PSI Fill Station Operator (FSO)

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PSI Fill Station Operator (FSO)

• General info. on compressors
• Types of Fill stations
• Why to fill cylinders in a dry environment
• Fill station operator responsibilities
• Pre-fill check
• Attaching cylinders
• Filling cylinders
• MLML compressor

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General Info. on Compressors

• Compressors should have ample space away from
  walls and all moving parts should have a guard
  on them
• Air intake should be obstruction free
• High pressure piping should be anchored at least
  every 2 ft.
• Moisture separators should be visually inspected
  and retested based on manufactures guidelines

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Types of Fill Stations

• Full containment - cylinders sealed in ¼ steel
  explosion proof container for filling
• Partial containment - placed in ¼ steel cabinet
  rupture cylinder contents vented out steel tube
  to the rear
• Total diversion MLML? ruptured contents
  diverted up
• Open stations MLML portable compressor

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CYLINDERS SHOULD ALWAYS BE FILLED IN A DRY
ENVIRONMENT!!!

• Wet environments do not control or dissipate
  explosive forces!!
• Wet fills do not effectively cool down the fill
• Wet fill stations do not provide fresh water
  rinse as water bath becomes contaimanated with
  sea water over time
• Wet fills make it easier to introduce water into
  the fill process causing corrosion in cylinder

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Fill Station Operator (FSO) responsibilities

• Upkeep of fill station/compressor
• Safety of all cylinders to be filled (owner is
  also responsible for cylinder safety)
• FSO must screen all cylinders prior to filling
  and look for
• Government approval (ICC,DOT, CTC, TC, etc.)
• Material composition (3A, 3AA, 3AL, etc.)
• Service/Working pressure
• Serial
• Manufacture
• Hydrostatic Test or Retest information
• Evidence of Inspection(EOI)/VIP sticker

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Pre-fill check

• Ensure air intake is not fouled and no exhaust or
  other noxious fumes are near or upwind of the
  intake.
• Visually inspect exterior of compressor and
  ensure condensate collection bottle is not full
  (If bottle is full contact safety officer for
  proper disposal prior to turning on compressor).
• Check compressor oil level weekly by removing
  side panel and using the dipstick. ONLY use
  synthetic Bauer Compressor oil.
• Ensure shut-off valve is adjusted to the proper
  setting and valve to the banks is closed.

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Attaching the cylinders

• Before attaching any tank confirm it has a
  current Hydro. and VIP. Determine working
  pressure. Convert Bar to PSIG prior to starting
  fill.
• Visually inspect outside of tank and valve for
  obvious signs of damage, there is no need for a
  hammer test for aluminum cylinders
• Put tank in rack and crack the valve to blow off
  any residual water on valve.
• Attach fill whip, close bleeder valve and open
  tank valve completely with a ¼ turn back.
• Open up valve to compressor to equalize pressure
  in the system

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Filling cylinders

• While air is equalizing in system, fill out
  compressor log and check for notes from last fill
• Put on ear protection and turn on compressor
• Check SECURUS indicator on compressor to ensure
  filters are functioning properly
• Check oil pressure gauge
• Go out to fill station and make sure all tank
  valves are open, compressor valves are open and
  bleeder valves on whips are closed
• Double check shut-off valve is set at proper psi

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Filling cylinders (cont.)

• Max fill rate is 300 600 psig. If you see that
  the cylinders are filling faster then this close
  the compressor valves on all the tanks slightly
  to slow down the fill.
• Check on tanks every 5 mins. DO NOT RELY SOLELY
  ON SHUT-OFF VALVE!
• When working pressure is reached compressor
  should shut-off. If it doesnt shut it off
  manually.
• Shut compressor valves and turn off tank valves
  completely.

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Filling cylinders (cont.)

• Open bleeder valves and depressurize fill whip.
• Remove fill valve, replace valve cover on tank
  valve, and put in the appropriate numbered slot
  in tank rack.
• If you are filling another round of tanks get
  next empty, blow off valve, and reattach fill
  whip.
• Open tank valve, but dont open compressor valves
  until you have at least three empties hooked up.
• Open tank valves incrementally to avoid fast
  fills as you continue to switch out tanks. Go
  back to step 5.

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Filling cylinders (cont.)

• Open bleeder valves and depressurize fill whip.
• Remove fill valve, replace dust cap on tank
  valve, and put in the appropriate numbered slot
  in tank rack.
• If you are filling another round of tanks get
  next empty, blow off valve, and reattach fill
  whip.
• Open tank valve, but dont open compressor valves
  until you have at least three empties hooked up.
• Open tank valves incrementally to avoid fast
  fills as you continue to switch out tanks. Go
  back to step 5.

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MLML Compressors

• MLML has a Bauer VT20 air compressor at the
  firehouse and a Bauer portable compressor kept in
  storage next to Norte
• Both compressors need service from Bauer
  technician ever 50 hrs or yearly depending on use
• FSO certification at MLML is compressor specific.
  You must receive hands-on training on each
  compressor to be approved to use them.
• Nitrox filling is NOT including in the basic FSO
  certification and requires additional training.

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Misc. Information

• 90 of all explosions take place during the
  filling process
• Older tanks with vinyl coating require special
  diligence when inspecting for damage
• All high pressure cylinders regardless of volume
  require the same VIP and Hydro. testing intervals
• Nitrox labeled tanks should not be filled with
  air
• If you think there is damage to a tank. DONT
  FILL IT! Do a thorough internal and external
  examination prior to condemning
• Report any suspected damage to DSO IMMEDIATELY
  and do not fill!