Acetylene Cylinder Fire

Safety Lesson Learned: Acetylene Cylinder Fire
Location of Incident: Kuantan, Pahang

Brief Account of Incident
A contractor was performing gas cutting of handrail modification work on the platform above a sacrificial heater. A flashback occurred of the acetylene supply, back to the cylinder. The firewatcher under the working area noticed the acetylene cylinder had caught a fire. He put out the fire by extinguisher at once with the help of one operator on site. After the fire was extinguished, they found the drain plug of the cylinder was leaking, so they took it to a safe place to let it vent to atmosphere.
An investigation team was organized at once. Later analysis found the probably cause was the acetylene hose at the connection with the flammable arrester was cracked. Simultaneously the drain plug was leaking, which was ignited by flashback.

Potential Outcome
- Cylinder gas explosion
- injury and/or fatality

What Went Well
- The flashback arrester was used and the cylinder explosion was avoided.
- The extinguiser was well prepared and both firewatcher and operator reacted rapidly to deal with the emergency situation

What Went wrong
- The worker did not check gas cylinder for leakage prior to the work commencement.
- The gas hose was aging and has no securing clip.

Immediate Causes
- Following Procedure: The worker didn’t check the tools and equipment properly.
- Use of Tools or Equipment: The hose connection was cracked and without securing clip.
- Inattention/Lack of Awareness: The workers were unaware of leakage and flashback.
- Tools, Equipment and Vehicle: The cylinder had a drain plug leakage and the hose was defective