Tips for Filler

1. Before Filling

  • A gas cylinder should be Loaded, Unloaded and kept at the pre defined and designated place only under the supervision of trained person.
  • A competent person shall examine and inspect the cylinder before sending it for filling.
  • Cylinders accompanied with History cards, must only be sent for filling. History card has got Hydrostatic Test Date mentioned over it.
  • A Test Due cylinders shall not be filled at any cost unless it’s been hydraulically tested.
  • Hydraulically tested cylinders, when inspected by eye if posses any dent, corrosion, welding mark or burn mark shall not be accepted for filling and should straight way sent for cylinder testing and cylinder disposal by cutting into two pieces.
  • Each and every cylinder should be inspected thoroughly before going to cylinder filling area.
  • Once cylinder is confirmed to be fit for filling, then only it shall be sent to designated cylinder filling area.

2. Open Spindle

At filling area, following procedures must be adopted:
  • Check the pressure inside the cylinder. It should have small positive pressure or residual pressure.
    • If there is excess pressure, release the same at a safe place using proper safety precautions as per different type of gases. ( Please take extreme care while releasing the gas as there are statutory norms according to CCOE using which only a gas cylinders can be decanted ).    A cylinder having positive pressure or residual pressure is considered to be accepted for filling.
    • Pressure is not coming out, Purge cylinder with the required gas to get purity. If any doubt is there, examine cylinder internally.
  • Check and replace defective Valves and spindle
  • Before filling, conduct hammer test and if dull, unclear sound is heard, check for weight loss.

3. During Filling

  • Check test pressure of each cylinder.
  • Check that every cylinder in the bay had got residual pressure.
  • Purge the cylinders properly for better purity.
  • Check that the cylinders are properly fitted to filling hose without any leak.
  • Check that the cylinders are standing properly on even ground.
  • Check that no cylinder is heating up un necessarily.
  • Check that spindle of all the cylinders is open up properly.
  • Check the gauge pressure at least in 2 gauges in the same bay.
  • Take number of each cylinder for records.
  • Check the gland nuts for any leakage.

4. During Storage

  • Cylinder storage area shall be free from any dirt, oil or grease, moisture or water at any which is highly undesirable because it might affect the quality and can react with some gases as well creating explosion and can damage a human life.
  • The cylinder storage areas shall we well ventilated.
  • No Smoking Sign must be put all around.
  • Cylinders shall always be stored at a proper flooring area so that they will not fall down.
  • Filled and empty cylinders must have separate designated storage area.
  • Different type of gases must be stored separately.
  • A cylinder shall always contain a label mentioning gas name contained in it and Empty or Filled mark.

5. Quality Of Gas

  • A gas shall be as free from moisture as possible. Presence of moisture might accelerate corrosion thereby damaging the cylinder shell from inside and resulting in its weight loss.
  • A cylinder shall be free from impurities of Sulfur as far as possible.
  • Once filled label the cylinder properly with its content gas name

6. Record

A Filling station must always have the following record of each cylinder

  • Cylinder Number
  • Manufacturer name
  • Owner Name
  • Cylinder Specifications conforming to which standard
  • Original Hydrostatic test Date
  • Test reports and certificates furnished by the manufacturer, if available;
  • Maximum working pressure
  • Test Pressure
  • Tare weight of the cylinder
  • Date of the last hydrostatic stretch test and name of the testing station;
  • Water capacity
  • Variation, if any, in the tare marked on the cylinder and tare weight now
  • Name of gas
  • Remarks


Permission obtained from the statutory authority permitting the use of cylinder shall be preserved till the cylinder is condemned.

Always keep the MSDS of required gas ready.
Inform the higher authorities as soon as possible in case of any mishappening.