Gas and mixture filling system for Cylinder assemblies and Gas Cylinder Bundles 02x12

A gas and mixture filling system for Cylinder assemblies and Gas Cylinder Bundles is a filling stand facility for filling cylinders in pallets, racks, and monoblocks with technical gases or mixtures of those, with air-operated drop-down protective screens with a control and parameter monitoring system.

The system is designed for optimizing, increasing the capacity of, and improving the safety of the cylinder filling process in conditions where technical gases or mixtures of those are manufactured.

When in the baseline design version, it consists of the following:

• several (as requested by the Customer) filling modules (filling posts with air-operated drop-down protective screens),
• near-post platforms for the operator,
• an inspection stand,
• valve boards for feed and distribution filling lines,
• vacuum and gas-discharge lines, and
• a control and parameter monitoring panel/cabinet.

Each module of the system is designed as a stand-alone post with a filling line installed in a basket at the top of the post.

The filling feed line consists of the fixed portion of the pipeline and the movable portion of the pipeline with a coil’s spiral tube. Components of the filling feed line are shut-off valves intended to disconnect individual connections for filling, rotary units, and inlets to connect cylinders to be filled.

The filling modules can be equipped with individually closing inlet to fill monoblocks.

Components of the filling system delivery set may include steel structures designed for personnel movement in order to make their access to cylinders to be filled easier (movement areas).

The module is equipped with a pneumatically controlled movable protective screen.

A difference in height and the need for sideways deviation of the filling tip in cylinders to be filled are compensated by stretching the coil’s spirally wound tube that is spring-loaded at the top. Cylinder connection assemblies can rotate through 360°, which allows the coil to be oriented to match the cylinder position.

For easy installation and connection, the equipment is supplied in packages with outlets to be welded or threaded joints in order to connect feed and discharge pipelines as well as cables for connection to the control and parameter monitoring cabinet.

Equipment in the standard design version can be operated indoors at an ambient temperature in a range of +5 °C to +40 °C.

The system’s equipment is attended by one operator, who shall ensure that cylinders are handled under pressure and filled.

The system design type is determined by the gas medium (oxygen, nitrogen, argon, carbon dioxide, etc.). Gas to fill the cylinders can be of one kind or be a two/three/multi-component gas mixture.

Depending on the Customer’s requirements, when preparing multi-component mixtures, the cylinders can be filled either by the gravimetric method using a weighing indicator and a control cylinder or by the partial method—by mixing gases in the cylinder while it is being consecutively filled with different gases until reaching certain pressure values.

The pressure in the filling lines is tracked by monitoring and measuring instruments and the parameter monitoring panel.

The filling systems can be manufactured as follows:

• in a single-module or multi-module design version;
• with modules for different quantities of cylinders in a pallet (12, 15, 16, 20, …);
• with modules for different sizes of cylinder pallets and racks;
• with a manually or automatically operated drop-down protective screen;
• using handling platforms of different constructions and sizes;
• using quick-disconnect couplings for cylinders and swivel joints for connection coils.

The filling systems are made of modern materials and components that meet high quality standards. The system is fabricated using reliable valves by national and foreign manufacturers.

To ensure compliance with the GOST requirements, pipelines and valves of the systems in the oxygen version are made of copper and copper-containing alloys.

The maximum operating pressure is determined by the Customer, while the filling lines are fabricated with the operating pressure of 150, 200, 300 bars or higher.

Each project is adapted for the Customer’s needs. The concept of development of these projects was based on the need for lower-cost counterparts to German and Czech filling systems.

The use of this system results for the Customer in the following:

• an increased capacity of the cylinder filling shop as a consequence of the great effectiveness of cylinder filling and replacement (the filling system ensures fault-free operation when connecting 12 to 72 cylinders or more);
• a high degree of safety of operating procedures for charging cylinders with gas;
• the decreased labour input and the increased performance of production and accounting operations for cylinders and their movements around the shop;
• the increased efficiency of process control due to the provided easy monitoring of compliance with current filling and vacuum parameters (gas pressure in cylinders and lines, gas weight in cylinders, gas temperature in cylinders and lines);
• convenient cylinder connection mechanisms.

Overall, the operating conditions, specific version, and scope of supply of the filling system shall be tailored to the Customer and approved in the drawing documentation.