(1) Inspection and treatment before filling
1. Before filling, the gas cylinders should be inspected one by one, and the inspection content and requirements should at least include:
(1) Whether the domestic gas cylinders are produced by a unit with a "special equipment manufacturing license" and have a supervision and inspection mark;
(2) Whether the imported gas cylinders have been approved by the special equipment safety supervision and management department;
(3) The filled gas should be consistent with the name or chemical formula of the filled gas in the seal mark of the gas cylinder manufacturing;
(4) The name and chemical formula of the bottled gas printed on the warning label should be consistent with the cylinder seal mark;
(5) The gas cylinder shall be the gas cylinder owned by the filling station or the gas cylinder managed by the filling station;
(6) The color mark on the outer surface of the cylinder shall comply with the provisions of GB/T 7144 "Color Marking of Gas Cylinders" and be clear and easy to recognize;
(7) The screw type of the outlet of the gas cylinder valve shall comply with the provisions of GB 15383 "The Connection Type and Size of the Outlet of the Gas Cylinder Valve", that is, the outlet thread of the cylinder valve for combustible gas shall be left-handed, and the outlet thread of the cylinder valve for other gases shall be right-handed;
(8) The outer surface of the cylinder should be free of cracks, serious corrosion, obvious deformation and other serious external damage defects;
(9) The gas cylinder shall be within the specified inspection period;
(10) The safety accessories of the gas cylinder should be complete and meet the safety requirements;
(11) The cylinder body and valve of the cylinder filled with oxygen or other strong oxidizing gases shall not be contaminated with grease or other combustibles.
2. Gas cylinders that do not meet the above conditions are prohibited from filling.
3. If the color or other signs and the outlet thread of the bottle valve do not conform to the provisions of the gas filled, in addition to not being inflated, the reason should also be found out and reported to the local special equipment safety supervision and management department for processing.
4. The newly put into use or the gas cylinder that is inflated for the first time after internal inspection shall be vacuumed or replaced according to the regulations before filling, and can only be filled after being confirmed to be qualified.
5. If the cylinder filled with flammable gas and oxidizing gas is not equipped with a residual pressure holding valve, it should be vacuumed before repeated filling. Flammable gas cylinders are vacuumed to below -80kPa, and oxidizing gas cylinders are vacuumed to -50kPa or less.
6. During the validity period of the inspection, if the appearance inspection finds that there are major defects or doubts about the internal condition of the cylinders, cylinder valves and accessories, they should be sent to the inspection agency first, and the technical inspection and assessment shall be carried out according to the regulations, and the inspection can be reused only after passing the inspection. Cylinders that are in stock and out of service for more than one inspection cycle should be inspected before they are put into use.
7. When the gas cylinders imported from abroad and the gas cylinders used abroad are required to be filled in the mainland, they shall first be approved by the special equipment safety supervision and management department and inspected by the inspection agency.
8. Gas cylinders that fail to pass the inspection (including those to be treated) should be stored in isolation from the qualified gas cylinders and clearly marked to prevent confusion with each other.
(2) Filling
1. The connection type between the gas cylinder filling pipeline and the cylinder valve should be threaded connection, and it is forbidden to use clamps to connect and fill.
2. The accuracy of the pointer pressure gauge used in the gas cylinder filling system should not be less than 1.6 grades, the diameter of the dial should not be less than 100mm, and the calibration cycle should not exceed 6 months.
3. The impurity content in the gas to be filled should meet the requirements of the corresponding gas standard, otherwise it is forbidden to fill.
4. When filling gas cylinders, the following regulations should be strictly observed:
(1) Before filling, it should be checked to confirm whether the gas cylinder has passed the inspection (there should be a record);
(2) When filling with an error-proof joint, the thread of the outlet of the bottle valve should be carefully checked to see if it is consistent with the thread type specified in the gas, and whether the parts of the fault-proof joint are flexible and easy to use;
(3) When opening the bottle valve, it should be operated slowly, and attention should be paid to whether there is abnormal sound in the bottle;
(4) It is forbidden to knock on the bottle valve and pipeline with metal appliances such as wrenches;
(5) Before the gas pressure in the cylinder reaches 7MPa, the temperature of the cylinder should be checked one by one to see if the temperature of the cylinder is consistent, and before the gas pressure in the cylinder reaches 10MPa, the cylinder valve and the sealing of each connecting part should be checked one by one, and the abnormality should be dealt with in a timely and proper manner;
(6) The filling flow rate of the gas cylinder shall not be greater than 8m3/h (under the standard state);
(7) When filling gas cylinders with inflatable busbars, it is forbidden to insert empty bottles for filling during the filling process.
5. The filling volume of the gas cylinder should be strictly controlled to ensure that the pressure of the gas in the cylinder does not exceed 2/3 of the pressure of the cylinder hydrostatic test under the benchmark temperature (20 °C for domestic use).
6. For several characteristic gases, the maximum filling pressure (when the reference temperature is 20 °C) is limited as follows:
(1) The filling pressure of fluorine (F2) and oxygen difluoride (OF2) is not more than 3.0MPa, the hydraulic test pressure of the gas cylinder is not less than 20MPa, and the fluorine filling capacity of each cylinder is not more than 5 kg;
(2) The filling pressure of nitric oxide (NO) is not more than 5MPa, and the pressure of the hydrostatic test of the gas cylinder is not less than 20MPa;
(3) Carbon monoxide (CO) dry (water content less than 5✖10-6) and no sulfur can be filled with steel cylinders, but the maximum filling pressure should not exceed 5/6 of the nominal working pressure of the cylinder, and not more than 13MPa.
7. The filling pressure (gauge pressure) of all kinds of commonly used compressed gases filled with domestic gas cylinders shall not exceed the maximum filling pressure of commonly used compressed gases specified in Table 1 of GB/T 14194-2017 "Regulations on the Filling of Compressed Gas Gas Cylinders" at different filling temperatures. The filling pressure of other compressed gases shall not exceed the pressure value calculated by equation (1) in GB/T 14194-2017 "Regulations on the Filling of Compressed Gas Cylinders".
8. The filling temperature should be determined according to the following methods:
The ambient temperature of the filling room plus the temperature difference between the filling temperature (refers to the difference between the gas filling temperature and the room temperature actually measured during the temperature measurement test) is used as the filling temperature of the cylinder. The difference in charging temperature should be determined by the test at the specified filling speed. The test results should be posted on the wall.
9. The following regulations should also be observed during the filling process of gas cylinders after evaporation of low-temperature liquefied gas:
(1) Before filling, check whether the gas outlet temperature and pressure control device of the cryogenic liquid vaporizer are in a normal state;
(2) Before the cryogenic liquid pump is opened, there should be a cold pump process (refer to the pump instruction manual for the cold pump time;
(3) During the filling process of gas cylinders, the cryogenic liquid vaporizer shall not have serious icing, and the temperature from the vaporizer gas outlet to the filling pipeline shall not be lower than -30 °C.
(4) In the cryogenic liquid pressurized gasification bottle filling device, the liquid discharge volume of the cryogenic pump should be matched with the heat exchange area and filling capacity of the vaporizer, and the filling time of each bottle of gas should not be less than 30min; When the outlet temperature of the vaporizer is lower than -30°C and overpressure, there should be a system alarm and an interlocking pump stop device;
(5) The operator of the cryogenic liquid filling station should be equipped with reliable anti-frostbite labor protection supplies.
(3) Inspection after filling
After filling, there should be a special person responsible for inspecting the cylinders one by one. When the requirements are not met, it is forbidden to leave the factory and be properly disposed of. At a minimum, the inspection includes:
(1) Whether the pressure (filling volume) and quality in the bottle meet the requirements of safety technical specifications and related standards;
(2) Whether the thread of the outlet of the bottle valve and its sealing surface are good;
(3) Whether there are serious defects such as bulging deformation or leakage after filling the cylinder;
(4) Whether there are signs of abnormal increase in the temperature of the bottle;
(5) Whether the cap, filling label and warning label of the gas cylinder are complete.
(4) Filling records
1. The filling unit shall have a special person responsible for filling in the gas cylinder filling record, and the content of the record shall at least include the filling date, bottle number, room temperature, filling medium, filling pressure, filling start and end time, filling person, whether there is any abnormal situation, etc.
2. The filling unit shall be responsible for properly keeping the gas cylinder filling records, and the storage time shall not be less than 1 year.
[Note: The above are the basic processes, requirements and key points of the safe operation procedures for gas cylinder filling, and cannot be directly used as the operating procedures of the gas cylinder filling unit.] The gas cylinder filling unit shall, according to the filling process, equipment and the characteristics of the gas cylinder, conduct a risk analysis of the filling process, formulate corresponding control and preventive measures, as the basis for the preparation of operating procedures, and prepare the safe operation procedures for gas cylinder filling according to the establishment of operating posts. 】