MODULE 8 Filling Cylinders

Introduction You have now learned how to properly prepare cylinders for filling including inspecting cylinders, purging them of air, and replacing any damaged, defective, or outdated valves. In this lesson, you will learn the features and equipment of cylinder filling stations. You will also learn procedures for filling cylinders and vehicle-mounted ASME tanks at the bulk plant. After completing this module, you will be able to: Identify common features and equipment of cylinder filling stations List procedures for filling cylinders by weight or volume at the bulk plant List steps for preparing and filling both motor fuel tanks and mobile fuel tanks at the bulk plant

LESSON 1 Filling Cylinders

Introduction Once you have determined that a cylinder is suitable for continued service, it is ready to be filled at the bulk plant. Becoming familiar with the filling equipment at your bulk plant will enable you to safely fill cylinders and protect your customers, your workplace, and yourself. The exact set up and features of cylinder filling stations vary from one bulk plant to the next based on the type and number of customers you serve and the volume of propane your plant is designed to dispense. This lesson will provide an overview of the most common features and equipment used at a typical cylinder filling station. This lesson also presents detailed procedures for filling cylinders by weight and by volume from cylinder filling stations at the bulk plant.

Characteristics of Cylinder Filling Stations Cylinder filling stations are comprised of the following: ASME storage tank that supplies propane to the dispensing equipment Valves to control the flow of propane through the piping system Extra heavy piping and forged steel pipe fittings Propane pump driven by an explosion-proof electric motor Platform scale for weighing cylinders during and after filling Automatic pump bypass valve(s) to protect the pump, piping and hoses against excessively high pressures when the hose end valves are closed and the pump is running. Electrical wiring, fixtures, and switches to control the propane pump motor and provide for emergency shutdown. MORE

Characteristics of Cylinder Filling Stations cont. Metering system for measuring liquid propane transferred into appropriate containers Propane transfer hose assemblies for cylinder filling and ASME tank filling. Hose-end adapters to accommodate the different valves used on DOT cylinders and ASME tanks. An emergency break-away device for vehicle mounted containers designed to provide protection in case of a pull-away. These are usually on the ASME tank transfer hose assembly to stop the flow of gas if the customer drives away with the hose attached. A fenced enclosure or lockable cabinet to secure the dispenser when not in use. Depending on the site and enclosure, traffic barricades may also be required.

Types of Cylinder Filling Stations The two types of cylinder filling stations are: Manual shutdown filling stations: Rely on the operator to determine when the maximum permitted filling level for a cylinder is reached, and to stop the flow of liquid into the cylinder by manually closing one or more valves. The operator must closely observe the platform scale balance beam, close the hose end valve immediately after the balance beam rises, and then shut down the liquid transfer pump. MORE

Types of Cylinder Filling Stations cont. The two types of cylinder filling stations are: Automatic shutdown filling stations: Used primarily where several cylinders are being filled at the same time such as the cylinder dock at a bulk plant. They provide additional protection against overfilling cylinders. These systems normally consist of a sensor or trip lever mounted on the balance beam of the scale, and a master control valve that controls the flow of liquid propane to the dispensing hose. Regardless of whether the dispensing equipment is manual or automatic, the operator must set the platform sale for the proper filling weight.

Characteristics of Platform Scales During U.S. Department of Transportation (DOT) cylinder filling operations, platform scales are used to determine when the proper fill weight is reached and when to stop the flow of liquid propane into the cylinder. Platform scales are rugged yet sensitive measuring devices. In many jurisdictions, scales must have certification decals from weights and measures officials. Platform scales require periodic inspection and maintenance, regular calibration, and daily checks for accuracy. They must be level and protected from weather, especially from any accumulation of water, snow, or ice.

Single and Double Beam Platform Scales Single beam platform scales determine the proper filling weight for the cylinder by adding the cylinder tare weight, the maximum permitted propane weight, and the weight of the dispensing hose, hose end valve, and adapters. The total of these three weights must be set using the beam weight, and additional counter weights as required. MORE

Single and Double Beam Platform Scales cont. Double beam platform scales combine two balance beams into one assembly and allow for two scale readings for greater accuracy and convenience. One scale is set for the cylinder tare weight, while the second scale is set for the propane weight and dispenser hose weight. After the cylinder is filled, the second scale can be reset for only the propane fill weight so that the net weight and proper filling weight can be checked.

Setting Scale Weight Follow these steps to determine the total filled weight of a cylinder: Step 1: Check the water capacity and tare weight stamped on the cylinder or its protective collar. Step 2: Determine the propane capacity from the conversions table. Remember, if you don’t have a conversion table handy, you can determine propane capacity by using the following formula: w.c. (lb) X .42 = propane capacity (lb) Step 3: Add the tare weight and propane capacity together to determine the total filled weight of the cylinder. Step 4: Set the scales to indicate the proper total filled weight of the container plus the weight of the hose and connectors.

Cylinder Filling Precautions Understand the following precautions when filling cylinders: Always inspect the cylinder filling station equipment prior to filling. Know your plant’s fire prevention and emergency evacuation plans. Make sure that an operator is always in attendance during the entire filling operation. Know where and how to operate emergency shutdown and pump controls. Know the location of the nearest fire extinguishers and make sure they are in proper working condition. Use fire extinguishers only to create an escape route, not to fight a propane fire. Remember that a propane fire can only be safely extinguished by stopping the flow of propane. MORE

Cylinder Filling Precautions cont. Before operating a filling station, ensure there are no ignition sources or combustible materials within 25 feet of the point(s) of transfer, or metal working operations (including grinding, oxygen-fuel gas cutting, brazing, soldering, or welding) within 35 feet. Be sure that valves are properly protected with a valve cap or protective collar. Do not allow any unauthorized people in the transfer area. Always use proper cylinder handling techniques.

Filling Cylinders: Connections You’ll need to ensure that you have the correct connections to accommodate different valves used to fill DOT cylinders. The type of connection needed to connect the hose to the cylinder is determined by some of the following factors: Valve used to fill:  Using a designated filler valve requires a different connection than filling the cylinder through the service valve.  Type of service:  In general, service valve connections are different for liquid and vapor applications. Both have unique filling connections that are not interchangeable. OPD Connections (Type 1 CGA Standard ACME Connection) provide a service connection to the POL or the newer ACME connection designs. MORE

Filling Cylinders: Connections POL Vapor Connections are a common connection found on many DOT cylinders and often used to fill the cylinders when the cylinder is not equipped with a filler valve. Stationary Cylinder Connections are used on stationary cylinders which are filled on site from a bobtail. The cylinder will have a 1¾" filler valve either as a separate item or as a part of the multivalve. Motor Fuel Connections are typically used in forklift cylinders and ASME motor fuel applications. These containers may have a 1¾" ACME filler valve or in the case of forklift cylinders a 1¼" acme fitting. The adapters used to fill these containers are the same in design the only difference being the size of the ACME threads. Liquid Connections (CGA 555) are used only for liquid service and may be found on the service valves on cylinders designed for liquid service.

Step-By-Step: Filling Cylinders by Weight Follow these steps when filling portable cylinders by weight. It’s important to note that the steps provide general guidelines and that each operation may vary depending on your company policy and the type of equipment installed at the plant. An operator must be in attendance during the entire filling procedure. The propane employee in the following photos is shown filling a 20 lb portable cylinder. He has already calculated the total filled weight of the cylinder by adding the propane capacity, tare weight, and weight of the hose and connectors. MORE

Step-By-Step: Filling Cylinders by Weight cont. MORE

Step-By-Step: Filling Cylinders by Weight cont. MORE

Step-By-Step: Filling Cylinders by Weight cont.

Automatic versus Manual Shutdown Systems The steps to fill a cylinder by weight using an automatic shutdown system and a manual system are generally the same, with the exception of the stop filling trigger. In an automatic system, when the balance beam rises it triggers the automatic shutdown device and stops the flow of liquid propane. In the manual shutdown system the operator physically shuts a valve to stop the flow of propane when the beam rises. Typically where multiple filling stations are operated, the pump by-pass circuit is designed to allow high capacity by-passing so that the pump is not shut down while filling and changing cylinders. Regardless of whether the dispensing equipment is manual or automatic, the operator must set the platform scale for the proper filling weight and be in attendance during the entire filling process.

Filling Cylinders by Volume Follow these general steps when filling cylinders by volume. The operation may vary depending on your company policy and whether you are filling from a plant dispensing station or from a bobtail at a residential, industrial or commercial location. An operator must be in attendance during the entire filling procedure. Always wear protective gloves and eye protection when filling cylinders. Open the appropriate liquid outlet and bypass return valves on the cargo tank or storage tank as necessary. Open the vent valve on the fixed maximum liquid level gauge to make sure the tank isn’t already full or out of gas. Connect the hose to the filling connection such as the filler valve or service valve as appropriate. Start the pump and slowly open the valve on the end of the hose. MORE

Filling Cylinders by Volume cont. Open the service valve on the cylinder if filling through this connection. When a steady white mist appears from the fixed maximum liquid level gauge, immediately close the hose end valve. Close the fixed maximum liquid level gauge and shut off the pump. Close the cylinder service valve (if using this connection to fill), disconnect the hose and store it properly. Check the cylinder for leaks and apply any DOT or hazard warning labels as necessary.

Post-Filling Procedures After the cylinder filling operation is completed or anytime the filling station is unattended follow these steps: Close valves at the storage tank. Disconnect and store the hose(s) on a rack inside a fence-protected area, inside the dispenser cabinet, or secured to a supporting structure inside the filling room. Install a dust cap or plug into the hose filling adapter if the location isn’t weather protected. Secure the installation against tampering or unauthorized use.

LESSON 2 Filling Vehicle-Mounted ASME Tanks

Introduction In addition to filling cylinders, propane filling stations serve as a convenient fueling source for automobiles, fleet vehicles, RV tanks, and even your own truck. You play a critical role by safely and efficiently providing propane to business and recreational customers. Some bulk plants may serve customers at the cylinder refilling dock while others may have a separate filling station area. This lesson does NOT address filling stations at industrial sites, hardware stores, campgrounds, rental equipment companies, and gasoline stations. This lesson will cover procedures for filling two types of vehicle-mounted ASME tanks: Motor fuel tanks which supply fuel to the vehicle’s engine. Mobile fuel tanks which supply propane vapor to appliances used in recreational vehicles, campers, and catering trucks.

Propane Filling Operation Responsibilities During propane filling operations, you are responsible for: Understanding how to operate filling equipment, pertinent regulations, and the routine inspections which you should perform before each use. Inspecting customer containers to ensure that they are safe for filling. Filling containers to their proper levels and preventing overfilling. Communicating product information and warnings to customers such as how to properly secure containers for transport. Maintaining a secure propane filling and transfer area to control ignition sources and to prevent tampering or accidental propane release. Knowing how to shut down and secure the filling station in an emergency.

Features of Vehicle-Mounted ASME Tanks Motor and mobile fuel tanks have several features in common: Data Plate and/or Cylinder Markings Fixed Maximum Liquid Level Gauge Float Gauge Liquid Service Valve Relief Valve 1¾″ ACME Filler Valve Stop-Fill/Auto-Stop Valves Valve and Fitting Enclosures

Discovery: Features of Vehicle-Mounted ASME Tanks

Preparing to Fill Vehicle-Mounted ASME Tanks Before filling ASME motor and mobile fuel tanks: Be sure no one is inside the vehicle. Make sure the vehicle ignition is turned off. Inspect the tank to be sure it has all the correct markings, is in good condition, and is safe for filling. Restrict customers from the immediate area around the liquid propane transfer operation. Make sure there are no ignition sources or combustible materials within 25 feet of the filling connection, or metal working operations (including grinding, oxygen-fuel gas cutting, brazing, soldering, or welding) within 35 feet. Note: If filling a motor fuel tank on an RV, be sure to turn off all appliance pilot lights and electronic ignition systems.

Steps for Filling Vehicle-Mounted ASME Tanks Make sure no one is inside the vehicle and that the ignition is turned off. Customers are restricted from the immediate area around the liquid propane transfer operation. Make sure there are no ignition sources within 25 feet of the point of transfer, or metal working operations (including grinding, oxygen-fuel gas cutting, brazing, soldering, or welding) within 35 feet. MORE

Steps for Filling Vehicle-Mounted ASME Tanks cont. MORE

Steps for Filling Vehicle-Mounted ASME Tanks cont.

Tank Decals A propane decal is required on vehicles equipped with motor and/or mobile fuel tanks. This decal alerts emergency response personnel that propane containers are present. Location requirements for the decal include: On vehicles with motor fuel tanks, the decal must be on the lower right rear of the vehicle near the bumper. On vehicles with mobile fuel tanks, the decal must be on or near the access panel door or fender skirt.

Summary Some important points to remember from this module are: You must understand how to properly operate the filling equipment at your bulk plant to safely fill cylinders and protect yourself, your customers, and your workplace. Cylinder filling stations vary. Yours is based on the type and number of customers served and the volume of propane your plant is designed to dispense. Propane filling stations are also used to refuel motor fuel and mobile fuel tanks. Motor and mobile fuel tanks are very similar in design and function, except mobile fuel tanks do not supply fuel to the vehicle engine. Mobile fuel tanks are used to supply propane appliances that are possible ignition sources. Therefore, it’s critically important to turn off appliance pilots and electronic ignition systems before refilling mobile fuel tanks.