X-STORE periodic inspection (SLW)

X-STORE periodic inspection

for Super Lightweight V2 modules

The following document is intended to be used as a guideline, based on the standards upon which the units
were built. It is the owner responsibility to observe and apply local legislation and procedures.
X-STORE periodic inspection (SLW)
1. Object
Super Lightweight version of X-STORE Multi Element Gas Containers, must be according to ISO 11119-3, ISO
11623 and EN 12245, inspected in a regular basis after manufactured. This inspection includes the container as
system, meaning the cylinders, piping, valves, fittings, supports, measuring devices and container structure
must be inspected. This document is the guideline for the inspection procedure regarding the codes under
which the SLW version of X-STORE units is build.

There is the possibility, developed together with the BAM (Federal Institute for Materials Research and
Testing), of an assessment based in a 5 cylinder per container partial sample slow burst test, where and
when the local authorities do so authorize it.

This means that when local authorities accept it, the internal visual inspection of all cylinders can be replaced by
a 5 cylinder per container slow burst test. This does not replace the remaining inspection procedures.

2. In factory first inspection

The in-factory first inspection after production of the container is not considered in this document.

3. Periodicity
First inspection of the complete unit must be done 5 years after the in-house inspection (manufacturing date).

Afterwards it must be inspected according to the following table:

Item Periodicity Inspection to be done Relevant standard

Container structure every 24 month after first According to point 1 and CSC (Annex II,
inspection 2 of inspection table. Regulation 2 point 4)

Dekra Hinweis: 2008

Complete system every 5 year after first According to the ISO 11623:2002 (Table
including piping, inspection complete inspection 3)
equipment and internal table.
visual inspection of the
cylinders
D/BAM/DG-13-001
(TC_500 Type
approval)

NOTE: The periodicity and the items to be checked can be more demanding according to national regulations.
The unit owner must observe the local demands.

The periodic inspections cannot be replaced by the periodic maintenance program and do not replace it.
X-STORE periodic inspection (SLW)
4. Inspection expert and certificates
Tests and inspections should be carried out by the expert approved by the competent authority and a certificate
shall be issued showing the results, even in the case of negative results. The unit documentation must be
updated as also the marking on the CSC plate.

5. Safety

As in any other work performed on or around the X-STORE containers, all security
measures must be guaranteed. This includes proper grounding before starting the inspection, prevention
measures such as having fire protection devices at hand, and a well-lighted, well ventilated working area. A
safety perimeter must be established. Please consider all the security instructions referred to in the
container´s manual.

Do not start any work before you have your safety equipment on. A safety helmet,
gloves and safety shoes are mandatory. More safety equipment, e.g. a harness, could apply depending on
the nature of the work to be done.

Always check for any leakage in the system before starting any work.

Always purge the pipes with nitrogen before starting any work.

Container periodic inspections should only be performed by xperion authorized trained

personnel.
X-STORE periodic inspection (SLW)
6. Preparation activities

Before any inspection, unit should be tested for leakage, cylinders closed and lines purged.

For the cylinders internal visual inspection the complete system must be purged, including the
cylinders.

>> Resources

Quant. Units Description Code

1 Pc. Metric socket wrench kit w/ ½” and ¼” ratchet incl. adapters
1 Pc. Combination wrench kit (10mm – 42 mm)
1 Pc. Adjustable spanner wrench
1 Pc. Small telescopic mirror
1 L Soapy water spray
50 L Nitrogen bottle with pressure reducer (min pressure 50 bar)
1 Pc Portable flashlight

6.1 Container should be delivered for inspection with no more than 20 bar but with at least 10 bar.

6.2 Container must be parked in a well-ventilated area with good light and a safety perimeter (other containers
or activities should not interfere in this area).

6.3 When the tractor remains connected to the chassis, tractor must be braked and engine off. Wheel chocks
must be placed on all rear wheels.

6.4 Chassis landing gear must be in full contact with ground. If container is for any reason full or its weight
overcomes the landing gear capacity hydraulic-jacks must be applied – these should be in full contact with the
ground and if auxiliary support parts are used (such as wood blocks between jacks and ground/container)
complete stability must be assure.

6.5 If the tractor is not connected to the chassis or the container is removed from the chassis, a sturdy surface
must be provided – ensure that container weight is accounted for and full stability is assured.

6.6 Connect container to earth connection – grounding connection must be independent, e.g. cannot be shared
with the electrical network grounding.

6.7 With soapy water check all piping, valves and cylinder valve adapters for leakage. In some situations the
use of a small telescopic mirror is required. Start the check-up procedure at the container cabinets, then piping,
finally cylinder valve adapters and valves. Once each cylinder is checked, close the correspondent cylinder
valve. All cylinders must be checked and all cylinder valves closed.

6.8 If the inspection to be done is the 5 yearly complete inspection (the one that includes internal visual
inspection of the cylinders), all the cylinders must be re-open before venting.

6.9 Vent the system through the vent line valve. Connect the nitrogen to the quick coupling and fill the piping
with at least 50 bar. More than 100 bar is not required. Empty the piping through the vent line. Repeat this
operation 3 times for a complete pipe purging.
X-STORE periodic inspection (SLW)

Nitrogen is a relatively inexpensive, widely available, inert gas that is perfectly suitable for
purging. Using compressed air or any other non-inert gas might lead to a dangerous CNG / oxygen
explosive concentration. Only use nitrogen for purging.

The internal inspection of the cylinders requires an approved inspection body with proper
facilities and resources - in case of any doubt please contact xperion before your inspection period expires.

6.10 For the internal visual inspection of the cylinders, after purging, the cylinders must be taken out of
the unit in order to be inspected. This process is described in its own service instruction, available
upon request.
X-STORE periodic inspection (SLW)
7. Inspection methods and acceptance criteria

A list of the items to be checked and the inspection method is provided along with the acceptance criteria.
Although the list is extensive the inspector must be aware of other possible not listed problems and if found
report them.

A report based on the inspection list must be issued and signed by the inspector and customer - even if the
inspection results in non-conformity. A copy should be issued to xperion.

The report must contain all the items checked and if they are conform or not according to the acceptance
criteria, when not-conform the found problem must be described and documented, preferably with photos.

For the possibility of an assessment based in a 5 cylinder per container partial sample slow burst test, please
contact xperion.

When doubts occur over the acceptance criteria the manufacturer must be addressed.

Item Inspection method Acceptance Criteria

1. Container
Structure

1.1 Tarps A visual inspection must be carried Tarps must be tensioned, completely
out on all tarp elements. stretched, without cuts or tearing.

For systems assembled with rivets; all

rivets must be secure, no corrosion is
allowed on the rivets or their mounting
strip.

For systems with rail assembly, rails

must be in perfect condition, without
deformations, and clamps must
completely stretch the tarp. No
corrosion is allowed in the rail or clamp
mechanism.

1.2 Corrosion Visual inspection. Check for signs of The container structure is galvanized,
corrosion in container frame but some corrosion might occur due to
elements, cabinet doors, locks and scratching or weathering.
top plates.
Small isolated spots of corrosion are
acceptable.

Corrosion that spans a complete

element is not acceptable.

Item Inspection method Acceptance Criteria

X-STORE periodic inspection (SLW)
1.3 Mechanical Visual inspection. Check for Small isolated dents in the container
Deformations mechanical deformations in frame are acceptable as long as they
container frame elements, metal don´t result in element center line
sheet panels, top plates and cabinet deviation. Mechanical deformation in
doors. junction elements is not acceptable.

Small isolated dents in the metal sheet

panels are acceptable. Contact
between the panels and cylinders or
piping due to deformations is not
acceptable.

Top plates must be flat and fastened.

Dents or loose parts are not
acceptable.

Cabinet doors must open and close

freely and the locks must work
properly.

For this step use your hand or a Broken bars are not acceptable. Loose
rubber hammer to ensure tarp is not bars are not acceptable.
damaged.

The diagonal bar´s integrity can be Missing central protection rubber is not
tested by pounding them through the acceptable.
tarps. Removing the tarps isn't
required. Pound on the bars center
cross and corner points.

1.4 Signs, stickers and Visual inspection. Illegible or missing safety signs,
plates. container identification and stickers
are not acceptable.

Sunburned reflective stickers are not

acceptable.

Illegible or un-updated CSC plate is

not acceptable.

Item Inspection method Acceptance Criteria

X-STORE periodic inspection (SLW)
1.5 Chassis Visual inspection of corner points,
overhangs, container frame lower
side elements and container support
bars.
Space between container support bars
and chassis is not acceptable.
Overhangs resting on the chassis are
not acceptable.
Corner casts under stress, indicating
that they are load points, are not
acceptable.
Frame lower side elements resting on
the chassis is not acceptable.

2. Cylinder support

2.1 Top bearing Visual inspection. Cracked, broken, loose or gouged

bearing case or bearing is not
acceptable.

Gap between case bearing and

support bars is not acceptable.

By hand check if the valve adapter Tilting of the valve is not acceptable.
tilts. The maximum gap between valve
adapter and bearing must be less than
0,3 mm.

2.2 Lower groove nut Visual inspection. Corrosion, gouges or cracks are not
acceptable.

Check nut tightness with a torque A lower grooved nut that is not
wrench using a torque slightly lower completely fastened or tight with less
(300 Nm for example) than the than required torque is not acceptable.
required (350 Nm).

Item Inspection method Acceptance Criteria

X-STORE periodic inspection (SLW)
3. Cylinders

3.1 Cylinder leakage Leak test with soapy water on the Leakage is not acceptable.
upper and lower boss parts and
valve adapter. Bubbles indicate
leakage.

3.2 Cylinder surface: Visual inspection. Acceptable situations:

scratches, loose
fibers, delamination,
impact damages. Scratches:
Scratch traces on the surface are
allowed! Individual filaments of the
fibers can separate from the surface.
Avoid pulling on the loose fibers. Such
scratches can result from sliding the
part on a wooden pallet.

Dull surface: The surface is dull, but there are no

loose fibers.

Glossy surface:
The Cylinder has a glossy surface.
The striped pattern of the individual
fibers is visible

Visual inspection. Acceptable situations:

X-STORE periodic inspection (SLW)
3.2 Cylinder surface: Air bubbles: Air bubbles in the surface have no
scratches, loose negative impact of the function of the
fibers, delamination, cylinder.
impact damages.
(cont.)

Trapped fiber:
During the winding process a piece of
fiber has been trapped in the resin.
This has no negative impact on the
function of the cylinder.

Ridges:
Raised ridges up to 5mm higher than
the surrounding area are acceptable.

Gaps:
Gaps of up to 4 mm are acceptable in
the diagonal wrapping.

3.2 Cylinder surface: Dry and/or dull finish:

X-STORE periodic inspection (SLW)
scratches, loose A section wrapped drier than the
fibers, delamination, surrounding area is acceptable; a dull
impact damages. finish next to a glossy finish may be
the result. This has no negative impact
on the function of the cylinder.
The width of the wrapping must be at
least 22 mm.

Visual inspection: Not acceptable situations:

Layer separation: Layer separation is not acceptable. A

complete roving is not allowed to be
detached.

Milky background:
A milky white background is the result
of forceful contact. This is not
acceptable.

Damaged surface:
The cylinder’s surface is damaged. A
roving has become detached due to
contact with a foreign object.

3.3 Top and bottom Visual inspection Sunburned, gouged or cut material is
X-STORE periodic inspection (SLW)
protective rubber not acceptable.

Manually check for tight fit between Loose protective rubbers are not
the protective rubber and the acceptable.
cylinder.

3.4 Liner* Internal visual inspection* Discoloration, chemical corrosion or

abrasions of the liner are not
Method use shall be endoscopy. acceptable.

Any cylinder showing presence of Liner separation is not acceptable.

foreign matter or signs of more than
light surface corrosion shall be
cleaned internally under closely
controlled conditions by controlled
water jet cleaning or a method
recommended by the manufacturer.
Any chemical solutions used for
cleaning and/or cleaning methods
used shall be strictly in accordance
with the cylinder manufacturer‘s
procedures.

After cleaning and drying, the

cylinders shall be inspected again
and any cylinder showing
discoloration or other surface defects
such as heat damage shall be
permeability tested.

* this must be applied also to the

sample of 5 cylinders per
container, if sample test are
approved by local authorities.

3.5 Neck threads* The neck threads (valve Damaged, cracked, deformed threads
connections) of the cylinder shall be are not acceptable.
inspected and gauged to ensure that
they are:
– clean and of full form;
– free from burrs or damage;
– free from cracks.

* this must be applied also to the

sample of 5 cylinders per
container, if sample tests are
approved by local authorities.
X-STORE periodic inspection (SLW)
3.6 Permeation tests Where there is doubt concerning The rate of loss shall be less than 0,25
(according to ISO the type or severity of a defect ml.hr-1 per liter of cylinder water
11623:2002) found on visual inspection capacity. If the leakage rate is greater
additional tests or methods of or equal to 0,25 ml.hr-1 per liter of
examination may be applied. cylinder water capacity then the
cylinder shall be rejected.
The following method for
permeability testing is recommended
but alternatives are permitted which
achieve the same result.
This entire test shall be performed at
a temperature of (20 ± 5) °C. The
cylinder shall be charged to its
working pressure with air or an inert
gas and the valve and the junctions
of the liner (if present) with the
metallic bosses or rings shall be
visually checked for leaks (e.g. with
soapy water). Any leaks shall be
eliminated, where the design
permits, before proceeding with this
test.
The cylinder is then recharged, if
necessary, to its working pressure,
weighed and the mass of the stored
gas recorded. The accuracy of the
weighing scales shall be such as to
detect the expected mass change.
The cylinder shall be weighed after
24 h (or longer in case of any doubt)
and the loss of mass shall be
determined.

3.7 Pressure test Each cylinder* shall be submitted to The permanent volumetric expansion
a pressure test using a suitable fluid, shall not exceed 5 % or such lower
(according to ISO normally water, as the test medium. figure as required by the competent
11623:2002) authority for a specific design.
This may be a proof pressure test, or
a volumetric expansion test (see
annex C), as appropriate to the
design of the cylinder.

The method used shall not reduce

the integrity of the cylinder.

* A sample test of 5 cylinders per

container can be done, if sample
tests are approved by local
authorities.
X-STORE periodic inspection (SLW)
4. Cylinder Valves
4.1 Leakage Leak test with soapy water between
valve and cylinder, fittings and safety
devices. Bubbles indicate leakage.
4.2 Manual operation Close all cylinders and vent the
section line. Open, listen for flow
noise, and immediately close the
valve. Flow noise indicates valve
operation.
4.3 Safety devices Visual inspection of burst disc and
TPRD devices.
4.4 Corrosion and Visual inspection of valve body,
handles. handles and fitting connections.
Leakage is not acceptable.
Valve handles must close and open
the valve fully. Valve should operate
freely without resistance.
Flow noise with a closed valve
indicates a faulty valve.
TPRD bulb must be intact. A cracked
or broken TPRD bulb is not
acceptable.
The burst disc must be intact.
Some minor isolated corrosion points
are acceptable.
Corrosion on fittings is not acceptable.
Broken, gouged or cracked valve
handles is not acceptable.
X-STORE periodic inspection (SLW)
5. Piping
5.1 Leakage Use soapy water to leak test every
pipe fitting including the manifold.
Bubbles indicate leakage.
5.2 Support Visual inspection of pipe support
brackets.
Manually check that the pipes fit tight
to the brackets.
5.3 Corrosion and Visual Inspection. Ensure to not
deformation confuse corrosion with dirt.
6. Section valves
6.1 Leakage Use soapy water to leak test the
valve body and its fittings. Bubbles
indicate leakage.
6.2 Internal Leakage Close all sections valves. Vent the
(unwanted passage manifold through the vent valve.
of gas through a Close the vent valve. If the pressure
closed valve) reading in manometer rises it
indicates an internal leakage.
6.3 Manual operation Close all section valves. Open the
vent valve. Open a section valve,
listen for flow noise and then
immediately close the valve. Flow
noise indicates valve operation.
6.4 Corrosion Visual inspection of valve body and
its fittings.
Leakage is not acceptable.
Broken, cracked, gouged or loose
brackets are not acceptable. A gap
between brackets base and support
bars is not acceptable.
Corrosion of brackets metal holder is
not acceptable.
All pipes must be held tight by the
support brackets.
Corrosion is not acceptable.
Bent, dented or pipes with deep
scratches are not acceptable.
Leakage is not acceptable.
Internal leakage is not acceptable.
Valve must close and open fully.
Valve should operate freely without
resistance.
Ball valves have only one closed
position. A false closed indication is
not acceptable.
Some minor isolated corrosion points
on the valve body are acceptable.
Corrosion on fittings is not acceptable.
X-STORE periodic inspection (SLW)
7. Main valves

7.1 Leakage Use soapy water to leak test the Leakage is not acceptable.
valve body and its fittings. Bubbles
indicate leakage

7.2 Internal leakage Close all sections and vent valves. Internal leakage is not acceptable.
(unwanted passage Close main valves.
of gas through a
closed valve) Ensure to have at least 10 bar of
pressure in the manifold.
Connect an open hose to the quick
coupling. Ensure the hose is held
secure in to a fixed point with a
safety chain.

If the pressure reading in manometer

decreases it indicates an internal
leakage.

7.3 Manual operation Close all main valves and vent valve. Valve must close and open fully. Valve
Open all section valves. should operate freely without
resistance.
Connect a free open hose to the
quick coupling. Open the main valve,
listen for flow noise and immediately
close the valve.

Flow noise indicates valve operation.

8. Couplings

8.1 Corrosion and Visual Inspection Some minor isolated corrosion points
deformation are acceptable.

Corrosion in the sealing area is not

acceptable.

Dents or cracks are not acceptable.

8.2 Leakage Use soapy water to leak test the Leakage above 5 bar in connection
quick coupling body and connection port is not acceptable.
port. Bubbles indicate leakage.
Leakage in fittings is not acceptable.
X-STORE periodic inspection (SLW)
8.3 Dust protection Make sure the dust protection caps Missing dust protection caps are not
caps fit tighten and chains are not broken. acceptable.

Check if the dust protection cap is Dirt inside the dust protection cap is
clean inside. not acceptable.

9. Vent line and vent

line valve

9.1 Corrosion, Visual inspection Corrosion on vent line pipe is not

deformation and acceptable.
support
A missing or loose support bracket is
not acceptable.

Some minor isolated corrosion points

in the vent line valve are acceptable.

9.2 Leakage Use soapy water to leak test the vent Leakage is not acceptable.
line valve body and its fittings.
Bubbles indicate leakage.

9.3 Internal leakage With the vent valve closed check at Internal leakage is not acceptable.
(flow passage when the exhaust of vent line for gas flow.
vent valve is close)

9.4 Manual operation
Open one section valve. Open the
vent valve, listen for flow noise and
immediately close the valve. Flow
noise indicates valve operation.
Valve must close and open totally.
Valve must operate freely without
resistance.
Ball valves have only one close
position. False close indication is not
acceptable.

10. Grounding earth

set

10.1 Cable and Visual inspection A missing crocodile clip plug is not
crocodile clip plug acceptable.

With an ohmmeter set to a low An interrupted circuit is not acceptable.

measuring range (less than 1 KΩ)
measure conductivity between
cable´s crocodile clip and piping.
Reading must be near 0 Ω. Infinite or
extremely high values indicate circuit
is interrupted.
X-STORE periodic inspection (SLW)
10.2 Reel Visual inspection Some minor isolated corrosion points
are acceptable. A missing reel is not
acceptable.

Test the reel by rolling at least two A jammed reel is not acceptable.
complete turns of cable.

11. Safety valve

11.1 Leakage Use soapy water to leak test the Leakage is not acceptable.
valve body and its fittings. Bubbles
indicate leakage.

11.2 Internal leakage Ensure that the exhaust pipe Internal leakage is not acceptable.
(flow passage protective caps are removed.
when valve isn´t With the normal working pressure
activated) (P<250 bar) check for gas flow on
the safety valve exhaust.

11.3 Corrosion and Visual inspection Corrosion on the valve body is not
deformation acceptable. Exhaust pipe corrosion,
bending or dents are not acceptable.
Corrosion on fittings is not acceptable.

12. Excess flow valve

(when applicable)

12.1 Leakage Use soapy water to leak test the Leakage is not acceptable.
valve body and its fittings. Bubbles
indicate leakage.

12.2 Operation With all the main valves closed and Valve must close and reset
the corresponding section valve automatically.
open, connect an open hose to the
quick coupling.
Ensure hose is held secure in to a
fixed point with a safety chain.
Quickly open the main valve so that
the flow can reach its maximum
value. The excess flow valve should
close quickly and automatically reset
after pressure equalization.

12.3 Corrosion Visual inspection Corrosion on the valve body is not

acceptable.
X-STORE periodic inspection (SLW)
13. Temperature
Module

13.1 Battery Check if display is showing any A dead battery is not acceptable.
reading.

13.2 Mounting Check that the temperature module A loose case or content is not
is properly mounted and perform a acceptable.
visual inspection

13.3 Case Open the case and perform a visual Moisture inside is not acceptable.
inspection.
Corrosion on battery contacts or
electronic components is not
acceptable.

13.4 Display reading Watch and record the readings while Values must correspond with the
filling and emptying. known temperature behavior.

14. Pressure Gauge

14.1 Display reading Watch and record the readings while Values must correspond with the
filling and emptying. known pressure available.

Close all section valves and open the The manometer must read 0 bar.
vent line valve.

14.2 Leakage With the vent line valve and main Leakage is not acceptable.
valves closed and the section valves
open, do a leak test with soapy water
on manometer valve body,
manometer body and its fittings.
Bubbles indicate leakage.

Close the manometer valve, remove Manometer valve internal leakage is

the manometer and check for gas not acceptable.
flow on the manometer valve exit.

14.3 Manometer valve Close the manometer valve. Close Valve must close and open totally.
operation the section valves and open the vent
line valve. Check pressure drop in Valve must operate freely without
manometer. If the pressure drops resistance.
quickly it indicates that valve is not
closing.

Close the vent line valve and open

the section valves. Open manometer
valve. The pressure in the
manometer should rise immediately.
X-STORE periodic inspection (SLW)
15. Immobilizer (when
applicable)

15.1 Operation Perform this test first only with the Ability to drive is not acceptable.
left door open, then only with the
right door open and finally with both
doors opened.

With the cabinet doors open, try to

drive away the trailer. Trailer must be
braked and unable to move.

15.2 Support and corrosion Visual inspection A loose mechanism is not acceptable.

Some minor isolated corrosion points

are acceptable.

15.3 Horn (when With the doors open try to drive. Silence during an attempt to drive is
applicable) Horn must be audible. not acceptable.

15.4 Pneumatic Valve Visual inspection Some minor isolated corrosion points
are acceptable.

A dry or torn actuator rubber is not

acceptable.