Gas Bottle Refilling – LPG Gas Bottle Refills – How to Refill Gas Bottle – LPG Refill
Gas bottle refilling (LPG gas refill) is done by decanting or by weight.
Gas bottle refills (refill gas bottle) should only be done by trained technicians.
When you refill gas bottles (gas bottles refill) they require 20% room for expansion – ullage – be maintained whilst you refill gas bottle (LPG refill).
Gas Bottle Refills (Refill Gas Bottle) by Decanting
Gas bottle refills (refill gas bottle) by decanting is the process you observe when you fill gas bottle at servo (LPG refill).
The trained gas bottle refilling (refill gas bottles) technician does gas bottle refilling (gas bottle refills) from a large gas cylinder – typically a 210kg gas cylinder – into a smaller gas bottle – typically 9kg gas bottle refills (refill gas bottles).
You would also have seen the gas bottles refills (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 gas bottle refilling (LPG refill), to prevent overfilling.
The bleed screw is connected to a dip tube that extends down to the 80% vleel of the gas bottle, leaving the required 20% ullage or room for expansion when you refill gas bottles (gas bottles refill).
Gas Bottle Refills (Refill Gas Bottle) by Weight:
For this method of gas bottle refilling (LPG refill), the gas bottle refills (refill gas bottle) is placed on an electronic scale.
The gas bottle refilling (LPG refill) 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 refill (LPG gas refill) weight.
The scale either signals when the desired gas bottle refilling (LPG refill) is done, so the technician stops the gas bottles refill, or the scale automatically shuts off the LPG gas refill (LPG refill) flow.
These LPG refill (gas bottle refills) scales have an LPG gas refill (LPG refill) hose connected to a solenoid valve, which closes when the refill gas bottles (LPG refill) reaches the desired weight.
When the total weight equals the empty weight plus the appropriate gas bottles refill (LPG gas refill) weight, the gas bottle refilling (gas bottles refill) is complete.
Gas bottle refills (LPG refill) by weight are the more accurate way to do a gas bottle refills (LPG gas refill)l.
LPG cylinders are placed on an LPG refill (gas bottles refill) scale, and the operator inputs the tare weight. Depending on the cylinder’s weight capacity and size, the electronic LPG gas refill (gas bottle refills) scale will transfer gas into the cylinder and shut off the valve as soon as the desired gas bottles refill (LPG gas refill) weight is reached.
Gas Bottle Refilling (LPG refill) is NOT a DIY Process
Gas bottle refilling (gas bottles refill) is not a DIY task.
A gas bottle refills (LPG gas refill) should only be done by trained technicians with proper PPE and clothing material
Improper gas bottle refilling (gas bottles refill) or using unproven methods to refill gas bottles (gas bottles refill) can result in overfilled cylinders, which is a serious safety hazard.
The untrained person performing the gas bottle refills (LPG gas 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 (LPG gas refill) Methods
Refill Gas Bottles by Weight – Pros
Accuracy: When you refill gas bottles (gas bottles refill) by weight, it is more precise, as the gas bottle refills (gas bottles refill) gross weight is continuously measured. Its automatic shut-off helps in prevent underfilling or overfilling.
Safety: A properly calibrated and maintained LPG refill (gas bottles refill) scale can ensure gas bottle refilling (gas bottles refill) operations are within safety standards.
Compliance: Electronic LPG refill (gas bottle refills) scales are more accurate and precise than gas bottles refill (refill gas bottles) by decanting. They also meet most regulatory standards, as scales provide a clear, measurable, and standardised way to refill gas bottles (gas bottles refill).
Efficiency: Automating the gas bottle refilling (gas bottles refill) process significantly speeds up the LPG gas bottles refills (refill gas bottles) process, eliminates human error, and maximises efficiency.
Refill Gas Bottles (LPG refill) by Weight – Cons:
Cost: Using electronic scales and automatic gas bottle refilling (gas bottles refill) systems requires stations to purchase expensive equipment. Maintaining the equipment can also increase overall expenses.
Technical Requirements: Operating an electronic LPG gas refill (gas bottles refill) scale requires thorough training and skilled personnel to operate the machinery, perform routine maintenance, and calibrate the electronic scales annually.
Infrastructure: Gas bottles refill (refill gas bottles) 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 LPG refill (gas bottles refill) scales’ accuracy isn’t affected by environmental factors like temperature and pressure.
Gas Bottles Refill (LPG gas refill) by Decanting – Pros:
Simplicity: Gas bottles refill (refill gas bottles) by decanting uses less equipment than gas bottle refills (gas bottles refill) by weight and is more straightforward. It also requires less automation as human operators manually close the LPG refill (gas bottle refills) valves.
Lower Initial Investment: Since gas bottles refill (refill gas bottles) by decanting requires less equipment, service stations can start gas bottle refilling (gas bottles refill) empty tanks with less capital and leverage faster turnarounds.
Flexibility: Decanting can be performed in various locations and remote areas.
Gas Bottles Refill (LPG refill) by Decanting – Cons:
Less Accurate: Gas bottles refill (refill gas bottles) 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 bottles refill (refill gas bottles) operators to have sufficient training and certification. This is necessary to perform the gas bottle refilling (gas bottles refill) and handle gas bottle refills (refill gas bottles) 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 (gas bottles refill) , complicating the operation and possibly affecting accuracy.
See VIDEO (Disclaimer: This video on how to refill gas bottles (gas bottles refill) is only a supplement and refresher for trained individuals and professionals. Untrained individuals must not attempt gas bottle refills (refill gas bottles) by decanting.)
Current Inspection Date Required for Gas Bottle Refills (LPG refill)
No matter which of the gas bottles refill (refill gas bottles) methods is used, the cylinder must have a current inspection date.
The gas bottle refills (refill gas bottles) technician is responsible for checking the inspection date stamped into the neck ring of the gas cylinder before they refill gas bottles (gas bottle refills) .
Out-of-date gas cylinders cannot be refilled until re-inspected and stamped with a new inspection date.
Faster Way for Gas Bottle Refilling (LPG gas refill) with Carousels
A side benefit of using scales for gas bottle refills (refill gas bottles) is speed.
The LPG refill (LPG gas refill) supply line can be pump-driven for faster gas bottle refills (refill gas bottle) times.
This is impossible with decanting, as the operator might be too slow to stop the gas bottles refill (refill gas bottles) process, resulting in dangerous overfilling.
Digital LPG refill 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 (refill gas bottle).
Even the keypad step can be eliminated in fully automated plants with gas bottles refill (refill gas bottles) carousels.
The gas bottles refill (refill gas bottle) carousel digitally reads an RFID chip on the cylinder that contains the tare weight and automatically sets the LPG gas bottles refill (refill gas bottles) amount.
Refill Gas Bottle at Servo (LPG refill) – Refill LPG Bottles from Bowser (LPG gas refill)
When you refill gas bottle (gas bottle refill) at servo, refill gas bottles (gas bottles refill) 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 (refill gas bottle) 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 (gas bottles refill), 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 (refill gas bottle) 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 Bottles Refill (LPG refill) Technicians
Doing LPG gas bottle refills (refill gas bottle) 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 (refill gas bottles) and the subsequent venting of gas.
They must know about the gas bottle refilling (gas bottles refill) 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 (refill gas bottle).
Gas Bottle Refill (LPG gas refill) FAQs
Is it cheaper to refill gas bottles (gas bottles refill) or swap a bottle?
Gas bottle refilling (gas bottle refills) 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 (gas bottles refill) station, or is opting for SWAP’n’GO LPG gas bottles a better 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 bottles refill (refill gas bottle) 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 (LPG refill)?
On average, 9kg gas bottle refills (refill gas bottle) takes 5-10 minutes to refill via decanting or an electronic LPG gas refill (gas bottle refills) scale.
45kg gas bottle refills (refill gas bottle) can take 10-15 minutes to fill using an LPG refill (gas bottles refill) scale and 15-20 minutes to fill via decanting.
How long LPG gas bottle refills (gas bottles refill) take depends on how well the gas bottle refilling (gas bottle refills) equipment is maintained, what gas bottles refill (refill gas bottle) method is used, the quality of gas accessories, and the pressure differential between the empty refill gas bottle (gas bottle refill) and the supply tank (especially for decanting)
Can I refill gas bottle (LPG gas refill) that is expired or damaged?
It is illegal and dangerous to refill gas bottles (gas bottles refill) 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 removal of gas
- Internal & external inspection
- Valve inspection or replacement of gas accessories
- Re-stamping
How can I do a gas bottle disposal?
ELGAS accepts 9kg 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 0800 435 427, 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 (LPG refill)?
Gas bottle refills (refill gas bottle) 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 bottles refill (LPG refill)and cylinder exchange services for your bottles.
We provide on-site and in-house forklift gas bottle refilling (LPG gas refill) services for 15kg or 18kg gas bottle refills (refill gas bottle).
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 (gas bottles refill) with our EasyGas™ automatic tanker LPG gas bottles refill (refill gas bottle) service.
Business and industrial cylinders such as 210kg gas bottle refills (refill gas bottles) can be done on-site with EasyGas tanker LPG gas bottle refills (refill gas bottle) supply.
Where can I get my gas bottle refills (LPG gas refill)?
You can get LPG gas bottle refills (refill gas bottle) 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 (gas bottle 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 refill (gas bottles refill) and cylinder exchange or switching to ELGAS and swapping out the old cylinder from your previous supplier. We’ve got you covered.