STANDARD OPERATING PROJECT: 2 X 100M3 LPG
PROCEDURE: STORAGE & 600 LPG BOTTLES
LPG CAROUSEL FILLING SYSTEM WITH PER HOUR FILLING
DOCUMENT NO.: GS-CSPH/SPDC-BMDA-052025
ELECTRONIC FILLING MACHINES SUBMITTED: 03-MAY-2025
PREPARED BY JENS PRODUCTIONS LIMITED
ABOUT THE FILLING SYSTEM
The filling system is an electronic LPG bottles filling system consisting of LPG
carousel filling scales and standalone filling scales. The plant includes:
• Carousel filling and standalone filling machines: These are the devices that
precisely weigh and fill LPG into the bottles. The plant is a 12 post (filling scale)
capacity capable of filling up to 600-700 LPG bottles of 12.5kg per hour. The
carousel is driven by a 0.75kw gear box motor. The LPG carousel is an automated
system for filling gas into LPG bottles in the bottling plant, designed for
high-speed and accurate filling. It utilizes a rotating platform with multiple filling
post, allowing for efficient and continuous LPG bottles filling with automatic
bottles input mechanism into the carousel and output from the carousel. There are
4nos. standalone filling machines. Two (2) of these machines are for filling
18kg-50kg while the other two (2) are for filling 3kg-6kg bottles. All the filling
scale in the plant are equipped with double filling nozzles. One nozzle is for filling
bottles with F-valves (manual connection) while the other nozzle is for filling
bottles with self-closing valves (automatic connection).
• LPG bottles input mechanism fed by a chain conveyor. The input mechanism offers
fast and safe transportation of LPG bottles from the chain conveyor to the filling
carousel. Input and output mechanism synchronizes the filling process of the
carousel in fast way.
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• Utility connections: LPG pneumatic, electrical installations are connected to make
the carousel ready for use. LPG Piping connection supply to the carousel is 3” and
the carousel pneumatic system piping connection is 1” operating at 8bar.
• Grounding-the carousel system is grounded to provide protection against
electrostatic effects.
• Current total storage capacity of the plant is 100ton of 50ton capacity storage
tanks each with provision of additional 100ton in the future
• The LPG is received through bulk road trucks, discharge into the storage tanks by
means of LPG compressor or LPG pumps. The gas is stored inside the stationery
storage tank at the facility.
• The plant is equipped with 3nos. of 24m3/hr LPG pumps and 2nos. 57m3/hr LPG
compressors.
• The LPG is transferred through a pipeline network from the LPG storage tanks to
the carousel and standalone filling machines.
• Chain Conveyor: a system that automatically moves bottles onto and off of the
carousel and other critical machines. There are three (3) driving unit motor of each
5.5kw driving the chain conveyor.
• Data system for scales with data collection server system software. This helps to
record instant filling information providing hourly, daily, yearly retrospective
bottles kg quantity information remotely.
• Telescopic conveyors: the installed input and output telescopic conveyor capacity
are 1200 bottles per hour respectively. Telescopic conveyors are manufactured and
installed to facilitate bottles transportation from and to the transfer trucks serving
customers. The telescopic conveyor is design in a way that they can be operated
into the trucks delivering to the plant and taking away bottles from the plant into
the transportation trucks. Operators can easily control the telescopic conveyor into
loading and unloading of LPG bottles
• Check scale: the check scale is a PLC enabled device that is synchronize into the
LPG carousel system for seamless operations of the LPG carousel. It is a special
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check scale mounted on the chain conveyor by a special chassis. It is used to
control the weights of the filled bottles to determine if over-filled or under-filled.
• Correction scale: the correction scale is PLC enabled and it is synchronized with
the LPG carousel system for filling efficiency and transparency. It is the final
control scale. In case any filling deficiencies is found, bottle is to be separated
automatically by the separating piston to the verification weigh bridge roller
conveyor. Then under filled bottles are filled to required capacity by the operator
in duty while excess filled bottles are reduced to the required volume. The excess
reduction is sent back into the facility storage tanks.
• In-line leak detection pool: the leak detection pole has a capacity to detect
leakages within the filled LPG bottles passing through the pool. The Leakage test
of the bottles passing through the water-filled conveyorized pool is done by visual
inspection. Leakage from the body or the valve can be detected. Test type is full
body and valve leak control.
• LPG bottles leakage detector: the device sensitivity is 2500ppm. Filled bottles are
stopped automatically by a stopper while they are still on the conveyor. The
detecting head of the automatic leakage detector positions itself over the bottles by
a centering mechanism. It controls whether the cylinder valve is leaking or not.
Bottles with detected leaking valve head are separated from the non-defective
bottles.
• Valve shrinking machine: this is a steam operated automatic valve sealing
machine. It ensures labeling of the checked cylinders after filling. It consists of an
automatic shrink head and a vapor generator. Vapor obtained by the vapor
generator is delivered through the pipes to the automatic shrink machine so bottles
passing on the conveyor get sealed here.
• Valve screwing and unscrewing machine: the Valve Screwing and Unscrewing
Machine is used to replace defective cylinder valves.
• Defective bottles evacuation machine/Decanting machine: the defective bottles
evacuation unit is used to discharge gas from inside the defective LPG bottles and
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the gas is returned back to the LPG storage tanks for reuse. There is a uniquely
suitable head compactable to bottles for each discharge head.
• Air compressor: This device provides compressed air for pneumatic operations of
pneumatic system. The compressed air system comprises of an air storage tank, air
dryer and air generator.
DESCRIPTION OF THE LPG CAROUSEL ELECTRONIC FILLING SYSTEM
The LPG carousel system is an automated system for filling LPG bottles in the
filling plant, designed for high-speed and accurate filling. It utilizes a rotating
platform with multiple filling posts, allowing for efficient and continuous bottles
filling.
The filling process:
1. Trucks deliver empty LPG bottles to the filling plant
2. The empty LPG bottles are loaded into the receiving telescopic conveyor
3. The telescopic conveyor transports the empty LPG bottles into the chain
conveyor
4. The chain conveyor transports the empty LPG bottles to the LPG carousel
intake system which automatically introduce the bottles into the carousel. The
carousel is rotating thereby taking the bottles to the different 12 post filling
scales. Before the bottles are transported to the carousel system, the operator
on duty would have programmed the carousel filling scales PLC/counter to
fill desired volume, preferably 12.5kg capacity. In addition, the operator
would have calibrated the filling scales to accuracy filling levels. The
calibration should be done with preferably 40kg test weights.
5. Once the empty bottles are loaded on the carousel filling scales, the filling
scale automatically detects the tare weight of the bottle. Thereafter, if bottles
with F-valve are being filled, the operator opens the LPG bottles valve and
connects the scale filling nozzle/head to the bottle valve manually. The tare
weight is automatically displayed on the filling scale monitor. The operator
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then input the tare weight in the space provided in the scale monitor. The
filling scale PLC system automatically add up the tare weight and the
programmed filling volume (e.g.12.5kg). The total of tare weight and the
filling volume is displayed on the scale monitor and the bottle filling is
started. For example, if tare weight is 11kg and the volume programmed to be
filled is 12.5kg, the total weight displaying on the scale monitor would be
23.5kg. Dring the process of filling the bottle, the scale monitor would be
counting from the tare weight to 23.5kg and once the reading on the scale
monitor reaches 23.5kg, the bottle filling would stop automatically. While the
filling is ongoing, the scale monitor screen is blue color but once the filling is
completed, the scale monitor screen color changes to green. But if bottles
with self-closing valves are being filled, the scale filling nozzle/head
automatically connects to the bottles valve without the operator support. In
this case, the filling scale detects the tare weight automatically, input the tare
weight automatically and add up tare weight plus filling volume
automatically without need of the operator inputting the displayed tare
weight. The carousel system operates with bottles having Self-closing
valve automatically. The operator is not required to input tare weight
manually.
6. The carousel continues rotating and when filled bottles get to the filled bottles
ejection point, the carousel automatically ejects the filled bottle from the
carousel into the chain conveyor.
7. The chain conveyor then transports the filled bottles to the check scale which
then checks the bottles if they are filled correctly or not.
8. If the check scale detects over filling, it sends the bottle to the correction scale
where the excess overfilling is decanted and sent back into the storage tank
through the pipelines.
9. If the check scale detects under-filling, it sends the bottle to the correction
scale for appropriate filling to the required volume.
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10. After the correction scale completes its refilling or decanting process
depending on the situation, it sends the bottle into the chain conveyor from
where the bottles move into the leak detector for the bottles valve inspection
for any possible leakages around the bottle valve. If the leak detector detects
any bottle valve leaking, the bottle is separated and taken for repairs (before
taking the bottle for repair, the LPG inside the bottle would be decanted first
at the decanting station. After decanting, the bottle is taken to the valve
screwing and unscrewing machine to fix the valve), but if the detector does
not discover any leaking valve, the leak detector would then send the bottle
into the chain conveyor. The chain conveyor transports the non-leaking
valves bottle to the leak bath detection pool for inspection of the bottle body
for any possible leakage. If any bottle body is discovered leaking, such bottle
is separated and taken for repairs. Non-leaking bottles are transported from
the leak bath detection pool to the chain conveyor.
11. Non defective bottles leaving the leak bath detection pool into the chain
conveyor, move into the valve shrinking machine for valve sealing/tamper
proofing.
12. From the valve sealing machine, the bottles move into the chain conveyor and
thereafter move into the output telescopic conveyor, and from the output
telescopic conveyor, the filled bottles are loaded into waiting trucks for
onward delivery to customers.
13. Below is a list of attached manuals for the installed equipment described
above:
• Electronic filling scale
• LPG Pumps
• LPG Compressor
• Leak detector
• Check scale
• Correction scale
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• Valve screw and unscrew machine
• Gas evacuation machine
• LPG Carousel
• Valve shrinking/sealing machine
• Telescopic conveyor
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