Gas Bottle Refill – LPG Gas Refill – How to Gas Refill
Gas bottle refill (gas cylinder refill) or LPG gas refill is done by decanting or by weight.
Gas refill should only be done by trained technicians.
Gas cylinder refill requires that 20% room for expansion – ullage – be maintained when you fill gas bottle.
Gas Bottle Refill (Gas Cylinder Refill) by Decanting
Gas bottle refill (gas cylinder refill) by decanting is the process you observe when you fill gas bottle at servo.
The trained technician does LPG filling from a large gas cylinder – typically a 210kg gas cylinder – into a smaller gas bottle – typically a 9kg gas bottle.
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 bottle 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.
Gas Bottle Refill (Gas Cylinder Refill) by Weight:
For this method of LPG gas refill, the gas bottle refill is placed on an electronic scale.
The 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 LPG filling is done, so the technician stops the gas cylinder refill, or the scale automatically shuts off the gas refill flow.
These scales have a filling hose connected to a solenoid valve, which closes when the LPG reaches the desired weight.
When the total weight equals the empty weight plus the appropriate LPG gas refill weight, the gas cylinder refill is complete.
Gas bottle refill by weight is 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 filling scale will transfer gas into the cylinder and shut off the valve as soon as the desired full weight is reached.
Fill Up Gas Bottle is NOT a DIY Process
To fill up gas bottle is not a DIY task.
LPG gas refill should only be done by trained technicians with proper PPE and clothing material
Improper refilling or using unproven methods to fill up 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 LPG Filling Methods
LPG Filling by Weight – Pros
Accuracy: LPG filling by weight is more precise, as the LPG 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 operations are within safety standards.
Compliance: Electronic scales are more accurate and precise than decanting. They also meet most regulatory standards, as scales provide a clear, measurable, and standardised way to perform gas bottle refill.
Efficiency: Automating the filling process significantly speeds up the LPG filling process, eliminates human error, and maximises efficiency.
LPG Filling by Weight – Cons:
Cost: Using electronic scales and automatic filling systems requires stations to purchase expensive equipment. Maintaining the equipment can also increase overall expenses.
Technical Requirements: Operating an electronic filling scale requires thorough training and skilled personnel to operate the machinery, perform routine maintenance, and calibrate the electronic scales annually.
Infrastructure: LPG filling 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.
LPG Filling by Decanting – Pros:
Simplicity: Decanting uses less equipment than filling by weight and is more straightforward. It also requires less automation as human operators manually close the filling valves.
Lower Initial Investment: Since decanting requires less equipment, service stations can start filling empty tanks with less capital and leverage faster turnarounds.
Flexibility: Decanting can be performed in various locations and remote areas.
LPG Filling by Decanting – Cons:
Less Accurate: 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 operators to have sufficient training and certification. This is necessary to perform the gas bottle refill and handle 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 transfer, complicating the operation and possibly affecting accuracy.
See VIDEO (Disclaimer: This video on how to Fill a Gas cylinder is only a supplement and refresher for trained individuals and professionals. Untrained individuals must not attempt LPG 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 refill technician is responsible for checking the inspection date stamped into the neck ring of the gas cylinder before refilling it.
Out-of-date gas cylinders cannot be refilled until re-inspected and stamped with a new inspection date.
Faster Way for LPG Filling with Carousels
A side benefit of using scales for gas bottle refill is speed.
The LPG supply line can be pump-driven for faster gas bottle refill.
This is impossible with decanting, as the operator might be too slow to stop the gas cylinder 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 refill.
Even the keypad step can be eliminated in fully automated plants with gas cylinder refill carousels.
The carousel digitally reads an RFID chip on the cylinder that contains the tare weight and automatically sets the LPG gas refill amount.
Fill Gas Bottle at Servo – Filling LPG Bottle from 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 to fill gas bottle at 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.
Properly filled gas cylinders, 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, a gas cylinder has 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 Refill Technicians
Doing LPG gas refill incorrectly could result in cold burns (liquid LPG is -42°C), fire, or even an explosion, as well as dangerous overfilling of a gas cylinder and the subsequent venting of gas.
They must know about the gas bottle 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 LPG bottle refill.
Gas Bottle Refill FAQs
Is it cheaper to refill or swap my LPG bottle?
Refilling or swapping has pros and cons that affect the overall price and value.
Consider whether you have the time to travel to the refill 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 LPG gas cylinders. It’s also cheaper since you’re getting a new LPG bottle that’s well-maintained and passes our quality standards without spending the price of a new one.
How long does it take to refill an LPG bottle?
On average, an 9kg gas bottle takes 5-10 minutes to refill via decanting or an electronic filling scale.
A 45kg gas bottle can take 10-15 minutes to fill using an LPG filling scale and 15-20 minutes to fill via decanting.
How long LPG gas refill takes depends on how well the LPG filling equipment is maintained, what gas bottle refill method is used, the quality of gas accessories, and the pressure differential between the empty bottle and the supply tank (especially for decanting)
What happens if my LPG bottle is expired or damaged?
It is illegal and dangerous to fill gas bottle that has 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 dispose of my old LPG bottle?
ELGAS accepts 3.7kg and 8.5kg gas bottle disposal as part of our ongoing community service to ensure safe gas cylinder recycling.
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 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 them for a full one.
On what size LPG gas bottles can you do an LPG gas refill?
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 LPG gas refill services for 15kg and 18kg forklift gas bottles.
For 45kg bottles, you can opt for a cylinder exchange and we’ll replace it with a full bottle at your location or refill it with our EasyGas™ automatic tanker LPG gas refill.
Business and industrial cylinders such as 90-\kg and 210kg gas bottles can be refilled on-site with EasyGas tanker LPG gas refill supply.
Where can I get my gas bottle refill?
You can get LPG gas refill 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.