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Section 402.04
2216 psi SCBA Cylinder Filling Procedures
I. Scope:
This standard establishes guidelines for the safe and proper procedure for filling 2216 psi SCBA air cylinders from the 4500 psi Fire Hall Cascade system, the 4500 psi Rescue Unit Cascade System or the Fire Hall Compressor. It was created to:
A. Prevent accidents, injuries or deaths that might result from the improper or unsafe methods of filling 2216 psi SCBA air cylinders from the 4500 psi Fire Hall Cascade, the 4500 psi Rescue Unit Cascade or the Fire Hall 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 and compressor systems are permitted to recharge air cylinders.
2. Only qualified persons are permitted to conduct maintenance on the compressor, cascade cylinders or 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 The Fire Chief is to be informed of any problems such as outdated test dates on air cylinders or deficiencies in the compressor, cascade system or refill station.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 2216 psi Cylinder from Hall Cascade ONLY:
A. Place 2216 psi cylinder in wooden fill box with valve in the upright position.
B. Attach green fill whip to the cylinder.
C. Turn green valve, on the 2216 psi side, to the “CLOSED” position.
D. Fully open the 2216 psi cylinder in the fill box.
E. Slowly turn the green valve, on the 2216 psi side, to the “OPEN” position.
F. Turn the red main valve to the “OPEN” position.
G. 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).
H. When the pressure from C-1 and the BA cylinder equalizes or the desired pressure is reached, turn off the valve on C-1.
I. Check pressure on all gauges including the BA cylinder gauge, ensuring the BA cylinder is full.
J. If more air is required use C-2, repeating steps H, I, J, and on to C-3, C-4, etc, as needed.
K. When BA cylinder is full, check that all cascade cylinders are closed.
L. Turn red main valve to the “OFF” position.
M. Close the BA cylinder valve.
N. Turn the green valve, SLOWLY, to the “DUMP” position.
O. When the line is empty, unscrew the green fill whip from the BA cylinder.
P. Turn the green valve, on the 2216 psi side, to the “CLOSED” position.
Q. Document number of cylinders filled into the Log Book.
R. Return the full BA cylinder to the place of origin.
IV. Simultaneously Filling Two 2216 psi Cylinders from Hall Cascade:
A. Place both 2216 psi BA cylinders in wooden fill box with valves in the upright position.
B. Attach the green fill whip to one cylinder and the white fill whip to the other.
C. Turn the green and white valves, on the 2216 psi side to the “CLOSED” position.
D. Fully open both 2216 psi cylinders in the fill box.
E. Slowly turn the green and white valves on the 2216 psi side, to the “OPEN” position.
F. Turn the red main valve to the “OPEN” position.
G. 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)
H. When the pressure from C-1 and the BA cylinders equalize or the desired pressure is reached, turn off the valve on C-1.
I. Check the pressure on all the gauges, including the BA cylinder, ensuring the BA cylinder is full.
J. If more air is required, use C-2, repeating steps G, H, I, and onto C-3, C-4, etc, as needed.
K. When the BA cylinders are full check that the cascade valves are closed.
L. Turn the red main valve to the “OFF” position.
M. Close both BA cylinders.
N. Slowly turn the green and white fill whip valves to the “DUMP” positions.
O. When the green and white fill lines are empty, unscrew the green and white lines from the BA cylinders.
P. Turn the green and white fill valves to the “CLOSED” position.
Q. Document number of cylinders filled into the Log Book.
R. Return the BA cylinders to their place of origin.
V. Filling one 2216 psi Cylinder from the Rescue Cascade:
A. Remove 2216 psi cylinder from SCBA harness, if attached.
B. Connect “SCBA FILL” line to 2216 psi bottle.
C. Make sure “CASCADE FILL” valve and bleeder are “CLOSED”, and the “SCBA FILL” valve and bleeder are “CLOSED”.
D. Open the 2216 psi cylinder valve.
E. Open C-7.
F. Open the “SCBA FILL” line valve. Fill slowly (a quick fill will produce unwanted heat and condensation in the air system).
G. When the BA cylinder gauge shows full move to Step I.
H. If more air is required use C-8, repeating steps E and F, and on to C-9, C-10, etc, as needed. Remember, you should only have one cascade cylinder open at any one time. If you are unable to completely fill the 2216 psi bottle after going through all cascade cylinders, report this to any officer on the scene.
I. Close the valve on the cascade cylinder.
J. Close the valve on the 2216 psi cylinder.
K. Open the “SCBA FILL” bleeder valve and drain the line pressure.
L. Remove the SCBA Fill line.
M. Secure the SCBA Fill line to line mount and close “ALL” valves.
N. Return BA cylinder to place of origin.
VI. Filling One 2216 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 2216 psi cylinder in the wooden fill box with the valve in the upright position.
C. Connect the green fill whip to the 2216 psi cylinder.
D. Turn the valve on the 2216 psi cylinder to the “OPEN” position.
E. Turn the green valve on the 2216 psi side to the “OPEN” position.
F. When the 2216 psi cylinder is full, turn the green valve on the 2216 psi side to the “CLOSED” position.
G. Turn the valve on the 2216 psi cylinder to the “CLOSED” position.
H. Slowly turn the green valve on the 2216 psi side to the “DUMP” position.
I. When the line is empty, disconnect the green fill whip.
J. Turn the green valve, on the 2216 psi side to the “CLOSED” position.
K. Follow SOG#402.03, Air Compressor Use procedure in this manual “To Shut Down the Compressor”.
L. Document the number of cylinders filled into the Log Book.
M. Return full cylinder to place of origin.
VII. Simultaneously Filling Two 2216 psi Cylinders From Compressor:
A. Follow SOG#402.03, Air Compressor Use procedure, in this manual “To Start the Compressor”.
B. Place both 2216 psi cylinders in the wooden fill box with the valves in the upright position.
C. Connect the green and white fill whips to the 2216 psi cylinders.
D. Turn both valves on the 2216 psi cylinders to the “OPEN” position.
E. Turn the green and white valves on the 2216 psi side to the “OPEN” position.
F. When the 2216 psi cylinders are full turn the green and white valves on the 2216 psi side, to the “CLOSED” position.
G. Turn both valves on the 2216 psi cylinders to the “CLOSED” position.
H. Slowly turn the green and white valves on the 2216 psi side to the “DUMP” position.
I. When the lines are empty, disconnect the green and white fill whips.
J. Turn the green and white valves on the 2216 psi side to the “CLOSED” position.
K. Follow SOG#402.03, Air Compressor Use procedure in this manual “To Shut Down the Compressor”.
L. Document the number of cylinders filled into the Log Book.
M. Return full cylinders to place of origin.
VIII. 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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