Technical services from the people who build the plants

Acetylene Plant Services — Safety Audits, Maintenance & Upgrades

An acetylene plant is only as safe and profitable as its weakest valve. IIGAS — an ISO 9001:2015 plant builder that operates its own filling stations — audits, maintains, upgrades and re-commissions acetylene and industrial gas plants of any make, anywhere in the world. We have done it for shipyards in Oman, gas producers in Malaysia, and plants across India.

Plant safety & operations audits

Our engineers spend days inside your plant — not hours — benchmarking every system against NFPA 51A, CGA, EIGA and Indian Standards: generator and screw feed, hydraulic back-pressure protection, purification and drying, compressor condition, flashback arrestors, manifold and filling practices, instrumentation, interlocks, carbide and sludge handling, documentation and operator practice.

You receive a written audit report with photographed findings, each rated by risk and paired with a specific corrective action — the same discipline behind a recent proactive audit of a Malaysian acetylene producer that surfaced 34 prioritised findings before any of them could become an incident.

  • ✓Benchmarked to NFPA 51A · CGA · EIGA · IS 8471 and related codes
  • ✓Generator, purification, compression, drying and filling — end to end
  • ✓Decomposition-protection review: arrestors, back-pressure valves, vents, interlocks
  • ✓Photographed, risk-rated findings with specific corrective actions
  • ✓Re-audit and close-out support until every finding is resolved

Annual Maintenance Contracts (AMC)

An IIGAS AMC keeps your plant running to the standards it was built to. We supply the complete preventive-maintenance system — daily, weekly, monthly and yearly checklists, plant log sheets, preventive-maintenance schedules and training records — then our engineers visit on schedule to execute it, with breakdown support between visits.

Because we manufacture generators, compressors, purifiers, dryers and arrestors ourselves, AMC visits arrive with the parts and the judgement to fix things in one trip — not a report recommending another vendor.

  • ✓Scheduled preventive-maintenance visits with documented checklists
  • ✓Compressor and vane-pump overhauls, valve and safety-device servicing
  • ✓Annual flashback-arrestor gas-tightness and gas-return testing
  • ✓Calibration of gauges, transmitters, temperature and pressure controls
  • ✓Breakdown support and genuine spares between scheduled visits

Upgrades & refurbishment — proven in the Gulf

Older plants don’t need replacing — they need engineering. At a shipyard drydock acetylene plant in the Gulf, an IIGAS site audit led to a full modernisation: integration of a hydraulic screw-feed system with non-sparking stainless abortion screws, replacement of marine-corroded compressors with stainless-steel units and pipelines, an ammonia scrubber-cum-cooler-condenser for gas quality compliance, a new high-pressure drier, dry-type flashback arrestors across the manifold, back-pressure and vent valves, and level transmitters on the generator.

We deliver the same scope anywhere: capacity upgrades, screw-feed and automation retrofits, PSA purification retrofits for higher gas purity, DA and oxygen pipeline refurbishment for shipyards and steel plants, and corrosion-driven equipment replacement engineered for the site’s environment.

Critical spares & preventive-maintenance kits

Downtime usually waits for one small part. We assemble plant-specific critical spares kits — screw-feed diaphragms and brass pins, vane pumps and spiders, agitator arms and couplings, water-control and slurry-valve repair kits, flameproof RTDs, solenoid and I/P converters, safety valves for generator and compressor, NRVs, hopper O-rings, calcium chloride and more — tailored to your equipment list, so you never stock parts you won’t use or wait for parts you will.

Training, SOPs & commissioning

  • ✓Operator and supervisor training, on site, with documented training records
  • ✓Safety SOP manuals for manufacturing, handling and storage of oxygen, nitrogen and DA
  • ✓Job-safety analyses (JSA) and risk assessments for plant activities
  • ✓Erection, start-up and commissioning of new and relocated plants
  • ✓Resident supervision engineers for extended operations support

Every engagement is run by engineers who operate acetylene plants daily — members of the BIS committees CHD 6 and MED 16, working to the same codes we help write.

Related products

Frequently asked questions

Yes. We audit, maintain, upgrade and supply spares for acetylene and industrial gas plants of any make — in India and abroad. Share your plant type and equipment list and we will scope the work.
Everything from carbide handling to cylinder filling: generator, screw feed, purification, drying, compression, arrestors, back-pressure protection, instrumentation, interlocks and operating practice — benchmarked to NFPA 51A, CGA, EIGA and Indian Standards, with a risk-rated findings report and corrective actions.
Scheduled preventive-maintenance visits with daily/weekly/monthly/yearly checklist systems, compressor and valve servicing, arrestor testing, instrument calibration, genuine spares and breakdown support between visits. Scope and frequency are tailored to your plant.
Usually, yes — screw-feed and automation retrofits, stainless-steel compressors and pipelines, new purification (including PSA), driers, arrestors and instrumentation can modernise a sound plant at a fraction of replacement cost, as we did for a shipyard drydock acetylene plant in the Gulf.
Yes — on-site operator and supervisor training with documented records, safety SOP manuals, and JSA/risk assessments for plant activities.
Use the Request a Quote form or email marketing@iigas.com with your plant type, capacity, location and equipment list — we will propose the scope, team and schedule.

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