Breathing Air Cylinder Filling

Our client – a global manufacturer of fire and safety respiratory equipment – approached IGPH with a clear mission: to raise safety standards, increase productivity, and adapt to high-variety, fast-changing demand in their Breathing Air Cylinder Filling facility.

Together, we defined three key project objectives:
✔️Safety – less operator involvement and therefore less risk of injury
✔️Productivity – to cater for increased demand therefore enabling the company to easily cater for demand changes
✔️Flexibility – to cater for a high variety, erratic demand, without causing supply chain issues or late customer deliveries.

Phase One: FEED Study
Before implementation, we conducted a comprehensive Front-End Engineering Design (FEED) Study to:
✔️Supply system review (Compressors, Buffer tanks, and installation Pipework)
✔️Analyse operator workflows and performance targets
✔️Understand cylinder range and filling requirements
The result: a full mechanical, process, and electrical design

The Solution:
We delivered a Semi-Automatic Breathing Air Cylinder Filling system, increasing safety for all stakeholders, and enabling high levels of flexibility for different cylinder sizes, pressures, and production needs.

Beyond Equipment we delivered:
✔️ Process, Mechanical, Electrical, Instrumentation Engineering
✔️ Full Installation & Commissioning
✔️ HAZOP Safety Study
✔️ PFAT, FAT, SAT Documentation
✔️ Functional Design Specification (FDS)
✔️ H&S File

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