operated
depending on local norms. (Since
ammonia attacks brass material, com-
mon soap solutions such as washing
liquid should not be used for leak
checking of acetylene cylinder valves).
Acetylene valves commonly use non-
adjustable o-rings or packing to pre-
vent leakage through the top works.
Some cylinders may be equipped with
residual pressure valves with non-
return function (NR/RPV) or with an Ancillary equipment
integrated valve-pressure regulator Any equipment (torch, hoses, regu- Use appropriate regulators and
device. Acetylene cylinder valves have lator, flashback arrestors, etc.) used pressure relief devices when con-
various outlet configurations in accor- should be designed and constructed necting cylinders to equipment
dance with national/regional stan- to recognized standards for use with having lower service pressure
dards. For specifications, type testing acetylene. Equipment designed for use ratings.
and marking of acetylene cylinder with other flammable gases must not
valves see EN ISO 10297. For test and be used with acetylene. Monitor for leaks when first pres-
inspection requirements of valves see surizing equipment (at regulator,
EN ISO 14246. Keep equipment (torch, hoses, torch, hose and cylinder connec-
regulator, flashback arrestors, etc.) tions). Leaks in a confined area can
in good working condition and free cause acetylene to collect and read-
from oil or grease. ily attain concentrations above the
lower flammability limit of 2.4%
For cutting and welding appli- acetylene in the air.
cations, it is essential to install
flashback arrestors and check (non-
return) valves and ensure that are
in good working condition. Figure
2 is an example of the damage to
a regulator from flashback, if no
flashback arrestor was used.
4
Figure 3
Because small leaks can create explo- 4 Separate flammable gas cylinders from oxygen and other oxidizing gas
sive atmospheres, acetylene cylinders cylinders during storage.
must not be transported in an unven- 4 Separate full acetylene cylinders from empty cylinders.
tilated compartment within a vehicle.
4 When in storage or being moved, keep cylinder valves closed.
Do not store cylinder(s) inside any
vehicle. Figure 3 shows an explosion 4 When valve caps/guards are provided, they must be kept on the cylinders
that resulted from a leak of acetylene when being moved and in storage.
stored in a vehicle.
4 If a cylinder protective cap is difficult to remove (immediately before cylin-
der use), do not apply excessive force or pry the cap loose with a bar inserted
into the ventilation openings. Attach a label or tag to the cylinder identify-
ing the problem and return the cylinder to the supplier.
(continued on page 6)
5
Safety considerations
(continued from page 5)
4 Use the correct flow rate for the acetylene application. To minimize the
withdrawal of liquid solvent, acetylene should be withdrawn from the cyl-
inder at a rate not to exceed 1/10 (one-tenth) of the capacity of the cylinder
per hour during intermittent use. For full withdrawal of the contents of the
cylinder on a continuous basis, the flow rate should be no more than 1/15
(one-fifteenth) of the capacity of the cylinder per hour. Too high a flow rate
causes solvent carry-over, flame disturbance and reduces the effectiveness
of flashback prevention devices. Alternately, flashback may occur when the
acetylene flow rate is lower than equipment needs.
4 Always close the cylinder valve and bleed the pressure off the regulator and
torch equipment at the end of the shift or work day. Even though the pres-
sure gauge reads zero the acetone will still contain a quantity of dissolved
acetylene; therefore, an empty cylinder still represents a potential hazard
in a fire.
4 Wrenches should not be used on valves equipped with a hand wheel. If the
valve is faulty, attach a label or tag to the cylinder identifying the problem
and arrange timely return to the supplier.
4 Remove leaking acetylene cylinders to an open area and tag them indicating
the danger. Notify the supplier and local authorities as needed.
6
Personal protective Suspected or actual Rescue considerations
equipment acetylene leaks in the event of acetylene
Safety glasses, safety shoes, and ordi- Because acetylene and air mixtures leak
nary work gloves are recommended in almost all proportions are flam- The amount of acetylene gas neces-
for cylinder handling. For cutting mable, care should always be taken to sary to dilute the concentration of
and welding operations use: welders prevent acetylene leakage. oxygen in air, below levels neces-
gloves, welders helmet and goggles, sary to support life, is well above the
If a leak is suspected, do not operate
leather sleeves, a leather apron and minimum flammable concentration,
lights or other electrical equipment
other standard protective equipment making fire and explosion the prima-
as these could be a source of ignition.
in accordance with the appropriate ry hazards associated with acetylene
Close the cylinder valve. Brush or
task risk assessment. and air atmospheres. Only trained and
spray the suspected leakage area with
an appropriate leak detection solu- competent rescue teams should con-
tion. Bubbles of escaping acetylene template entering a potential acety-
through the film will indicate a leak. If lene atmosphere. These actions would
the leak has stopped, take the cylinder normally be undertaken only by
out of service, identify the cylinder, external emergency services. Rescuers
inform the supplier and arrange for must always assure their own safety
the cylinder to be collected. before entering an unknown atmo-
sphere. Adequate assessment of the
If the cylinder is still leaking, ventilate fire risk must be made for rescue situ-
the room by opening doors and win- ations. As a minimum, self-contained
dows. Avoid ignition sources such as breathing apparatus and fire-retar-
electrically operated fans. If possible dant personal equipment should be
and safe to do so, move the cylinder worn.
to a safe area outside and away from
ignition and heat sources and public
access. Evacuate the area within the First Aid after exposure
vicinity of the cylinder. Contact the Persons who have become incapaci-
cylinder supplier and emergency tated or comatose through oxygen
services as needed. deprivation or from the anaesthetic
action of acetylene should be moved
promptly to fresh air and medical as-
sistance sought. Consult the latest ver-
sion of Air Products safety datasheet
from: www.airproducts.com/MSDS
7
Operational procedures for acetylene cylinders
at and after fire/heat exposure
Any gas cylinder that is exposed to In the event of any cylinder fire, the UK HAZMAT guidance
fire or extreme heat may rupture due area should be evacuated as quickly The UK Fire & Rescue Services (FRS)
to an increase of temperature and as possible. If acetylene is involved in have published protocols including
pressure. If acetylene cylinders are the fire, caution should be taken in ex- the following decision trees to assist
exposed to fire or extreme heat, the tinguishing the fire until the source of emergency services in managing such
following actions are recommended: gas can be stopped. It is important to incidents. Excerpts are shown on the
prevent acetylene gas from collecting following pages:
Warn personnel and evacuate in a confined area, because the leaking
the area. For heated cylinders, a gas may reignite and/or explode. Reproduced from United Kingdom
suitably sized hazard zone of up to Fire and rescue Operational guid-
200 meters should be established, Water cooling is the most effective ance Incidents involving hazardous
based on a number of criteria, such method of preventing failure of any materials
as the size and number of cylinders cylinder and should be used when-
involved and shielding available ever it can be implemented without https://www.gov.uk/government/
compromising the safety of emer- publications/hazardous-materials-op-
Prevent access to the area. gency personnel. After the fire has erational-guidance-for-the-fire-and-
been extinguished, do not move the rescue-service
Call the emergency services and
the gas supplier. cylinder, continue cooling with water
See Section C5. pages 295-349
and ensure that experienced and
If safe to do so, immediately start competent personnel are in charge of Open licence government document
the cooling of heated cylinders by the emergency in order to apply the per: http://www.nationalarchives.gov.
deluging them with water from a recommended protocols. uk/doc/open-government-licence/
safe place (behind heavy machin- version/2/
ery or a solid wall) without ap-
proaching the cylinders.
8
Suspected acetylene cylinder exposed to heat
Does the cylinder show signs of heat damage, Are the cylinder labels burnt?
flash-back or direct flame contact? Has the plastic test ring melted?
Is the paint on the cylinder body scorched?
NO Is there any visible bulge in the cylinder?
Are pressure relief devices operating?
Allow to cool, hand YES Does the cylinder surface steam or dry out
over to responsible quickly when water is applied?
person/owner. Is there any other sign of heat?
Eyewitness testimony?
NO Interrupt cooling
Does the cylinder surface dry out rapidly? YES Re-apply cooling water for 1 hour
NO
Monitoring Phase Stop water cooling, do not move the cylinder, maintain an appropriate Hazard Zone,
re-apply the Wetting Test and/or thermal image equipment tests at 15 minute intervals for 1 hour.
If re-heating is observed water cool continuously for 1 hour then start the Monitoring Phase
No further action by Fire and Rescue Service (FRS), hand over to owner or responsible person/owner.
9
Operational key principle:
Single acetylene cylinders involved MONITORING PHASE When ef- Note: A cylinder which is leaking
in fire fective cooling of the cylinder shell significantly should not be moved
has been achieved, water cooling and should be allowed to vent safely.
Acetylene cylinders that have been
should be stopped. The cylinder The FRS (Fire and Rescue Service)
significantly heated or damaged by
should still not be moved for at should assess any fire or explosion
fire must not be moved.
least 1 hour and an appropriate, risk risks caused by the escaping gas and
They should be cooled as soon as assessed Hazard Zone should be continue cylinder shell temperature
possible with water spray and a maintained. This monitoring phase monitoring.
Hazard Zone designated around is required due to the possibility of
internal decomposition occurring Multiple cylinders (or substantially
them (Up to 200m for cylinders in
Note: Leaking acetylene cylinders concealed single cylinders)
the open with no shielding). Where
cylinders are heavily involved in have a higher risk of decomposition Where cylinders are very closely
fire an Exclusion Zone should also occurring. packed, and/or concealed/buried by
be considered to keep the public debris, there may be a risk that the
During the monitoring phase,
away. cooling water may not come into
temperature checks of the cylin-
der shell should be made every 15 contact with a substantial propor-
COOLING PHASE Water cooling
minutes. If any increase in temper- tion of the cylinder shell, therefore
should be continued for at least 1
ature is observed, a further 1 hour limiting the effect of cooling. If the IC
hour. Ground monitors and lashed
continuous water cooling should (Incident Commander) considers that
jets should be used; any fire-fight-
be applied to the cylinder before its significant areas of the cylinder are
ers carrying out essential tasks
temperature is re-checked. dry then the cooling phase should
within the Hazard Zone must have
be extended (e.g. if 50% of a cylinder
appropriate PPE and make full use
When the cylinder remains ef- is not being touched by cooling water
of all available substantial cover/
fectively cooled for the whole of (i.e. dry metal) then consider increas-
shielding.
the monitoring phase (i.e. the shell ing the cooling phase to 3 hours).
After a minimum of 1 hour of water temperature remains at ambient
cooling the cylinders tempera- temperature for 1 hour without
ture should be checked to see if being water cooled), and is not
it has been effectively cooled. leaking, there is no risk of cylinder
Note: effective cooling means failure and it should be handed
bringing the cylinder shell tem- over to the responsible person or
perature down to ambient tem- agency on-site.
perature. The Wetting test and/
or thermal imaging equipment
should be used to do this.
10
A flame from an acetylene cylinder Additional resources
whose valve cannot be closed shall
Acetylene safety data sheet (www.airproducts.com/MSDS)
normally be left to burn while cooling
the cylinder with water. If the flame European Industrial Gas Association (EIGA) publications
is extinguished and the acetylene (www.eiga.eu/index.php?id=156)
continues to escape, it can cause a
flammable gas accumulation. The Safety Leaflet SL 04, the safe transport, use and storage of Acetylene
flame should only be extinguished if; cylinders.
it is safe to do so and no additional EIGA document IGC Doc 123, Code of practice Acetylene.
risks are incurred in approaching EIGA Safety Information Info 05 Flashback and flame arrestors.
the cylinder. In such a case, apply the (currently under revision)
relevant recommendations above and
EIGA Safety Information Info 02, Handling of Gas Cylinders at and after Fire/
ventilate abundantly and naturally.
Heat Exposure.
EIGA PP18 Transfilling of Industrial Gas Cylinders
NFPA 51, Standard for the Design and Installation of Oxygen-Fuel Gas Systems
for Welding, Cutting and Allied Process. (www.nfpa.org)
NFPA 51B, Standard for Fire Prevention During Welding, Cutting, and other
Hot Work.
(www.nfpa.org)
11
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