Gas Bottle Refilling – LPG Gas Bottle Refill – How to Refill Gas Bottle
Gas bottle refilling (gas bottle refill) or LPG gas refill is done by decanting or by weight.
Gas bottle refill should only be done by trained technicians.
When you refill gas bottles they require 20% room for expansion – ullage – be maintained whilst you refill gas bottle.
Gas Bottle Refill (Refill Gas Bottle) by Decanting
Gas bottle refill (refill gas bottle) by decanting is the process you observe when you fill gas bottle at servo.
The trained gas bottle refill technician does gas bottle refilling from a large gas cylinder – typically a 210kg gas cylinder – into a smaller gas bottle – typically a 9kg gas bottle refill.
You would also have seen the LPG gas refill process proceed until a white cloud of escaping gas is seen.
The gas escapes through a small bleed screw, alerting the technician to stop the LPG gas refill, to prevent overfilling.
The bleed screw is connected to a dip tube that extends down to the 80% level of the gas bottle, leaving the required 20% ullage or room for expansion when you refill gas bottle.
Gas Bottle Refill (Refill Gas Bottle) by Weight:
For this method of gas bottle refilling, the gas bottle refill is placed on an electronic scale.
The gas bottle refilling technician then reads the tare weight (empty weight) on the gas bottle neck ring and inputs it into the scale, as well as the desired LPG gas refill weight.
The scale either signals when the desired gas bottle refilling is done, so the technician stops the gas bottle refill, or the scale automatically shuts off the LPG gas refill flow.
These scales have an LPG gas refill hose connected to a solenoid valve, which closes when the gas bottle refill reaches the desired weight.
When the total weight equals the empty weight plus the appropriate LPG gas refill weight, the gas bottle refilling is complete.
Gas bottle refills by weight are the more accurate way to do an LPG bottle refill.
LPG cylinders are placed on a scale, and the operator inputs the tare weight. Depending on the cylinder’s weight capacity and size, the electronic gas bottle refilling scale will transfer gas into the cylinder and shut off the valve as soon as the desired gas bottle refill weight is reached.
Gas Bottle Refilling is NOT a DIY Process
Gas bottle refilling is not a DIY task.
Gas bottle refilling should only be done by trained technicians with proper PPE and clothing material
Improper gas bottle refilling or using unproven methods to refill gas bottle can result in overfilled cylinders, which is a serious safety hazard.
The untrained person performing the gas bottle refill is also at risk of injury from cold burns due to escaping gas, burns from fire caused by static electricity or improper grounding or even an explosion.
The simple advice is JUST DON’T DO IT!
Pros & Cons of the Gas Bottle Refilling Methods
Gas Bottle Refilling by Weight – Pros
Accuracy: Gas bottle refilling by weight is more precise, as the gas bottle refill gross weight is continuously measured. Its automatic shut-off helps in prevent underfilling or overfilling.
Safety: A properly calibrated and maintained scale can ensure gas bottle refilling operations are within safety standards.
Compliance: Electronic scales are more accurate and precise than gas bottles refill by decanting. They also meet most regulatory standards, as scales provide a clear, measurable, and standardised way to refill gas bottle.
Efficiency: Automating the gas bottle refilling process significantly speeds up the LPG gas bottles refill process, eliminates human error, and maximises efficiency.
Gas Bottle Refilling by Weight – Cons:
Cost: Using electronic scales and automatic gas bottle refilling systems requires stations to purchase expensive equipment. Maintaining the equipment can also increase overall expenses.
Technical Requirements: Operating an electronic LPG gas bottle refilling scale requires thorough training and skilled personnel to operate the machinery, perform routine maintenance, and calibrate the electronic scales annually.
Infrastructure: Gas bottle refilling by weight should only be done in a controlled environment. Temperature and pressure may affect the scale’s accuracy.
A more controlled environment is needed to ensure the scales’ accuracy isn’t affected by environmental factors like temperature and pressure.
Gas Bottle Refilling by Decanting – Pros:
Simplicity: Gas bottle refilling by decanting uses less equipment than gas bottle refills by weight and is more straightforward. It also requires less automation as human operators manually close the LPG filling valves.
Lower Initial Investment: Since gas bottle refilling by decanting requires less equipment, service stations can start gas bottle refilling empty tanks with less capital and leverage faster turnarounds.
Flexibility: Decanting can be performed in various locations and remote areas.
Gas Bottle Refilling by Decanting – Cons:
Less Accurate: Gas bottle refilling by decanting heavily relies on visual indicators to close the valve, particularly the venting of excess gas via the bleed screw. Because of this, the amount of gas transferred significantly varies and may lead to underfilling or overfilling.
Safety Risks: Overfilling beyond the required ullage (20% of volume) may exert too much pressure on the gas bottles in warm weather. When exposed to direct heat or higher ambient temperature, the gas could expand, further increasing the internal pressure. This increases the potential for the venting of gas through the pressure relief valve.
Skill Requirement: Safety regulations and practices require gas bottle refill operators to have sufficient training and certification. This is necessary to perform the gas bottle refilling and handle gas bottle refills safely. This lack of automation means higher expertise is required and increased reliance on human skills.
Environmental Factors: Ambient pressure and temperature all slightly influence the behaviour of the gas during gas bottle refilling, complicating the operation and possibly affecting accuracy.
See VIDEO (Disclaimer: This video on how to refill gas bottles is only a supplement and refresher for trained individuals and professionals. Untrained individuals must not attempt to refill gas bottles by decanting.)
Current Inspection Date Required for LPG Gas Refill
No matter which of the LPG gas refill methods is used, the cylinder must have a current inspection date.
The gas bottle refill technician is responsible for checking the inspection date stamped into the neck ring of the gas cylinder before they refill gas bottles.
Out-of-date gas cylinders cannot be refilled until re-inspected and stamped with a new inspection date.
Faster Way for Gas Bottle Refilling with Carousels
A side benefit of using scales for gas bottle refills is speed.
The gas bottle refilling supply line can be pump-driven for faster gas bottle refill times.
This is impossible with decanting, as the operator might be too slow to stop the gas bottle refill process, resulting in dangerous overfilling.
Digital scales and pump-driven LPG also allow the use of high-speed carousels, like the SWAP’n’GO carousel in the accompanying image, for LPG gas bottle refills.
Even the keypad step can be eliminated in fully automated plants with gas bottle refill carousels.
The gas bottle refill carousel digitally reads an RFID chip on the cylinder that contains the tare weight and automatically sets the LPG gas bottle refill amount.
Fill Gas Bottle at Servo – LPG Filling from a Bowser
When you fill gas bottle at servo, filling LPG bottle from bowser with digital scale or by transfer from a large cylinder, the technician uses one of the aforementioned techniques.
Decanting is the process most often used for 9kg gas bottle refills at a servo.
20% Oversized for Expansion
LPG vapour pressure rises with temperature.
The gas will expand if a gas cylinder is exposed to higher temperatures.
LPG cylinders are designed to be full while allowing 20% of the space, called “ullage”, for the natural expansion of the LPG.
Proper gas bottle refills, with the required 20% ullage, should never have a problem.
An overfilled cylinder may vent gas when hot, through the pressure relief valve that is built into the main valve.
Overfilling is Unsafe
When overfilled, gas bottle refills have less than 20% ullage, creating the possibility of the unwanted release of gas into the atmosphere through the pressure relief valve.
The pressure relief valve is incorporated into the main gas valve on the cylinder.
It’s a valve within a valve that is designed to vent gas in order to prevent dangerous overpressure situations.
So, overfilling combined with heat can result in gas venting from the pressure relief valve.
This is especially true in the warm climates.
Comprehensive Safety Training is Mandatory for LPG Gas Bottle Refill Technicians
Doing LPG gas bottle refilling incorrectly could result in cold burns (liquid LPG is -42°C), fire, or even an explosion, as well as dangerous overfilling of gas bottle refills and the subsequent venting of gas.
They must know about the gas bottle refilling procedure itself, the correct PPE, the proper clothing material that doesn’t generate static electricity, grounding, and more.
People who are untrained should never attempt gas bottle refills.
Gas Bottle Refill FAQs
Is it cheaper to refill gas bottle or swap a bottle?
Gas bottle refilling or swapping has pros and cons that affect the overall price and value.
Consider whether you have the time to travel to and wait at the gas bottle refilling station, or is opting for SWAP’n’GO LPG gas bottles a more viable option?
Swapping LPG bottles saves you more time and money on smaller gas bottles. It’s also cheaper since you’re getting a fresh gas bottle refill that’s well-maintained and passes our quality standards without spending the price of a new one.
How long does it take to do gas bottle refills?
On average, 9kg gas bottle refills takes 5-10 minutes to refill via decanting or an electronic gas bottle refilling scale.
45kg gas bottle refills can take 10-15 minutes to fill using an gas bottle refilling scale and 15-20 minutes to fill via decanting.
How long LPG gas bottle refill takes depends on how well the gas bottle refilling equipment is maintained, what gas bottle refill method is used, the quality of gas accessories, and the pressure differential between the empty refill gas bottle and the supply tank (especially for decanting)
Can I refill gas bottle that is expired or damaged?
It is illegal and dangerous to refill gas bottles that have an expired date and/or is damaged.
When SWAP’n’GO maintains LPG gas bottles, we perform gas cylinder testing and re-stamp at approved test stations.
SWAP’n’GO also accepts out-of-date gas bottles for swap.
Expired LPG bottles undergo rigorous periodic overhauls every 10-15 years, including testing and safety checks such as:
- Degassing or disposing of gas
- Internal & external inspection
- Valve inspection or replacement of gas accessories
- Re-stamping
How can I do a gas bottle disposal?
ELGAS accepts 3.7kg and 8.5kg gas bottle disposal as part of our ongoing community service to ensure safe gas bottle recycling near tip workers.
Our trained gas handlers will perform a gas cylinder test, remove any traces of residual gas, remove the valves, and either refurbish LPG gas cylinders that are within quality standards or puncture the LPG bottle for gas bottle recycling.
You can contact us at 131 161, and we’ll provide handy tips on LPG safety until we arrive to pick them up or swap a bottle for a full one.
On what size LPG gas bottles can you do an LPG gas bottle refills?
Gas bottle refills can be done with any size gas bottle.
Whether you’re using LPG bottles for cooking, gas heater, room heating, or outdoor BBQ, we provide gas bottle refill and cylinder exchange services for your bottles.
We provide on-site and in-house forklift gas bottle refilling services for 15kg or 18kg gas bottle refill.
For 45kg bottles, you can opt for a cylinder exchange and we’ll replace it with a full bottle at your location or refill gas bottles with our EasyGas™ automatic tanker LPG gas bottle refill service.
Business and industrial cylinders such as 210kg gas bottle refills can be done on-site with EasyGas tanker LPG gas bottle refill supply.
Where can I get my gas bottle refills?
You can get LPG gas bottle refills at your local ELGAS stockist by visiting our locator or check out local SWAP’n’GO locations by typing in your suburb or postcode.
For businesses and industrial settings with 45kg to 210kg gas cylinders or 0.5 tonne up to 50 tonne LPG tanks, we provide tanker LPG gas refill supply with site engineering support, equipment testing & maintenance, and supply continuity services.
You can also contact us at 131 161 to enquire about LPG filling and cylinder exchange or switching to ELGAS and swapping out the old cylinder from your previous supplier. We’ve got you covered.