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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. General Info. on Compressors.

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psi fill station operator fso
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
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
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
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
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
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.
attaching the cylinders
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
filling cylinders
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
filling cylinders cont
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.
filling cylinders cont1
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.
filling cylinders cont2
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.
mlml compressors
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
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!
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