SOP for XL Grade Cylinder Filling

1. Pre-Fill Inspection:

a) Take the cylinder from the pallet towards the filling bay rack.
b) Check for the valve guard. If the valve guard is loose, then tight it. If
valve guard is not available, then fix the valve guard.
c) Check for color code. For Xl Argon cylinder the body of the cylinder
should be peacock blue in color, For Xl grade Oxygen it should be pitch
black in colour, for XL grade Nitrogen it should be gray and black
colour at neck.
d) Check for owner ship of the cylinder. If the cylinder is customer owned,
then check for the hydro testing ring. If the cylinder is tested in LINDE
or LINDE authorized test shop then take the cylinder for filling. Other
wise inform the supervisor.
e) Check for body condition of the cylinder. If any dents, cuts or welding
arc found in the cylinder sent the cylinder to test shop for further
inspection.
f) Check for the valve condition. If any valves are damaged or bend then
sent the cylinders to test shop for maintenance.
g) Check for oil contamination in the body or valve of the cylinder. If
found any oil or crease, sent the cylinders to the test shop for further
inspection.
h) Check for test due. If the cylinders are test due (5 years due hydro
testing date ) sent the cylinder to test shop for hydro testing. If all the
above said conditions are ok then take the cylinder near filling bay
i) Check the condition of filling hoses. If hoses are in good condition
connect the cylinders.
j) Remove old labels and shrink wrap from the cylinder.
2. Filling Procedure:

a) Close Filling valves in the Filling manifold. Connect the cylinders for
filling via hoses.
b) Open the corresponding vent valve in the manifold.
c) Open the spindles of the cylinder.
d) Vent the residual pressure.
e) Vacuum the cylinder. After getting the correct vacuum, purge the
cylinder. If the product is XL Grade, then purge the cylinder 3-4 times.
f) After purging the cylinder, open the corresponding filling valve in the
manifold.
g) Set the filling pressure and Start the pump, using the PLC.
h) Around 80 Kg/Cm2 pressure, check the leak for the hose connection,
gland nut and neck of the cylinder.
i) Check the cylinder temperature for warmth by pointing heat gun
towards cylinder shoulder.
j) At 130 Kg/cm2, run the pump in slow speed. Also at this pressure check
the temperature of the cylinder using thermometer. Add 2 degree in
the temperature and check the corresponding filling pressure in the
pressure vs. temperature chart. Reset the filling pressure accordingly
in the PLC.
k) Apply the label in the cylinder. Label should contain the date and batch
number for that day.
l) The pump will trip at the set point.
m) Close the spindle.
3. Post-Fill inspection:

a) Close the Main filling valve for the corresponding Bay.

b) Vent the pressure using the vent valve.
c) Remove the filling connections.
d) Check the leak of cylinders.
e) Check one cylinder for purity. For xl grade gases trace oxygen and
moisture analyses should be < 2ppm.
f) Check at least one cylinder from the day’s production for corrects
pressure and keep aside for rechecking pressure after 24 hours. Settle
pressure should be in accordance with settle pressure chart.
g) Update the filling record.

Prepared By Approved By
Vikas kumar Tripathi Kannan Dhas Shummugam