PSI Fill Station Operator (FSO)

1. 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

2. 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

3. 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

4. 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

5. 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

6. 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.

7. 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

8. 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

9. 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 doesn’t shut it off manually. • Shut compressor valves and turn off tank valves completely.

10. 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 don’t 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.

11. 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 don’t 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.

12. 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.

13. 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!