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Section 402.05
4500 psi SCBA Cylinder Filling Procedures
I. Scope:
This standard establishes guidelines for the safe and proper procedure for filling 4500 psi SCBA air cylinders from the Fire Hall Cascade or Fire Hall Compressor system. It was created to:
A. Prevent accidents, injuries or deaths that might result from the improper or unsafe methods of filling 4500 psi SCBA air cylinders from the Fire Hall Cascade or compressor system.
B. Prevent damage to any SCBA equipment that might result from unsafe operation or misuse.
II. Safety:
A. High pressure air is extremely hazardous and must be dealt with very carefully.
B. The following safety precautions are mandatory:
1. Only members specifically trained in the operation of the cascade or compressor system are permitted to recharge air cylinders.
2. Only qualified persons are permitted to conduct maintenance on the compressor, cascade cylinders or the refill station.
3. Hearing and eye protection must be worn when recharging air cylinders.
4. All cylinder valves are to be opened slowly; opening too quickly may burst supply lines.
5. There is to be no horseplay with high pressure air; it can cause embolisms and severe skin and eye damage or even death.
6. The compressor room is to be kept clean at all times.
7. SCBA cylinders not on vehicles are to be stored in the supplied cylinder box, in the compressor room.
8. The Fire Chief is to be informed of any problems such as outdated test dates on air cylinders or deficiencies in the compressor, cascade system or refill station.
9. Any SCBA sets that are malfunctioning or in need of repair, shall be tagged out of service followed by notification to an officer along with the appropriate report form filled out.
III. Filling one 4500 psi Cylinder from Hall Cascade ONLY:
A. Place 4500 psi cylinder in wooden fill box with valve in the upright position.
B. Attach blue fill whip to the cylinder.
C. Turn blue valve, on the 4500 psi side to the “CLOSED” position (turn clockwise).
D. Turn line bleeder valve directly under the blue valve clockwise to the “OFF” position.
E. Fully open the 4500 psi cylinder in the fill box.
F. Slowly turn the blue valve, on the 4500 psi side, to the “OPEN” position (turn counter-clockwise).
G. Turn the red main valve to the “OPEN” position.
H. Slowly open the C-1 cylinder on the hall cascade. Fill slowly (a fast fill will produce unwanted heat and condensation in the air system).
I. When the pressure from C-1 and the BA cylinder equalizes or the desired pressure is reached, turn off the valve on C-1.
J. Check pressure on all gauges including the BA cylinder gauge, ensuring the BA cylinder is full.
K. If more air is required use C-2, repeating steps H, I, J, and on to C-3, C-4, etc, as needed.
L. When BA cylinder is full, check that all cascade cylinders are closed.
M. Turn red main valve to the “OFF” position.
N. Close the BA cylinder valve.
O. Turn the blue valve, SLOWLY, to the “OFF” position (clockwise).
P. Turn bleeder valve directly under the blue valve counter-clockwise to the “OPEN” position.
Q. When the line is empty, unscrew the blue fill whip from the BA cylinder.
R. Turn the blue valve, on the 4500 psi side to the “CLOSED” position.
S. Turn the bleeder valve directly under the blue valve clockwise to the “CLOSED” position.
T. Document the number of cylinders filled into the Log Book.
U. Return the full BA cylinder to the place of origin.
IV. Simultaneously Filling Two 4500 psi Cylinders from Hall Cascade:
A. Place both 4500 psi BA cylinders in wooden fill box with valves in the upright position.
B. Attach the blue fill whip to one cylinder and the red fill whip to the other.
C. Turn the blue and red valves, on the 4500 psi side to the “CLOSED” position.
D. Turn both line bleeders directly under the blue and red valves clockwise to the “OFF” position.
E. Fully open both 4500 psi cylinders in the fill box.
F. Slowly turn the blue and red valves, on the 2216 psi side to the “OPEN” position.
G. Turn the red main valve to the “OPEN” position.
H. Slowly open the C-1 cylinder on the hall cascade. Fill slowly (a fast fill will produce unwanted heat and condensation in the air system)
I. When the pressure from C-1 and the BA cylinders equalize or the desired pressure is reached, turn off the valve on C-1.
J. Check the pressure on all the gauges, including the BA cylinder, ensuring the BA cylinder is full.
K. If more air is required, use C-2, repeating steps G, H, I, and onto C-3, C-4, etc, as needed.
L. When the BA cylinders are full, check that the cascade valves are closed.
M. Turn the red main valve to the “OFF” position.
N. Close both BA cylinders.
O. Slowly turn the blue and red fill whip valves to the “CLOSED” positions (clockwise).
P. Turn bleeder valves directly under the blue and red lines counter-clockwise to the “OPEN” position
Q. When the blue and red fill lines are empty, unscrew the green and white lines from the BA cylinders.
R. Turn the blue and red bleeder valves clockwise to the “CLOSED” position.
S. Document the number of cylinders filled into the Log Book.
T. Return the BA cylinders to their place of origin.
V. Filling One 4500 psi Cylinder from the Compressor ONLY:
A. Follow SOG#402.03, Air Compressor Use procedure, in this manual, “To Start the Compressor”.
B. Place the 4500 psi cylinder in the wooden fill box with the valve in the upright position.
C. Connect the blue fill whip to the 4500 psi cylinder.
D. Turn the line bleeder valve, directly under the blue valve, clockwise to the “CLOSED” position.
E. Turn the 4500psi cylinder valve to the “OPEN” position.
F. Turn the blue valve, on the 4500 psi side to the “OPEN” position.
G. When the 4500 psi cylinder is full, turn the blue valve, on the 4500psi side, to the “CLOSED” position.
H. Turn the valve on the 4500 psi cylinder to the “CLOSED” position.
I. Turn the bleeder valve, directly under the blue valve, counter-clockwise to the “OPEN” position.
J. When the line is empty, disconnect the blue fill whip.
K. Turn the bleeder valve, directly under the blue valve, clockwise to the “CLOSED” position.
L. Follow SOG#402.03, Air Compressor Use procedure, in this manual, “To Shut Down the Compressor”.
M. Document the number of cylinders filled into the Log Book.
N. Return the cylinder to place of origin.
VI. Simultaneously Filling Two 4500 psi Cylinders From the Compressor:
A. Follow SOG#402.03, Air Compressor Use procedure, in this manual, “To Start the Compressor”.
B. Place both 4500 psi cylinders in the wooden fill box with the valves in the upright position.
C. Connect the blue and red fill whips to the 4500 psi cylinders.
D. Turn the line bleeder valves, directly under the blue and red valves, clockwise to the “CLOSED” position.
E. Turn the 4500psi cylinder valves to the “OPEN” position.
F. Turn the blue and red valves, on the 4500 psi side to the “OPEN” position.
G. When the 4500 psi cylinders are full, turn the blue and red valves, on the 4500 psi side to the “CLOSED” position.
H. Turn the valves on the 4500 psi cylinders to the “CLOSED” position.
I. Turn the bleeder valves, directly under the blue and red valves, counter-clockwise to the “OPEN” position.
J. When the lines are empty, disconnect the blue and red fill whips.
K. Turn the bleeder valves, directly under the blue and red valves, clockwise to the “CLOSED” position.
L. Follow SOG#402.03, Air Compressor Use procedure, in this manual, “To Shut Down the Compressor”.
M. Document the number of cylinders filled into the Log Book.
N. Return the cylinders to place of origin.
VI. Responsibilities:
A. All members must understand their responsibilities and duties when working with high pressure air systems.
B. All members shall ensure that this guideline is followed.
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