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Service Manual X-STORE_TH_500_v2

1. 5 3 2 Gas composition 5 3 3 Temperature ranges 6 3 4 Cylinder handling 6 3 5 Behaviour after an accident or fire T 3 5 1 Accident 7 3 5 2 Fire 7 4 Installation instructions cccceeeeeeeeneeeeeeneeneeensenseeseenscnseensonsseneonsenseoneons 7 4 1 Assembly of a cylinder into a vehicle T 4 1 1 Bracket mounting 8 4 1 2 Mounting 9 4 1 3 Neck Mounting 9 4 2 Installation of valves 9 4 3 Removal of valves and safety adapters 12 5 Periodic Cylinder Inspection Gasanlagenprufung GAP according to ECE R 110 ISO 11439 Ce nee eee eee 13 5 1 Require
2. Manual X STORE TH 500 v 4 Oct 2012 Edition Rev 2 A D e f O nN 2 Environmental protection and waste disposal X Store cylinders are made of an HDPE liner connection parts out of aluminum and or stainless steel and carbon glass fiber reinforcement embedded in epoxy resin These substances are environmentally harmless and can be disposed after 20 years In accordance to the above mentioned materials the recycling processes should be arranged with the current state of the art technologies lf the entire cylinder will be recycled it must be disabled For this purpose a hole in the cylindrical wall of the cylinder with a diameter of at least 10mm must be drilled Prior to disposal the tank must be washed with nitrogen several times in order to prevent the formation of an ignitable mixture lf under certain circumstances the pressure of the cylinder has to be released i e change of a cylinder due to superficial damage local and country safety regulations should be followed Before venting the cylinder it is imperative to check all connections and pipelines between the cylinder valve and torch for leaks This can be done with leak detect spray The cylinder must be grounded with a suitable cable to prevent electrostatic charge A fire extinguisher must be accessible lf the gas will be relieved without a torch into the environment it is recommended to wear ear protection because a noise level of more than 110dB A
3. Neck Mounting The cylinder TH_ 500 HY_1 2 3 4 has been specifically designed to allow for neck mounted assembly A current listing of the containers suitable for the neck assembly can be supplied by contacting xperion or your local distributor With the neck assembly it is to be noted that there is a fixed bearing side container neck with valve and a floating bearing side 4 2 Installation of valves During assembly of valves please follow in accordance the points below Installation of valves with self sealing thread 1 Only xperion authorized valves and relief devices are to be used Fora listing of such approved devices please contact xperion or your local distributor 2 Ensure that the thread of the valve and adapter is compatible to the cylinder threads X Store cylinders have a connecting thread of 1 4 NPT 3 Check all threads for damage and dirt Remove dirt with a clean cloth Damaged parts must be replaced 4 Check that the valve and the supporting if there are no damages During the complete preparation the cylinders need careful handling Any impact drop damage or other visible damage e g scratches or notches t gt 0 5mm or surface damage must be recorded and reported to xperion as soon as possible 9 21 Service Manual X STORE TH_500 Iy i Oct 2012 Edition Rev 2 rN pe r O nN 5 The transportation valve is sealed with PTFE tape Manually by hand screw the valve until it is firmly applie
4. can occur 4 21 Service Manual X STORE TH 500 v 7 Oct 2012 Edition Rev 2 A D e f O nN In both cases it is important to note that the valve may cool down dramatically through the effusion of the gas Therefore gloves must be worn 3 Operating conditions 3 1 General X Store cylinders are designed for an operating pressure of 25 MPa 250bar at a surrounding temperature of 15 The cylinder may be filled only up to this pressure with a working pressure of not more than 25MPa 250bar at a surrounding temperature of 150 during the adjustments of the resulting temperatures within the cylinder This corresponds under normal operating conditions to a maximum of 32 5MPa 825bar The maximum filling pressure should never exceed more than 32 5MPa 825bar at any temperature lf the pressure is discharged for any reason and the cylinder should never be stored at elevated temperature without pressure for longer than 3 month If the cylinder is stored for a longer period more than 3 month the cylinder must be pressurized up to p gt 2 obar Pressurisation from ambient pressure if the cylinder is completely empty must be carried out according to special procedure Procedure can be provided by xperion The maximum useful life of the cylinder is 20 years in accordance with ECE R 110 ISO 11439 NGV2 This lifetime of a cylinder is shown on every cylinder label see ECE R110 chapter 5 2 2 as well as in the documents of the cyli
5. cylinders need careful handling Any impact drop damage or other visible damage e g scratches or notches t gt 0 5mm or surface damage must be recorded and reported to xperion as soon as possible o N 7 Pz _ s gt E i A rA E 5 Manually by hand screw the valve until it is firmly applied 6 Tighten the valve with the matching specialty tool with a torque of 130 Nm Applying a torque gt 130Nm to the cylinder is not permitted 11 21 Service Manual X STORE TH_500 V PF Oct 2012 Edition Rev 2 rx Q erion 7 Mark the transition from valve to the cylinder with a drop of sealing mark paint 8 Record the change of the valve in the documents 9 Test the system cylinder adapter valve for leaks 4 3 Removal of valves and safety adapters lt is important to ensure that the cylinder is depressurized The following steps should be followed To do so the manual valve must be closed Afterwards the automatic sealing device must be opened by special adapter to transfer the 12V For any further instructions please contact xperion The ear protection must be worn because the noise level through the out coming gas can reach more than 110dB A 12 21 Service Manual X STORE TH 500 v 7 Oct 2012 Edition Rev 2 A D e f O nN After the automatic sealing device has been opened the manual valve must be opened slowly If CNG effuses the cylinder is not completely empty In thi
6. distributor 5 1 Requirements for the auditor The auditor must be in possession of a certificate that he has been trained according to the GAP or as required by National regulations This GAP training instructs the safety and technology regulations when dealing with pressure cylinders and other CNG storage system components The GAP trainings are offered by various technical inspection authorities 13 21 Service Manual X STORE TH_500 Oct 2012 Edition Rev 2 lt is essential that the auditor is in possession of this service manual in order to ensure that important information is understood w All work performed on the cylinders and components are only allowed by trained and authorized staff only 5 2 Procedure of the cylinder inspection 5 2 1 Examination of documents At first the cylinders data must be recorded and be compared with the data from the logbooks if applicable 5 2 2 Data of the label example A S TORE CNG 4 xperion Energy amp Environment GmbH penotusater MM YYYY canker Type TH_500 Var HY_1 ee 350 L nnnnnnnlYY sea ala 142 kg woring senice pressure 29 MPa 25000 kPa 3626 psig 15 C rentuvearotapprvat gt 03 2012 ast ese 37 9 MPa Date of first pressure test MIM YYYY TS 40 C 65 C Hol oho MM YYYY Max Anzugsmoment 130 Nm Genehmigungsnummer ISO 11439 Maximum torque Ty peapproval 2011 CERT 010 Nur vom Hersteller zugelassenen Druck 110 R 000227 minderer verwend
7. Directly after the filling of the cylinder the pressure may exceed this pressure For example 25MPa 250bar 3626psi Permitted working 40 to 65 40F to 149F temperature Test pressure Pressure which is applied on the cylinder at the water pressure test in order to test the cylinder s strength For example 37 5MPa 3 75bar 5438psi Date of first pressure test Date on which the cylinder has first been tested and approved by the TUV MM YYYY by the certifying institute according to IS011439 by the certifying institute according to ECE R 110 According to This cylinder is approved according to DOT FMVSS304 NGV2 07 by an independent cylinder inspector 5 2 3 Optical control of the cylinder s surface X Store cylinders are partly handmade Therefore small optical differences between the cylinders may occur Superficial cracks The first pressure test during the manufacturing process of the cylinder may result in uncritical inter fibre failure These inter fibre failure are small harmless cracks in the surface of the cylinder The cracks usual occur in circumferential direction When a lot of resin accumulates at the surface cracks may also occur in axial direction These cracks do not have an impact on the function of the cylinder 15 21 Service Manual X STORE TH 500 v IN Oct 2012 Edition Rev 2 A pe r O N This part of the inspection is considered passed if the cracks are not running through t
8. Service Manual Pressure Cylinder A O TORE Type TH_500 Variant TH 500 HY 1 Variant TH_500 HY 2 Variant TH 500 HY 3 Variant TH 500 HY 4 Variant TH_500_ HY 5 Manufactured by xperion xperion Energy amp Environment GmbH PlanckstraBe 15 32052 Herford Germany 1 21 Servi STORE NAFI SE E xperion TABLE OF CONTENTS 1 General safety instructions sessnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnnm 3 1 1 Relevant Standards 3 In addition to this service manual for the operation of CNG Systems the following standards must be taken into account 3 e ECE R 110 3 e ECE R 115 3 e DIN EN ISO 11439 3 NGN2 3 1 1 Sign description 3 2 Environmental protection and waste disposal ccceesceeeeeeeeneeeneeeeneenees 4 3 Operating CONGINIOMS cisccsiscccseneiei sco ssapsiraneesincsetvneesntieenveter everett ere 5 3 1 General
9. d 6 The adapter is mounted with 400Nm Applying a torque gt 400Nm to the cylinder is not permitted Tighten the valve with the matching specialty tool with a torque of 130Nm Applying a torque of 130Nm 5Nm to the adapter cylinder is required 7 Mark the transition from valve to the cylinder with a drop of sealing mark paint 8 Record the change of the valve in the documents During dismounting processes the technician has to pay attention that no part of the PTFE tape gets into the cylinder 9 Test the system cylinder adapter valve for leaks 10 21 Service Manual X STORE TH 500 VAAI Oct 2012 Edition Rev 2 A D eC r O nN Installation of valves with o rings sealing system 1 Only xperion authorized valves and relief devices are to be used For a listing of such approved devices please contact xperion or your local distributor 2 Ensure that the thread of the valve and adapter is compatible to the cylinder threads X Store cylinders have a connecting thread of 1 125 12UNF 3 Check all threads for damage and dirt Remove dirt with a clean cloth Damaged parts must be replaced 4 Check that the o rings supportrings and the o ring groove has no damage If necessary replace the o ring supportring Please note that the Support ring has two different sizes The concave side is orientated to the o ring Add a small amount of Vaseline to the o ring and support ring During the complete preparation the
10. egree of delamination a repair at xperion ENERGY amp ENVIRONMENT may be feasible To evaluate the level of damage it may be helpful to send a digital photo to xperion ENERGY amp ENVIRONMENT GmbH or your local distributor In cases of doubt xperion ENERGY amp ENVIRONMENT GmbH or your local distributor is to be informed 5 2 4 Inspection of connected components Control of the valve The valve piping adapter must be in faultless condition Damaged components must be replaced The handwheel has to rotate smoothly 18 21 Service Manual X STORE TH 500 v 7 Oct 2012 Edition Rev 2 A D e f O nN Before unscrewing the valve or valve components it must be ensured that the cylinder is depressurised See also chapter 4 3 Please check that the glass bulb is completely intact at valves with a thermal pressure release device There should be no defects on such pressure release devices Damaged parts have to be replaced w Before unscrewing the adapter or adapter components it must be ensured that the cylinder is completely depressurised See also chapter 4 3 Leak test Xperion recommends using leak detection spray or soapsuds when leak testing composite cylinders Information of the testing by leak measuring machines so called sniffer devices and leak rate tests can be provided by xperion The evaluation of the leak test must be done under the regulations of the ECE R110 Extract out of the 7 adjusted versi
11. en For Use Only With The DOT FMVSS 304 Container Manufacturer s Approved Pressure NGV2 07 Type 4 Relief Devices and Valves This container should be visually NUR CNG CNG 4 CNG ONLY Seriennummer serial number zul Betriebste mperatur working temperature ECE Genehmigungsnummer ECE Typeapproval entspricht according to If there is a question about the proper use installation or maintenance of this container contact xperion Energy amp Environment GmbH D 34123 Kassel Otto Hahn Str 5 call 49 0 561 58549 0 Picture 2 14 21 inspected after a motor vehicle accident or fire and at least every 36 months or 36 000 miles whichever comes first for damage and deterioration Servi STORE NAFI Ee aie xperion NUR CNG CNG ONLY This cylinder is for compressed natural gas use only xperion Energy amp Manufacturer of the cylinder Environment GmbH Do not use after The maximum lifetime of a CNG cylinder After exceeding this date the cylinder must be decommissioned Date is listed as MM YYYY ID number ID number of cylinder If applicable the version number Serial number Continuous serial number of the cylinder ID number and serial number together guarantee an explicit allocation of the cylinder nnnnn YY Nominal water volume in litre at ambient pressure Empty weight Weight of the cylinder without the valve in kg Working pressure Working pressure after temperature balancing
12. erion or an authorized partner to re confirm its further suitability It is important to provide all available documentation of the accident i e photos Without such testing it is prohibited to use the damaged cylinder 3 5 2 Fire lf a cylinder has been involved in an event of a fire it must be decommissioned and destroyed according to chapter 2 4 Installation instructions All work on cylinders and gas equipment requires knowledgeable staff 4 1 Assembly of a cylinder into a vehicle The service technician who is doing the assembly of the car with the CNG Cylinders has to find out the best space in the car In special the following points have to be taken into account 7 21 Service Manual X STORE TH_500 wry Oct 2012 Edition Rev 2 JA D OC r O nN e Container assembly shall be mounted at least 100mm from the exhaust system of the vehicle It must be assured that the surface top of the cylinder never exceeds 65 e f assembly in the undercarriage of the vehicle is planned the cylinder must be sufficiently protected from road debris and contact e f assembly in the vehicle interior is planned the cylinder must be sufficiently protected against loose articles e g heavy tools or aggressive media e g solvents e Regulations ECE R110 ECE R115 ISO 11439 NGV2 and country regulations should be followed 4 1 1 Bracket mounting The distance between the strap mountings must be at least times the cyli
13. he fibres In cases of doubt xperion ENERGY amp ENVIRONMENT GmbH or your local distributor is to be informed Abrasion marks and scratches Abrasion marks scratches or scrapings i e through loose tie straps or rubber supports are without any harm to the cylinder as long as they do not reach the fibre itself It is important to find the reason for these damages before reinstalling the cylinder in order to avoid further damages When the scratches reach the fibre the cylinder must be decommissioned 16 21 Service Manual X STORE TH_500 Y li Oct 2012 Edition Rev 2 A D OC r O nN This part of the test is considered as passed if the scratches are within the resin layer but not the first fibre layer In cases of doubt xperion ENERGY amp ENVIRONMENT GmbH or your local distributor is to be informed Points of impact Shock or impacts onto the cylinder may be difficult to find and to evaluate the effect of it If the affected spot shows only small signs of scratches the cylinders is still usable lf the affected spot shows damage to the fibre the cylinder must be decommissioned Delamination 17 21 Service Manual X STORE TH 500 VIAASFI Oct 2012 Edition Rev 2 ADe r O nN Delamination In cases of doubt xperion ENERGY amp ENVIRONMENT GmbH or your local distributor is to be informed Loose fibre ends Loose fibre and delamination of fibre ends are not acceptable Depending on the d
14. l cracks not deeper than up to the first fibre layer L Yes allowed L No not allowed 5 2 Abrasion marks and scratches not deeper than up to the first fibre layer L Yes allowed L No not allowed 5 3 Points of impact are not or only to a small degree existent 5 4 Loose fibre ends are non existent 5 5 Valve and safety adapters are not damaged 5 6 The complete cylinder and attached components are without any leaks Signature of authorized auditor Each test criteria with not allowed errors causes the failure of the complete inspection After a possible repair the complete checklist must be processed again The inspection has only been passed if all cylinders positively tested 20 21 Service Manual X STORE TH 500 v Oct 2012 Edition Rev 2 A D e f O nN 6 Approach at failure of a cylinder xperion keeps record on all incidents which occur with X Store cylinders lf a cylinder fails during a pressure test xperion must be informed Please send the serial number of the cylinder and the reason for failure to contact address from chapter 7 7 Contact address xperion Energy amp Envrionment GmbH Otto Hahn StraBe 5 34123 Kassel Germany Phone 49 0 561 58549 0 Fax 49 0 561 58549 29 info xperion de www xperion de 21 21
15. ments for the auditor 13 5 2 Procedure of the cylinder inspection 14 SPAR Examination of documents 14 s VVA Data of the label example 14 a0 Optical control of the cylinder s surface 15 5 2 4 Inspection of connected components 18 D2 Procedure of the leak test 19 5 3 Checklist for the periodical inspection with X Store cylinders 20 6 Approach at failure Of a CYLINGeD cccceeeeeeeeeeeeeeeeeeeeseeeeeeeeeeenseeeeeeeneeeees 21 7 Contact address eorsccatetecccaetetecadecctevaeexcoasensudesesesudesvaosseugeaecussiuasexdesvexeuereesiiy 21 2 21 Service Manual X STORE TH 500 VwIAAFIC Oct 2012 Edition Rev 2 A D e f O nN 1 General safety instructions 1 1 Relevant Standards In addition to this service manual for the operation of CNG Systems the following standards must be taken into account e ECER110 e ECER115 e DIN EN ISO 11439 e NGV2 1 1 Sign description Prohibition signs Work is allowed by authorized persons only Warning of a danger point or safety note Warning of cold surfaces Service
16. nder During service a periodical inspection according to chapter 5 must be carried out After the expiry of the useful life the cylinder must be destroyed and disposed in accordance with the instructions from chapter 2 3 2 Gas composition lt must be ensured that the natural gas CNG corresponds with i e the ECE R 110 chapter 4 5 regulations when filling the cylinders The operator of the filling stations is responsible for this Arid Gas Cylinder TH_500_HY_4 is designed for a operating pressure of 20MPa 200bar 5 21 Service Manual X STORE TH 500 v 4 Oct 2012 Edition Rev 2 A D e f O nN Water vapour content lt 32mg m Pressure dew point at 20MPa minimum 9 Hydrosulphide and other soluble sulphides lt 23mg m Oxygen lt 1Vol Humid Gas e Water vapour content gt 32mg m Pressure dew point at 20MPa gt 9 Hydrosulphide and other soluble sulphides lt 23mg m Oxygen lt 1Vol Carbon dioxide lt 4Vol Hydrogen lt 0 1Vol 3 3 Temperature ranges X Store Cylinders are tested and homologated for a stabilized gas temperatures of 40 to 650 Exceeding this temperature range is not permitted at any time Even short time exposure to temperatures gt 65 during any hot wor k e g welding thermal cutting etc close to the cylinder is forbidden Furthermore the operator has to assure that the cylinder does not come in contact with any sparks caused by hot works 3 4 Cylinder ha
17. ndling To avoid injuries to the hands through loose fibre ends gloves must be worn at all times Cylinders may never be lifted at the valves adapters because this might cause damages not seen during visual inspection Even minor forces can cause a deformation of the electromagnetic device of the valve which may cause a malfunction of the automatic sealing device When dealing with composite pressure cylinders it is particularly important to ensure that no impact load i e through falling cylinders may occur To avoid abrasions at the cylinder s surface rubber layers must be used 6 21 Service Manual X STORE TH 500 v 7 Oct 2012 Edition Rev 2 A D e f O nN When storing cylinders the following points have to be considered e The cylinders must be secured against rolling or sliding e lf valves or adapters are screwed into the cylinder the openings must be closed with plastic plugs in order to eliminate the penetration of dirt particles e For long term storage more than one day the cylinder must be protected against UV radiation e Rubber layers should be used to avoid damage of the cylinder s surface by abrasion e tis not allowed to leave the cylinder without internal pressure fro more than 3 months 3 5 Behaviour after an accident or fire 3 5 1 Accident lf a cylinder has been involved in an accident and this incident resulted in a damage of the cylinder it must be tested by the company xp
18. ndrical length of the cylinder Ly x Ley In general the strap mountings should be installed at the outer ends of the cylinder Nevertheless the distance to the cylinder ends Leng should be at least 50mm Leyi Example Picture 1 When using strap mountings rubber layers must always be between the strap and the cylinder This rubber layer absorbs the axial and tangential expansion of the cylinder without damaging the surface of the cylinder xperion prescribes a rubber thickness of at least 2mm When using strap mountings produced by e g the company Hydac the rubber layer is part of the mounting system for Type 4 cylinders As an example Cylinder TH_500 HY_5 with a diameter of 500mm has an expansion of the circumference of about 0 8 at working pressure This equals an expansion of 8 21 Service Manual X STORE TH 500 v 7 Oct 2012 Edition Rev 2 A D e f O nN the circumference of 12 5mm or an expansion of the diameter of 4mm between 0 and 250bar The axial elongation is 0 5 or about 7 5mm between 0 and 250bar Similar expansion percentages for the other cylinder sizes covered by this manual can be expected If further clarification is required please contact xperion or your local distributor The TH_500_HY_5 is designed for belly mounting only 4 1 2 Mounting The variants of TH_500 HY_1 3 have been specifically designed to allow a vertical storage If there are question please contact xperion 4 1 3
19. on from 37 of February 2008 chapter 17 1 5 The system may not have permeable spots That means that the system must be bubble free for three minutes Please consider that small sized bubbles may appear when using leak detection spray These bubbles must disappear after a few seconds These bubbles have nothing to do with permeation or leakage of the cylinder Should a cylinder or valve be permeable a clear bubble growth can be detected 5 2 5 Procedure of the leak test The cylinder must be filled up to the appropriate working pressure After filling the cylinder must rest for at least 2 hours in order to gain stable pressure and stable temperature conditions If the cylinder is heated due to the filling the leak detecting spray or the soapsuds may evaporate which causes incorrect test results The complete cylinder should be leak tested Especially the connection valve cylinder adapter must be tested because these are the most critical joints If bubbles emerge within 3 minutes the test has not passed Leaking components must now be replaced and the leak test carried out again 19 21 Service Manual X STORE TH 500 v 4 Oct 2012 Edition Rev 2 A D e f O nN 5 3 Checklist for the periodical inspection with X Store cylinders 1 Serial number of the cylinder 2 Year and month of the initial approval 3 Date of last inspection 4 Executing company name of auditor 5 Test criteria 5 1 Superficia
20. s case please proceed as shown in chapter 2 lf you have to remove the valve from the cylinder please have a look into the standard of ISO 11623 2002 page 25 For further instructions regarding the removal and service of the valve please refer to the valve manufacturer instructions available by contacting xperion or your local distributor 5 Periodic Cylinder Inspection Gasanlagenpr fung GAP according to ECE R 110 ISO 11439 NGV2 At regular intervals however no longer than 48 months cylinders for CNG use in vehicles must be inspected The test intervals are defined within the ECE R110 ISO 11439 and NGV2 respectively within the regulations of each country During the inspection the cylinder is examined whether any inadmissible damages have occurred Periodic inspections with water pressure tests and dismounting of the cylinder are no longer necessary Every vehicle run with CNG must be undertaken a GAP For example in Germany the period between the last GAP and the next general vehicle inspection may never be longer than 12 months Due to the inspection interval of 24 months between the general vehicle inspections of a passenger car the maximum inspection interval adds up to 36 months The standard instructs that a visual inspection must be performed every three years Similar regulations apply accordingly in other countries National regulations should always be followed If in doubt please contact xperion or your local

Service Manual X-STORE_TH_500_v2

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