1. Filling of SAPPHIRE 25 & 42 Bar Systems (TFPP Hardware)
FSP04; V4; February 2013
Option 1 Title Slide: Title of Presentation can be added in the included place holder text box.

2. Equipment Fill Rig Assembly Agitator Bulk Tank Nitrogen Skid
Weigh Scales
Thermometer
Multi-meter or test box.
Snoop / Leak Detection Spray
Overhead Gantry / Jib Crane
Filling Records 1 2 3 4 5 7 6 8 10 9

3. Filling of SAPPHIRE from 1100kg Tote Instructions
4. Remove container packing protection sleeve & Schrader protection cap, then record tare weight. Caution: Container & Valve assemblies are purged with nitrogen to remove moisture at the Primary manufacturing facility and short burst of nitrogen is applied to close the shuttle for transportation

4. Filling of SAPPHIRE from 1100kg Tote Instructions
Open isolation valves on fill line. Open liquid switch on panel. Fill container to required weight; refer to the fill tolerances as detailed below. For auto fill rigs, the pump will automatically cut off once the desired fill is reached. For manual rigs, the operator must manually cut off the pump once the desired fill is reached.
Open Isolation Valves

5. Filling of SAPPHIRE from 1100kg Tote Instructions
Set the regulator to 30bar (25bar system) or 50bar (42bar system).
Apply 2 short bursts of nitrogen to push through remainder of agent in fill line and record agent weight in fill records.
Close the fill adaptor ball valve and disconnect the fill line at the quick connect.
Verify agent temperature by measuring skin temperature of container below the liquid level line (bottom 1/3 of the container).

6. Filling of SAPPHIRE from 1100kg Tote Instructions
21. Ensure that:
Only trained authorised operators use mechanical lifting equipment
Any container protection is removed (plastic mesh, cardboard etc)
Container is positioned in back left-hand corner of agitator
The outlet of the valve is orientated facing away from the operator
Safety cap is secured or removed

7. Filling of SAPPHIRE from 1100kg Tote Instructions
Press blue button (photo cell) to reset the protection beam.
Set counter to 60 cycles (10 minutes agitation).
Switch to Automatic.
Press Start Button to begin agitation.

8. Filling of SAPPHIRE from 1100kg Tote Instructions
Agitate for 60 cycles (10 minutes).

9. Filling of SAPPHIRE from 1100kg Tote Instructions
Counter will automatically stop agitator or to manually stop, Press Stop Button, Switch to Manual, Press ‘Start Position’ Button to return to start position.

10. Filling of SAPPHIRE from 1100kg Tote Instructions
After agitation, reconnect the fill hose ensuring the fill-line vent-line is closed.
Re-pressurise the fill-line to desired pressure (after adjusting for temperature, nominally 25 20oC or 42 20oC for 42 bar containers). Open the fill line isolation valve and observe container pressure. If master gauge pressure reads between 0.25 bar to 0.75 bar above the temperature adjusted pressure reading, pressurisation is complete. (See Temperature Vs Pressure Correction Table in appendix).

11. Filling of SAPPHIRE from 1100kg Tote Instructions
To close the container valve, open and close the ‘closing down line ball valve’ twice.

12. Filling of SAPPHIRE from 1100kg Tote Instructions
47. Do not vent the Nitrogen close down line at this stage - verify close down of container valve by venting fill hose through vent valve on the outlet adaptor. If nitrogen reading on master gauge drops rapidly, container valve has been closed correctly. If not, close vent valve and inform management.

13. Filling of SAPPHIRE from 1100kg Tote Instructions
48. Vent pressure within the closing down adaptor. Remove the closing down line, close down adaptor and fill line.

14. Filling of SAPPHIRE from 1100kg Tote Instructions
Test the Schrader valve for leaks using snoop / leak detection spray.
If any leaks are observed, inform management. Do not attempt to rectify leaks without management approval.

15. Filling of SAPPHIRE from 1100kg Tote Instructions
If no leakage is observed from the Schrader, release any pressure remaining in the fill adaptor by depressing the quick connect. With the container still clamped, remove the fill adaptor and leak check the outlet with snoop / Leak Detection Spray. Refit the safety outlet cap and Schrader protection cap.
Leak check all other remaining leakage paths with snoop / leak detection spray. (Pressure Gauge, Low Pressure Switch/port, Burst Disc, Bonnet and Neck ring). Then blow off remaining fluid with an airgun.