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

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

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

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

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

Pre-fill check 1.Ensure air intake is not fouled and no exhaust or other noxious fumes are near or upwind of the intake. 2.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). 3.Check compressor oil level weekly by removing side panel and using the dipstick. ONLY use synthetic Bauer Compressor oil. 4.Ensure shut-off valve is adjusted to the proper setting and valve to the banks is closed.

Attaching the cylinders 1.Before attaching any tank confirm it has a current Hydro. and VIP. Determine working pressure. Convert Bar to PSIG prior to starting fill. 2.Visually inspect outside of tank and valve for obvious signs of damage, there is no need for a hammer test for aluminum cylinders 3.Put tank in rack and crack the valve to blow off any residual water on valve. 4.Attach fill whip, close bleeder valve and open tank valve completely with a ¼ turn back. 5.Open up valve to compressor to equalize pressure in the system

Filling cylinders 1.While air is equalizing in system, fill out compressor log and check for notes from last fill 2.Put on ear protection and turn on compressor 3.Check SECURUS indicator on compressor to ensure filters are functioning properly 4.Check oil pressure gauge 5.Go out to fill station and make sure all tank valves are open, compressor valves are open and bleeder valves on whips are closed 6.Double check shut-off valve is set at proper psi

Filling cylinders (cont.) 7.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. 8.Check on tanks every 5 mins. DO NOT RELY SOLELY ON SHUT-OFF VALVE! 9.When working pressure is reached compressor should shut-off. If it doesn’t shut it off manually. 10.Shut compressor valves and turn off tank valves completely.

Filling cylinders (cont.) 11.Open bleeder valves and depressurize fill whip. 12.Remove fill valve, replace valve cover on tank valve, and put in the appropriate numbered slot in tank rack. 13.If you are filling another round of tanks get next empty, blow off valve, and reattach fill whip. 14.Open tank valve, but don’t open compressor valves until you have at least three empties hooked up. 15.Open tank valves incrementally to avoid fast fills as you continue to switch out tanks. Go back to step 5.

Filling cylinders (cont.) 11.Open bleeder valves and depressurize fill whip. 12.Remove fill valve, replace dust cap on tank valve, and put in the appropriate numbered slot in tank rack. 13.If you are filling another round of tanks get next empty, blow off valve, and reattach fill whip. 14.Open tank valve, but don’t open compressor valves until you have at least three empties hooked up. 15.Open tank valves incrementally to avoid fast fills as you continue to switch out tanks. Go back to step 5.

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.

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. DON’T FILL IT! Do a thorough internal and external examination prior to condemning Report any suspected damage to DSO IMMEDIATELY and do not fill!