Phosphorus (max)

.030 .045 .030 .030 Sulphur (max) .030 .030 .030 .030 Silicon (max) .75 1.00 .75 .75 Nickel 8.0/11.0 10.0/14.0 9.0/13.0 9.0/13.0 Chromium 18.0/20.0 16.0/18.0 17.0/20.0 17.0/20.0 Molybdenum 2.0/3.0 Titanium (') Columbium (2) 1 Titanium may not be less than 5C and not more than 0.60% 2 Columbium may not be less than 10C and not more than 1.0%. TABLE 3-CHECK ANALYSIS TOLERANCES Tolerance (percent) over the maximum limit or Element Limit or maximum specified under the minimum limit (percent) Under min- Over maximum limit imum limit Carbon To 0.15 Incl 0.01 0.01 Over 0.15 to 0.40 incl .03 .04 Manganese To 0.60 incl .03 .03 Over 1.15 to 2.50 incl .05 .05 Phosphorus 1 All ranges .01 Sulphur All ranges .01 Silicon To 0.30 incl .02 .03 Over 0.30 to 1.00 incl .05 .05 Nickel Over 5.30 to 10.00 incl .10 .10 Over 10.00 to 14.00 incl .15 .15 Chromium To 0.90 ind .03 .03 Over 0.90 to 2.10 incl .05 .05 Over 15.00 to 20.00 incl .20 .20 866 Pipeline and Hazardous Materials Safety Admin., DOT § 178.53 TABLE 3-CHECK ANALYSIS TOLERANCES-Confinued Tolerance (percent) over the maximum limit or Limit or maximum specified under the minimum limit Element (percent) Under min- Over maximum limit Imum limit Molybdenum To 0.20 Incl .01 .01 Over 0.20 to 0.40 incl .02 .02 Over 1.75 to 3.0 incl .10 .10 Titanium All ranges .05 .05 Columbium All ranges .05 .05 1 Rephosphorized steels not subject to check analysis for phosphorus. (c) Identification of material. Material E = 1.0 (for all other areas). must be identified by any suitable (2) Calculation for a cylinder must be method except that plates and billets made by the formula: for hotdrawn cylinders must be marked with the heat number. S = [P(1.3D² + 0.4d²)] / (D² - dT¹²) (d) Manufacture. Cylinders must be Where: manufactured using equipment and S = wall stress in psi; processes adequate to ensure that each P = test pressure prescribed for water jacket cylinder produced conforms to the retest, i.e., at least two times service presquirements of this subpart. No defect is sure, in psig; permitted that is likely to weaken the D = outside diameter in inches; finished container appreciably. A rea- d = inside diameter in inches. sonably smooth and uniform surface (f) Heat treatment. The completed cylfinish is required. Welding procedures inders must be uniformly and properly and operators must be qualified in acheat-treated prior to tests. cordance with CGA Pamphlet C-3 (IBR, (g) Openings in container. Openings in see $171.7 of this subchapter). cylinders must comply with the fol- (e) Wall thickness. The wall stress at lowing: the minimum test pressure may not ex- (1) Each opening in the container, exceed 24,000 psi, except where steels cept those for safety devices, must be commercially known as 4130X, types provided with a fitting, boss, or pad, se- 304, 316, 321, and 347 stainless steels are curely attached to the container by used, stress at the test pressures may brazing or by welding or by threads. If not exceed 37,000 psi. The minimum threads are used, they must comply wall thickness for any container havwith the following: ing a capacity of 1,100 cubic inches or (i) Threads must be clean cut, even, less is 0.04 inch. The minimum wall without checks, and tapped to gauge. thickness for any container having a (ii) Taper threads must be of a length capacity in excess of 1,100 cubic inches not less than that specified for Ameris 0.095 inch. Calculations must be done ican Standard taper pipe threads. by the following: (iii) Straight threads, having at least (1) Calculation for a "sphere" must 4 engaged threads, must have a tight be made by the formula: fit and calculated shear strength of at least 10 times the test pressure of the S = PD / 4tE container. Gaskets, adequate to pre- Where: vent leakage. are required. S = wall stress in psi; (2) Closure of a fitting, boss, or pad P = test pressure prescribed for water jacket must be adequate to prevent leakage. test, i.e., at least two times service pres- (h) Hydrostatic test. Each cylinder sure, in psig; must successfully withstand a hydro- D = outside diameter in inches; static test, as follows: t - minimum wall thickness in inches; (1) The test must be by water-jacket, E = 0.85 (provides 85 percent weld efficiency or other suitable method, operated so factor which must be applied in the girth weld area and heat affected zones which as to obtain accurate data. A pressure zone must extend a distance of 6 times wall gauge must permit a reading to an acthickness from center line of weld): curacy of 1 percent. An expansion 867 $ 178.53 49 CFR Ch. I (10-1-06 Edition) gauge must permit reading of total ex- (1) Physical test for spheres are repansion to an accuracy of either 1 perquired on 2 specimens cut from a flat cent or 0.1 cubic centimeter. representative sample plate of the (2) Pressure must be maintained for same heat taken at random from the at least 30 seconds and sufficiently steel used to produce the sphere. This longer to ensure complete expansion. flat steel from which the 2 specimens Any internal pressure applied after are to be cut must receive the same heat-treatment and previous to the ofheat-treatment as the spheres themficial test may not exceed 90 percent of selves. Sample plates must be taken for the test pressure. If, due to failure of each lot of 200 or less spheres. the test apparatus, the test pressure (2) Specimens for spheres must have cannot be maintained, the test may be a gauge length 2 inches with a width repeated at a pressure increased by 10 not over 1½ inches, or a gauge length percent or 100 psig. whichever is the at least 24 times the thickness with a lower. width not over 6 times the thickness is (3) Permanent volumetric expansion authorized when a wall is not over 3/16 may not exceed 10 percent of the total inch thick. volumetric expansion at test pressure. (3) Physical test for cylinders is re- (4) Containers must be tested as folquired on 2 specimens cut from 1 cyllows: inder taken at random out of each lot (i) Each container to at least 2 times of 200 or less. For lots of 30 or less, service pressure; or physical tests are authorized to be (ii) One container out of each lot of made on a ring at least 8 inches long 200 or less to at least 3 times service cut from each cylinder and subjected to pressure. Others must be examined the same heat treatment as the finunder pressure of 2 times service presished cylinder. sure and show no defects. (4) Specimens for cylinders must con- (i) Flattening test for spheres and cylform to the following: inders. Spheres and cylinders must be (i) A gauge length of 8 inches with a subjected to a flattening test as folwidth not over 1½ inches, or a gauge lows: length of 2 inches with a width not (1) One sphere taken at random out over 1½ inches, or a gauge length at of each lot of 200 or less must be subleast 24 times the thickness with a jected to a flattening test as follows: width not over 6 times the thickness is (i) The test must be performed after authorized when a cylinder wall is not the hydrostatic test. over 3/15 inch thick. (ii) The test must be between parallel (ii) The specimen, exclusive of grip steel plates on a press with a welded ends. may not be flattened. Grip ends seam at right angles to the plates. Any may be flattened to within 1 inch of projecting appurtenances may be cut each end of the reduced section. Heatoff (by mechanical means only) prior to ing of the specimen for any purpose is crushing. not authorized. (2) One cylinder taken at random out (5) The yield strength in tension of each lot of 200 or less must be submust be the stress corresponding to a jected to a flattening test, as follows: permanent strain of 0.2 percent of the (i) The test must be performed after gauge length. The following conditions the hydrostatic test. apply: (ii) The test must be between knife (i) The yield strength must be deteredges, wedge shaped, 60° angle, rounded mined by either the "offset" method or to 1/2 inch radius. For lots of 30 or less, the "extension under load" method as physical tests are authorized to be prescribed in ASTM E 8 (IBR, see $171.7 made on a ring at least 8 inches long of this subchapter). cut from each cylinder and subjected to (ii) In using the "extension under the same heat treatment as the finload" method, the total strain (or "exished cylinder. tension under load") corresponding to (j) Physical test and specimens for the stress at which the 0.2 percent perspheres and cylinders. Spheres and cylmanent strain occurs may be deterinders must be subjected to a physical mined with sufficient accuracy by caltest as follows: culating the elastic extension of the 868 Pipeline and Hazardous Materials Safety Admin., DOT § 178.55 gauge length under appropriate load The maximum water capacity of this and adding thereto 0.2 percent of the cylinder is 12 pounds or 333 cubic gauge length. Elastic extension calinches and the service must be 240 psig. culations must be based on an elastic The maximum outside diameter of the modulus of 30,000,000. In the event of shell must be five inches and maximum controversy, the entire stress-strain length of the shell is 21 inches. Cyldiagram must be plotted and the yield inders closed in by a spinning process strength determined from the 0.2 perare authorized. cent offset. (b) Steel. Open-hearth, basic oxygen, (iii) For the purpose of strain measor electric steel of uniform quality urement, the initial strain must be set must be used. Plain carbon steel conwhile the specimen is under a stress of tent may not exceed the following: Car- 12,000 psi and the strain indicator readbon, 0.25; phosphorus, 0.045; sulfur, ing being set at the calculated cor- 0.050. The addition of other elements responding strain. for alloying effect is prohibited. (iv) Cross-head speed of the testing (c) Identification of material. Material machine may not exceed 1/8 inch per must be identified by any suitable minute during yield strength determethod. mination. (d) Manufacture. Cylinders must be (k) Acceptable results for physical and manufactured using equipment and flattening tests. Either of the following processes adequate to ensure that each is an acceptable result: (1) An elongation of at least 40 percylinder produced conforms to the recent for a 2 inch gauge length or at quirements of this subpart. No defect is least 20 percent in other cases and permitted that is likely to weaken the yield strength not over 73 percent of finished cylinder appreciably. A reatensile strength. In this instance, the sonably smooth and uniform surface flattening test is not required. finish is required. Heads may be at- (2) An elongation of at least 20 pertached to shells by lap brazing or may cent for a 2 inch gauge length or 10 perbe formed integrally. The thickness of cent in other cases. Flattening is rethe bottom of cylinders welded or quired to 50 percent of the original outformed by spinning is, under no condiside diameter without cracking. tion, to be less than two times the min- (1) Rejected cylinders. Reheat-treatimum wall thickness of the cylindrical ment is authorized for rejected cylshell. Such bottom thicknesses must be inders. Subsequent thereto, containers measured within an area bounded by a must pass all prescribed tests to be acline representing the points of contact ceptable. Repair of welded seams by between the cylinder and the floor welding prior to reheat-treatment is when the cylinder is in a vertical posiauthorized. tion. Seams must conform to the fol- (m) Marking. Marking on each conlowing: tainer by stamping plainly and perma- (1) Circumferential seams must be by nently are only authorized where the brazing only. Heads must be attached metal is at least 0.09 inch thick, or on to shells by the lap brazing method and a metal nameplate permanently semust overlap not less than four times cured to the container by means other the wall thickness. Brazing material than soft solder, or by means that must have a melting point of not less would not reduce the wall thickness. than 1000 °F. Heads must have a driving fit with the shell unless the shell is [Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 66 FR 45386, 45388, Aug. 28, 2001; crimped, swedged, or curled over the 67 FR 51653, Aug. 8, 2002: 68 FR 75748, Dec. 31. skirt or flange of the head and be thor- 2003) oughly brazed until complete penetration of the joint by the brazing mate- § 178.55 Specification 4B240ET welded rial is secured. Brazed joints may be reor brazed cylinders. paired by brazing. (a) Type, spinning process, size and (2) Longitudinal seams in shell must service pressure. A DOT 4B240ET cylbe by electric resistance welded joints inder is a brazed type cylinder made only. No repairs to longitudinal joints from electric resistance welded tubing. is permitted. 869 $ 178.55 49 CFR Ch. I (10-1-06 Edition) (3) Welding procedures and operators (iii) Straight threads, having at least must be qualified in accordance with 4 engaged threads, to have tight fit and CGA C-3 (IBR, see § 171.7 of this subcalculated shear strength at least 10 chapter). times the test pressure of the cylinder; (e) Welding or brazing. Only the atgaskets required. adequate to prevent tachment, by welding or brazing, to the leakage. tops and bottoms of cylinders of (2) Closure of a fitting, boss, or pad neckrings, footrings, handles, bosses, must be adequate to prevent leakage. pads, and valve protection rings is au- (i) Hydrostatic test. Each cylinder thorized. Provided that such attachmust successfully withstand a hydroments and the portion of the container static test as follows: to which they are attached are made of (1) The test must be by water-jacket, weldable steel, the carbon content of or other suitable method, operated so which may not exceed 0.25 percent. as to obtain accurate data. The pres- (f) Wall thickness. The wall stress sure gauge must permit reading to an must be at least two times the service accuracy of 1 percent. The expansion pressure and may not exceed 18,000 psi. gauge must permit reading of total ex- The minimum wall thickness is 0.044 pansion to an accuracy of either 1 perinch. Calculation must be made by the cent or 0.1 cubic centimeter. following formula: (2) Pressure must be maintained for at least 30 seconds and sufficiently S = [P(1.3D² + 0.4d²)] / (D² - d2) longer to ensure complete expansion. Where: Any internal pressure applied after heat-treatment and previous to the of- S - wall stress in psig; ficial test may not exceed 90 percent of P = 2 times service pressure; D = outside diameter in inches; the test pressure. If, due to failure of d = Inside diameter in inches. the test apparatus, the test pressure cannot be maintained, the test may be (g) Heat treatment. Heads formed by repeated at a pressure increased by 10 drawing or pressing must be uniformly percent or 100 psig, whichever is the and properly heat treated prior to lower. tests. Cylinders with integral formed (3) Permanent volumetric expansion heads or bases must be subjected to a may not exceed 10 percent of total volnormalizing operation. Normalizing umetric expansion at test pressure. and brazing operations may be com- (4) Cylinders must be tested as folbined, provided the operation is carried lows: out at a temperature in excess of the (i) At least one cylinder selected at upper critical temperature of the steel. random out of each lot of 200 or less (h) Openings in cylinders. Openings in must be tested as outlined in paracylinders must comply with the folgraphs (i)(1), (i)(2), and (i)(3) of this seclowing: tion to at least two times service pres- (1) Each opening in cylinders, except sure. those for safety devices, must be pro- (ii) All cylinders not tested as outvided with a fitting, boss, or pad, selined in paragraph (i)(4)(i) of this seccurely attached to the cylinder by tion must be examined under pressure brazing or by welding or by threads. A of at least two times service pressure fitting, boss, or pad must be of steel and show no defect. suitable for the method of attachment (5) Each 1000 cylinders or less succesemployed, and which need not be idensively produced each day must contifled or verified as to analysis, except stitute a lot. One cylinder must be sethat if attachment is by welding, carlected from each lot and bon content may not exceed 0.25 perhydrostatically tested to destruction. cent. If threads are used, they must If this cylinder bursts below five times comply with the following: the service pressure, then two addi- (i) Threads must be clean cut, even tional cylinders must be selected and without checks, and tapped to gauge. subjected to this test. If either of these (ii) Taper threads to be of length not cylinders fails by bursting below five less than as specified for American times the service pressure then the en- Standard taper pipe threads. tire lot must be rejected. All cylinders 870 Pipeline and Hazardous Materials Safety Admin., DOT § 178.55 constituting a lot must be of identical prescribed in ASTM E 8 (IBR, see $171.7 size, construction heat-treatment, finof this subchapter). ish, and quality. (ii) In using the "extension under (j) Flattening test. Following the hyload" method, the total strain (or "exdrostatic test, one cylinder taken at tension under load") corresponding to random out of each lot of 200 or less, the stress at which the 0.2 percent permust be subjected to a flattening test manent strain occurs may be deterthat is between knife edges, wedge mined with sufficient accuracy by calshaped, 60° angle, rounded to 1/2 inch raculating the elastic extension of the dius. gauge length under appropriate load (k) Physical test. A physical test must and adding thereto 0.2 percent of the be conducted to determine yield gauge length. Elastic extension calstrength, tensile strength, elongation, culations must be based on an elastic and reduction of area of material, as modulus of 30,000,000. In the event of follows: controversy, the entire stress-strain (1) The test is required on 2 specidiagram must be plotted and the yield mens cut from 1 cylinder, or part strength determined from the 0.2 perthereof heat-treated as required, taken cent offset. at random out of each lot of 200 or less (iii) For the purpose of strain measin the case of cylinders of capacity urement, the initial strain must be set greater than 86 cubic inches and out of while the specimen is under a stress of each lot of 500 or less for cylinders hav- 12,000 psi and the strain indicator reading a capacity of 86 cubic inches or ing being set at the calculated corless. responding strain. (2) Specimens must conform to the (iv) Cross-head speed of the testing following: machine may not exceed 1/8 inch per (i) A gauge length of 8 inches with a minute during yield strength deterwidth not over 1½ inches, a gauge mination. length of 2 inches with a width not (1) Acceptable results for physical and over 1½ inches, or a gauge length at flattening tests. Acceptable results for least 24 times the thickness with a the physical and flattening tests are an width not over 6 times the thickness is elongation of at least 40 percent for a 2 authorized when a cylinder wall is not inch gauge length or at least 20 percent over 3/16 inch thick. in other cases and a yield strength not (ii) The specimen, exclusive of grip over 73 percent of tensile strength. In ends, may not be flattened. Grip ends this instance the flattening test is remay be flattened to within one inch of quired, without cracking, to six times each end of the reduced section. the wall thickness with a weld 90° from (iii) When size of cylinder does not the direction of the applied load. Two permit securing straight specimens, rings cut from the ends of length of the specimens may be taken in any lopipe used in production of a lot may be cation or direction and may be used for the flattening test provided straightened or flattened cold by presthe rings accompany the lot which sure only, not by blows. When specithey represent in all thermal procmens are so taken and prepared, the inessing operations. At least one of the spector's report must show in connecrings must pass the flattening test. tion with record of physical tests de- (m) Leakage test. All spun cylinders tailed information in regard to such and plugged cylinders must be tested specimens. for leakage by gas or air pressure after (iv) Heating of a specimen for any the bottom has been cleaned and is free purpose is not authorized. from all moisture, subject to the fol- (3) The yield strength in tension lowing conditions: must be the stress corresponding to a (1) Pressure, approximately the same permanent strain of 0.2 percent of the as but no less than service pressure, gauge length. The following conditions must be applied to one side of the finapply: ished bottom over an area of at least (i) The yield strength must be deter- 1/16 of the total area of the bottom but mined by either the "offset" method or not less than 3/4 inch in diameter, inthe "extension under load" method as cluding the closure, for at least 1 871 § 178.56 49 CFR Ch. I (10-1-06 Edition) minute, during which time the other psig. Closures welded by spinning procside of the bottom exposed to pressure ess not permitted. must be covered with water and closely (b) Steel. The limiting chemical comexamined for indications of leakage. position of steel authorized by this Except as provided in paragraph (n) of specification must be as shown in table this section, cylinders which are leak- I of appendix A to this part. ing must be rejected. (c) Identification of material. Material (2) A spun cylinder is one in which an must be identified by any suitable end closure in the finished cylinder has method except that plates and billets been welded by the spinning process. for hotdrawn cylinders must be marked (3) A plugged cylinder is one in which with the heat number. a permanent closure in the bottom of a (d) Manufacture. Cylinders must be finished cylinder has been effected by a manufactured using equipment and plug. processes adequate to ensure that each (4) As a safety precaution, if the cylinder produced conforms to the remanufacturer elects to make this test quirements of this subpart. No defect is before the hydrostatic test, he should permitted that is likely to weaken the design his apparatus so that the presfinished cylinder appreciably. A reasure is applied to the smallest area sonably smooth and uniform surface practicable, around the point of clofinish is required. Exposed bottom sure, and so as to use the smallest poswelds on cylinders over 18 inches long sible volume of air or gas. must be protected by footrings. Min- (n) Rejected cylinders. Repairs of re- Imum thickness of heads and bottoms jected cylinders is authorized. Cylmay not be less than 90 percent of the inders that are leaking must be rerequired thickness of the side wall. jected, except that: Seams must be made as follows: (1) Spun cylinders rejected under the (1) Circumferential seams must be provisions of paragraph (m) of this secwelded. Brazing is not authorized. tion may be removed from the spun (2) Longitudinal seams are not percylinder category by drilling to remove mitted. defective material, tapping, and plug- (3) Welding procedures and operators ging. must be qualified in accordance with (2) Brazed joints may be rebrazed. CGA C-3 (IBR, see $171.7 of this sub- (3) Subsequent to the operations chapter). noted in paragraphs (n)(1) and (n)(2) of (e) Welding. Only the welding of this section, acceptable cylinders must neckrings, footrings, bosses, pads, and pass all prescribed tests. valve protection rings to the tops and (o) Marking. Markings on each cylbottoms of cylinders is authorized. inder must be by stamping plainly and Provided that such attachments are permanently on shoulder, top head, made of weldable steel, the carbon conneck or valve protection collar which tent of which does not exceed 0.25 peris permanently attached to the cylcent. inders and forming an integral part (f) Wall thickness. The wall thickness thereof, provided that cylinders not of the cylinder must conform to the less than 0.090 inch thick may be following: stamped on the side wall adjacent to (1) For cylinders with an outside ditop head. ameter over 5 inches, the minimum wall thickness is 0.078 inch. In any [Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 66 FR 45386, Aug. 28, 2001; 67 FR case, the minimum wall thickness 51653, Aug. 8, 2002; 68 FR 75748, 75749, Dec. 31, must be such that the calculated wall 2003] stress at the minimum test pressure (in paragraph (i) of this section) may not § 178.56 Specification 4AA480 welded exceed the lesser value of either of the steel cylinders. following: (a) Type, size, and service pressure. A (i) One-half of the minimum tensile DOT 4AA480 cylinder is a welded steel strength of the material determined as cylinder having a water capacity required in paragraph (j) of this sec- (nominal) not over 1,000 pounds water tion; or capacity and a service pressure of 480 (ii) 35,000 psi. 872 Pipeline and Hazardous Materials Safety Admin., DOT § 178.56 (2) Calculation must be made by the (1) The test must be by water jacket, formula: or other suitable method, operated so S = [P(1.3D² + 0.4d²)] / (D² - d²) as to obtain accurate data. The pressure gauge must permit reading to an Where: accuracy of 1 percent. The expansion S - wall stress in psi; gauge must permit reading of total ex- P = minimum test pressure prescribed for pansion to an accuracy of either 1 perwater jacket test; cent or 0.1 cubic centimeter. D = outside diameter in inches; (2) Pressure must be maintained for d = inside diameter in inches. at least 30 seconds or sufficiently (3) The ratio of tangential length to longer to assure complete expansion. outside diameter may not exceed 4.0 for Any internal pressure applied after cylinders with a wall thickness less heat-treatment and before the official than 0.100 inch. test may not exceed 90 percent of the (g) Heat treatment. Each cylinder test pressure. If, due to failure of test must be uniformly and properly heat apparatus, the test pressure cannot be treated prior to tests. Any suitable maintained, the test may be repeated heat treatment in excess of 1100 °F is at a pressure increased by 10 percent or authorized except that liquid quench- 100 psig, whichever is lower. ing is not permitted. Heat treatment (3) Permanent volumetric expansion must be accomplished after all forming may not exceed 10 percent of the total and welding operations. Heat treatvolumetric expansion at test pressure. ment is not required after welding (4) Cylinders must be tested as folweldable low carbon parts to attachlows: ments of similar material which have (i) At least one cylinder selected at been previously welded to the top or random out of each lot of 200 or less bottom of cylinders and properly heat must be tested as described in paratreated, provided such subsequent graphs (i)(1), (i)(2), and (1)(3) of this secwelding does not produce a temperation, to at least two times service presture in excess of 400 °F., in any part of sure. If a selected cylinder fails, then the top or bottom material. two additional specimens must be se- (h) Openings in cylinders. Openings in lected at random from the same lot and cylinders must conform to the folsubjected to the prescribed test. If eilowing: ther of these falls the test, then each (1) All openings must be in the heads cylinder in that lot must be so tested; or bases. and (2) Each opening in the cylinder, ex- (ii) Each cylinder not tested as precept those for safety devices, must be scribed in paragraph (i)(4)(i) of this secprovided with a fitting boss, or pad, setion must be examined under pressure curely attached to the cylinder by of at least two times service pressure welding or by threads. If threads are and must show no defect. A cylinder used they must comply with the folshowing a defect must be rejected unlowing: less it may be requalified under para- (i) Threads must be clean-cut, even graph (m) of this section. without checks and cut to gauge. (j) Physical test. A physical test must (ii) Taper threads to be of length not be conducted to determine yield less than as specified for American strength, tensile strength, elongation, Standard taper pipe threads. and reduction of area of material, as (iii) Straight threads having at least follows: 6 engaged threads, must have a tight (1) The test is required on 2 specifit and a calculated shear strength at mens cut from one cylinder having least 10 times the test pressure of the passed the hydrostatic test, or part cylinder. Gaskets, adequate to prevent thereof heat-treated as required, taken leakage, are required. at random out of each lot of 200 or less. (3) Closure of a fitting, boss or pad (2) Specimens must conform to the must be adequate to prevent leakage. following: (i) Hydrostatic test. Each cylinder (i) A gauge length of 8 inches with a must successfully withstand a hydrowidth not over 1½ inches, a gauge static test as follows: length of 2 inches with a width not 873 § 178.56 49 CFR Ch. I (10-1-06 Edition) over 1½ inches, or a gauge length at (k) Elongation. Physical test specileast 24 times the thickness with a mens must show at least a 40 percent width not over 6 times thickness is auelongation for 2-inch gauge lengths or thorized when the cylinder wall is not at least a 20 percent elongation in over 3/10 inch thick. other cases. Except that these elon- (ii) The specimen, exclusive of grip gation percentages may be reduced nuends, may not be flattened. Grip ends merically by 2 for 2-inch specimens and may be flattened to within one inch of by 1 in other cases for each 7,500 psi ineach end of the reduced section. crement of tensile strength above 50,000 (iii) When size of cylinder does not psi to a maximum of four such increpermit securing straight specimens, ments. the specimens may be taken in any lo- (1) Tests of welds. Welds must be testcation or direction and may be ed as follows: straightened or flattened cold, by pres- (1) Tensile test. A specimen must be sure only, not by blows. When specicut from one cylinder of each lot of 200 mens are so taken and prepared, the inor less, or a welded test plate. The spector's report must show in connecwelded test plate must be of one of the heats in the lot of 200 or less which it tion with record of physical tests detailed information in regard to such represents, in the same condition and specimens. approximately the same thickness as (iv) Heating of a specimen for any the cylinder wall except that it may not be of a lesser thickness than that purpose is not authorized. required for a quarter size Charpy im- (3) The yield strength in tension pact specimen. The weld must be made must be the stress corresponding to a by the same procedures and subjected permanent strain of 0.2 percent of the to the same heat treatment as the gauge length. The following conditions major weld on the cylinder. The speciapply: mens must be taken across the major (i) The yield strength must be deterseam and must be prepared and tested mined by either the "offset" method or in accordance with and must meet the the "extension under load" method as requirements of CGA Pamphlet C-3. prescribed in ASTM E 8 (IBR, see § 171.7 Should this specimen fail to meet the of this subchapter). requirements, specimens may be taken (ii) In using the "extension under from two additional cylinders or weldload" method, the total strain (or "exed test plates from the same lot and tension under load"), corresponding to tested. If either of the latter specimens the stress at which the 0.2 percent perfail to meet the requirements. the enmanent strain occurs may be detertire lot represented must be rejected. mined with sufficient accuracy by cal- (2) Guided bend test. A root bend test culating the elastic extension of the specimen must be cut from the cylgauge length under appropriate load inder or a welded test plate, used for and adding thereto 0.2 percent of the the tensile test specified in paragraph gauge length. Elastic extension cal- (1)(1) of this section. Specimens must culations must be based on an elastic be taken from across the major seam modulus of 30,000,000. In the event of and must be prepared and tested in accontroversy, the entire stress-strain cordance with and must meet the rediagram must be plotted and the yield quirements of CGA Pamphlet C-3. strength determined from the 0.2 per- (3) Alternate guided-bend test. This cent offset. test may be used and must be as re- (iii) For the purpose of strain measquired by CGA Pamphlet C-3. The specurement, the initial strain reference imen must be bent until the elongation must be set while the specimen is at the outer surface, adjacent to the under a stress of 12,000 psi and the root of the weld, between the lightly strain indicator reading being set at scribed gage lines-a to b, is at least 20 the calculated corresponding strain. percent, except that this percentage (iv) Cross-head speed of the testing may be reduced for steels having a tenmachine may not exceed 1/8 inch per sile strength in excess of 50,000 psi, as minute during yield strength deterprovided in paragraph (k) of this secmination. tion. 874 Pipellne and Hazardous Materials Safety Admin., DOT § 178.57 (m) Rejected cylinders. Reheat treat- (b) Material. Material use in the conment of rejected cylinders is authorstruction of this specification must ized. Subsequent thereto, cylinders conform to the following: must pass all prescribed tests to be ac- (1) Inner containment vessel (cylinder). ceptable. Repair of welded seams by Designations and limiting chemical welding is authorized. compositions of steel authorized by (n) Markings. Markings must be this specification must be as shown in stamped plainly and permanently in table 1 in paragraph (o) of this section. one of the following locations on the (2) Outer jacket. Steel or aluminum cylinder: may be used subject to the require- (1) On shoulders and top heads not ments of paragraph (o)(2) of this secless than 0.087 inch thick. tion. (2) On neck, valve boss, valve protec- (c) Identification of material. Material tion sleeve, or similar part permamust be identified by any suitable nently attached to top end of cylinder. method. (3) On a plate attached to the top of (d) Manufacture. Cylinders must be the cylinder or permanent part thereof: manufactured using equipment and sufficient space must be left on the processes adequate to ensure that each plate to provide for stamping at least cylinder produced conforms to the resix retest dates: the plate must be at quirements of this subpart and to the least 1/16 inch thick and must be atfollowing requirements: tached by welding or by brazing at a (1) No defect is permitted that is temperature of at least 1100 °F, likely to weaken the finished cylinder throughout all edges of the plate. appreciably. A reasonably smooth and (4) Variations in location of markuniform surface finish is required. The ings authorized only when necessitated shell portion must be a reasonably true by lack of space. cylinder. (2) The heads must be seamless, con- [Amdt. 178-114, 61 FR 25942. May 23, 1996, as amended at 66 FR 45386, Aug. 28, 2001: 67 FR cave side to the pressure, hemi- 51653, Aug. 8, 2002; 68 FR 75748, 75749, Dec. 31, spherical or ellipsoidal in shape with 2003) the major diameter not more than twice the minor diameter. Minimum § 178.57 Specification 4L welded insuthickness of heads may not be less lated cylinders. than 90 percent of the required thick- (a) Type, size, service pressure, and deness of the sidewall. The heads must be sign service temperature. A DOT 4L cylreasonably true to shape, have no abinder is a fusion welded insulated cylrupt shape changes, and the skirts inder with a water capacity (nominal) must be reasonably true to round. not over 1,000 pounds water capacity (3) The surface of the cylinder must and a service pressure of at least 40 but be insulated. The insulating material not greater than 500 psig conforming to must be fire resistant. The insulation the following requirements: on non-evacuated jackets must be cov- (1) For liquefied hydrogen service, ered with a steel jacket not less than the cylinders must be designed to stand 0.060-inch thick or an aluminum jacket on end, with the axis of the cylindrical not less than 0.070 inch thick, so conportion vertical. structed that moisture cannot come in (2) The design service temperature is contact with the insulating material. If the coldest temperature for which a a vacuum is maintained in the insulacylinder is suitable. The required detion space, the evacuated jacket must sign service temperatures for each be designed for a minimum collapsing cryogenic liquid is as follows: pressure of 30 psig differential whether made of steel or aluminum. The con- Cryogenic liquid Design service temperature struction must be such that the total Argon Minus 320 °F or colder. heat transfer, from the atmosphere at Helium Minus 452 °F or colder. ambient temperature to the contents Hydrogen Minus 42 3 °F or colder. of the cylinder, will not exceed 0.0005 Neon Minus 411 °F or colder. Btu per hour, per Fahrenheit degree Nitrogen Minus 320 °F or colder. Oxygen Minus 320 °F or colder. differential in temperature, per pound of water capacity of the cylinder. For 875 § 178.57 49 CFR Ch. I (10-1-06 Edition) hydrogen, cryogenic liquid service, the (3) One-half of the minimum tensile total heat transfer, with a temperature strength of the base metal determined differential of 520 Fahrenheit degrees, as required in paragraph (j) of this secmay not exceed that required to vent tion. 30 SCF of hydrogen gas per hour. (4) The yield strength of the base (4) For a cylinder having a design metal determined as required in paraservice temperature colder than minus graph (1) of this section. 320 °F, a calculation of the maximum (5) Further provided that wall stress weight of contents must be made and for cylinders having longitudinal that weight must be marked on the seams may not exceed 85 percent of the cylinder as prescribed in $178.35. above value, whichever applies. (5) Welding procedures and oper- (6) Calculation must be made by the ations must be qualified in accordance following formula: with CGA Pamphlet C-3 (IBR, see S = [P(1.3D² + 0.4d²)] / (D² - d²) § 171.7 of this subchapter). In addition, an impact test of the weld must be perwhere: formed in accordance with paragraph S = wall stress in pounds psi; (1) of this section as part of the quali- P = minimum test pressure prescribed for fication of each welding procedure and pressure test in psig; D = outside diameter in inches; operator. (e) Welding. Welding of the cylinder d = inside diameter in inches. must be as follows: (g) Heat treatment. Heat treatment is (1) All seams of the cylinder must be not permitted. fusion welded. A means must be pro- (h) Openings in cylinder. Openings in vided for accomplishing complete penecylinders must conform to the foltration of the joint. Only butt or joggle lowing: butt joints for the cylinder seams are (1) Openings are permitted in heads authorized. All joints in the cylinder only. They must be circular and may must have reasonably true alignment. not exceed 3 inches in diameter or one (2) All attachments to the sidewalls third of the cylinder diameter, whichand heads of the cylinder must be by ever is less. Each opening in the cylfusion welding and must be of a inder must be provided with a fitting, weldable material complying with the boss or pad, either integral with, or seimpact requirements of paragraph (1) of curely attached to, the cylinder body this section. by fusion welding. Attachments to a (3) For welding the cylinder, each fitting, boss or pad may be made by procedure and operator must be qualiwelding, brazing, mechanical attachfied in accordance with the sections of ment, or threading. CGA Pamphlet C-3 that apply. In addi- (2) Threads must comply with the foltion, impact tests of the weld must be lowing: performed in accordance with para- (i) Threads must be clean-cut, even, graph (1) of this section as part of the without checks and cut to gauge. qualification of each welding procedure (ii) Taper threads to be of a length and operator. not less than that specified for NPT. (4) Brazing, soldering and threading (iii) Straight threads must have at are permitted only for joints not made least 4 engaged threads, tight fit and directly to the cylinder body. Threads calculated shear strength at least 10 must comply with the requirements of times the test pressure of the cylinder. paragraph (h) of this section. Gaskets, which prevent leakage and (f) Wall thickness. The minimum wall are inert to the hazardous material, thickness of the cylinder must be such are required. that the calculated wall stress at the (i) Pressure test. Each cylinder, before minimum required test pressure may insulating and jacketing. must be exnot exceed the least value of the folamined under a pressure of at least 2 lowing: times the service pressure maintained (1) 45,000 psi. for at least 30 seconds without evidence (2) One-half of the minimum tensile of leakage, visible distortion or other strength across the welded seam deterdefect. The pressure gauge must permit mined in paragraph (I) of this section. reading to an accuracy of 1 percent. 876 Pipeline and Hazardous Materials Safety Admin., DOT § 178.57 (j) Physical test. A physical test must yield strength determined from the 0.2 be conducted to determine yield percent offset. strength, tensile strength, and elon- (iii) For the purpose of strain measgation as follows: urement, the initial strain reference (1) The test is required on 2 specimust be set while the specimen is mens selected from material of each under a stress of 12,000 psi and the heat and in the same condition as that strain indicator reading being set at in the completed cylinder. the calculated corresponding strain. (2) Specimens must conform to the (iv) Cross-head speed of the testing following: machine may not exceed 1/8 inch per (i) A gauge length of 8 inches with a minute during yield strength determination. width not over 1½ inches, a gauge length of 2 inches with width not over (k) Acceptable results for physical tests. 1½ inches, or a gauge length at least 24 Physical properties must meet the limtimes thickness with a width not over its specified in paragraph (o)(1), table 1, 6 times thickness (authorized when cylof this section, for the particular steel inder wall is not over 1/16 inch thick). in the annealed condition. The specimens must show at least a 20 percent (ii) The specimen, exclusive of grip elongation for a 2-inch gage length. Exends, may not be flattened. Grip ends cept that the percentage may be remay be flattened to within one inch of duced numerically by 2 for each 7,500 each end of the reduced section. psi increment of tensile strength above (iii) When size of the cylinder does 100,000 psi to a maximum of 5 such innot permit securing straight specicrements. Yield strength and tensile mens, the specimens may be taken in strength must meet the requirements any location or direction and may be of paragraph (o)(1), table 1, of this secstraightened or flattened cold by prestion. sure only, not by blows. When speci- (1) Tests of welds. Welds must be testmens are so taken and prepared, the ined as follows: spector's report must show in connec- (1) Tensile test. A specimen must be tion with record of physical tests decut from one cylinder of each lot of 200 tailed information in regard to such or less, or welded test plate. The weldspecimens. ed test plate must be of one of the (iv) Heating of a specimen for any heats in the lot of 200 or less which it purpose is not authorized. represents, in the same condition and (3) The yield strength in tension approximately the same thickness as must be the stress corresponding to a the cylinder wall except that it may permanent strain of 0.2 percent of the not be of a lesser thickness than that gauge length. The following conditions required for a quarter size Charpy imapply: pact specimen. The weld must be made (i) The yield strength must be deterby the same procedures and subjected mined by either the "offset" method or to the same heat treatment as the the "extension under load" method as major weld on the cylinder. The speciprescribed in ASTM E 8 (IBR, see $171.7 men must be taken across the major of this subchapter). seam and must be prepared in accord- (ii) In using the "extension under ance with and must meet the requireload" method, the total strain (or "exments of CGA Pamphlet C-3. Should tension under load"), corresponding to this specimen fail to meet the requirethe stress at which the 0.2 percent perments, specimens may be taken from manent strain occurs may be detertwo additional cylinders or welded test mined with sufficient accuracy by calplates from the same lot and tested. If culating the elastic expansion of the either of the latter specimens fails to gauge length under appropriate load meet the requirements, the entire lot and adding thereto 0.2 percent of the represented must be rejected. gauge length. Elastic extension cal- (2) Guided bend test. A "root" bend culations must be based on the elastic test specimen must be cut from the modulus of the material used. In the cylinder or welded test plate, used for event of controversy, the entire stressthe tensile test specified in paragraph strain diagram must be plotted and the (1)(1) of this section and from any other 877 § 178.57 49 CFR Ch. I (10-1-06 Edition) seam or equivalent welded test plate if imum, but not necessarily from one of the seam is welded by a procedure difthe heats used in the lot of cylinders. ferent from that used for the major The test piece must be welded by the seam. Specimens must be taken across same welding procedure as used on the the particular seam being tested and particular cylinder seam being qualimust be prepared and tested in accordfied and must be subjected to the same ance with and must meet the requireheat treatment. ments of CGA Pamphlet C-3. (vi) Impact test specimens must be (3) Alternate guided-bend test. This cooled to the design service temperatest may be used and must be as specified in CGA Pamphlet C-3. The speciture. The apparatus for testing the men must be bent until the elongation specimens must conform to requirements of ASTM Standard E 23. The test at the outer surface, adjacent to the root of the weld, between the lightly piece, as well as the handling tongs, scribed gage lines a to b, is at least 20 must be cooled for a length of time sufpercent, except that this percentage ficient to reach the service temperamay be reduced for steels having a tenture. The temperature of the cooling sile strength in excess of 100,000 psig, as device must be maintained within a provided in paragraph (c) of this secrange of plus or minus 3 °F. The specition. men must be quickly transferred from (4) Impact tests. One set of three imthe cooling device to the anvil of the pact test specimens (for each test) testing machine and broken within a must be prepared and tested for detertime lapse of not more than six secmining the impact properties of the deonds. posited weld metal- (vii) The impact properties of each (i) As part of the qualification of the set of impact specimens may not be welding procedure. less than the values in the following (ii) As part of the qualification of the table: operators. (iii) For each "heat" of welding rodor Minimum Minimum wire used. Impact value required for Impact value (iv) For each 1,000 feet of weld made Size of specimen avg. of each permitted on with the same heat of welding rod or set of three one only of a set of three specimens wire. (ft.-lb.) (ft-lb.) (v) All impact test specimens must be 10 mmx10 mm 15 10 of the charpy type, keyhole or milled 10 mmx7.5 mm 12.5 8.5 U-notch, and must conform in all re- 10 mmx5 mm 10 7.0 spects to ASTM E 23 (IBR, see $171.7 of 10 mmx2.5 mm 5 3.5 this subchapter). Each set of Impact specimens must be taken across the (viii) When the average value of the weld and have the notch located in the three specimens equals or exceeds the weld metal. When the cylinder mateminimum value permitted for a single rial thickness is 2.5 mm or thicker, imspecimen and the value for more than pact specimens must be cut from a cylone specimen is below the required avinder or welded test plate used for the erage value, or when the value for one tensile or bend test specimens. The dispecimen is below the minimum value mension along the axis of the notch must be reduced to the largest possible permitted for a single specimen, a of 10 mm, 7.5 mm, 5 mm or 2.5 mm, deretest of three additional specimens must be made. The value of each of pending upon cylinder thickness. When the material in the cylinder or welded these retest specimens must equal or test plate is not of sufficient thickness exceed the required average value. to prepare 2.5 mm impact test speci- When an erratic result is caused by a mens, 2.5 mm specimens must be predefective specimen, or there is uncerpared from a welded test plate made tainty in test procedure, a retest is aufrom 1/8 inch thick material meeting thorized. the requirements specified in para- (m) Radiographic examination. Cylgraph (o)(1), table 1, of this section and inders must be subject to a radiohaving a carbon analysis of .05 mingraphic examination as follows: 878 Pipeline and Hazardous Materials Safety Admin., DOT $ 178.57 (1) The techniques and acceptability TABLE 2-PHYSICAL PROPERTIES of radiographic inspection must conform to the standards set forth in CGA Physical properties Pamphlet C-3. (annealed) (2) One finished longitudinal seam Tensile strength, p.s.i. (minimum) 75,000 must be selected at random from each Yield strength, p.s.i. (minimum) 30,000 lot of 100 or less successively produced Elongation In 2 Inches (minimum) percent 30.0 and be radiographed throughout its en- Elongation other permissible gauge lengths tire length. Should the radiographic (minimum) percent 15.0 examination fail to meet the requirements of paragraph (m) of this sec- TABLE 3-CHECK ANALYSIS TOLERANCES tion, two additional seams of the same Tolerance lot must be examined, and if either of over the these fail to meet the requirements of Elements Limit or specified range maximum (m) (1) of this section, only those pass- (percent) limit or under the minimum ing are acceptable. limit (n) Rejected cylinders. Reheat treat- Carbon To 0.030, incl 0.005 ment of rejected cylinders is author- Over 0.30 to 0.20, incl 0.01 ized. Subsequent thereto, cylinders Manganese To 1.00 incl .03 must pass all prescribed tests to be ac- Over 1.00 to 3.00, incl 0.04 Phosphorus To 0.040, incl 0.005 ceptable. Welds may be repaired by Over 0.040 to 0.020 incl 0.010 suitable methods of fusion welding. Sulphur To .40 incl 0.005 (o) Authorized materials of construc- Silicon To 1.00, incl 0.05 tion. Authorized materials of construc- Nickel Over 5.00 to 10.00, incl 0.10 Over 10.00 to 20.00, incl 0.15 tion are as follows: Chromium Over 15.00 to 20.00, incl 0.20 (1) Inner containment vessel (cylinder). Rephosphorized steels not subject to check analysis for Electric furnace steel of uniform qualphosphorus. ity must be used. Chemical analysis must conform to ASTM A 240/A 240M (2) Outer jacket. (i) Nonflammable (IBR, see $171.7 of this subchapter), cryogenic liquids. Cylinders intended Type 304 stainless steel. Chemical analfor use in the transportation of nonysis must conform to ASTM A240, Type flammable cryogenic liquid must have 304 Stainless Steel. A heat of steel an outer jacket made of steel or aluminum. made under table 1 and table 2 in this paragraph (o)(1) is acceptable, even (ii) Flammable cryogenic liquids. though its check chemical analysis is Cylinders intended for use in the transslightly out of the specified range, if it portation of flammable cryogenic liqis satisfactory in all other respects, uid must have an outer jacket made of steel. provided the tolerances shown in table 3 in this paragraph (o)(1) are not ex- (p) Markings. (1) Markings must be ceeded. The following chemical analstamped plainly and permanently on yses and physical properties are aushoulder or top head of jacket or on a thorized: permanently attached plate or head protective ring. TABLE 1-AUTHORIZED MATERIALS (2) The letters "ST", followed by the design service temperature (for exam- Designation Chemical analysis, ple, ST-423F). must be marked on cyllimits in percent inders having a design service tempera- Carbon 0.08 max. ture of colder than minus 320 °F only. Manganese 2.00 max. Location to be just below the DOT Phasphorus 0.045 max. mark. Sulphur 0.030 max. (3) The maximum weight of contents, Silicon 1.00 max. in pounds (for example, "Max. Content Nickel 8.00-10.50. Chromium 18.00-20.00. 51 #''), must be marked on cylinders Molybdenum None. having a design service temperature Titanium None. colder than minus 320 °F only. Loca- Columbium None. tion to be near symbol. ¹The carbon analysis must be reported to the nearest hun- (4) Special orientation instructions dredth of one percent. must be marked on the cylinder (for 879 $ 178.58 49 CFR Ch. I (10-1-06 Edition) example, THIS END UP). if the cyl- TABLE 1-AUTHORIZED MATERIALS-Continued inder is used in an orientation other 4130 Percent than vertical with openings at the top of the cylinder. Chromium 0.80/1.10. (5) If the jacket of the cylinder is Molybdenum 0.15/0.25. constructed of aluminum, the letters "AL" must be marked after the service TABLE 2-CHECK ANALYSIS TOLERANCES pressure marking. Example: DOT-4L150 AL. Tolerance (percent) over the (6) Except for serial number and jackmaximum limit or et material designation, each marking under the min- Limit or maximum imum limit prescribed in this paragraph (p) must Element specified (parcent) be duplicated on each cylinder by any Under Over minmax- suitable means. Imum imum (q) Inspector's report. In addition to limit limit the information required by 178.35, the Carbon Over 0.15 to 0.40 incl .03 .04 inspector's reports must contain infor- Manganese To 0.60 Incl 03 .03 mation on: Phosphorus¹ All ranges .01 Sulphur All ranges .01 (1) The jacket material and insula- Silicon To 0.30 incl .02 .03 tion type; Over 0.30 to 1.00 incl .05 .05 (2) The design service temperature Chromium To 0.90 incl .03 .03 Over 0.90 to 2.10 incl .05 .05 (°F); and Molybdenum To 0.20 incl .01 .01 (3) The impact test results, on a lot Over 0.20 to 0.40, Incl .02 .02 basis. Rephosphorized steels not subject to check analysis for phosphorus. [Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 66 FR 45386-45388, Aug. 28, 2001: 67 (c) Identification of material. Materials FR 51653, Aug. 8, 2002; 68 FR 75748, Dec. 31, must be identified by any suitable 2003] method except that plates and billets for hot-drawn containers must be § 178.58 Specification 4DA welded steel marked with the heat number. cylinders for aircraft use. (d) Manufacture. Cylinders must be (a) Type, size, and service pressure. A manufactured in accordance with the DOT 4DA is a welded steel sphere (two following requirements: seamless hemispheres) or a circum- (1) By best appliances and methods. ferentially welded cylinder (two seam- No defect is acceptable that is likely to less drawn shells) with a water capacweaken the finished container appreity not over 100 pounds and a service ciably. A reasonably smooth and unipressure of at least 500 but not over 900 form surface finish is required. No abpsig. rupt change in wall thickness is per- (b) Steel. Open-hearth or electric steel mitted. Welding procedures and operaof uniform quality must be used. A tors must be qualified in accordance heat of steel made under table 1 in this with CGA Pamphlet C-3 (IBR, see paragraph (b), check chemical analysis § 171.7 of this subchapter). of which is slightly out of the specified (2) All seams of the sphere or cylrange, is acceptable, if satisfactory in Inders must be fusion welded. Seams all other respects, provided the tolermust be of the butt or joggle butt type ances shown in table 2 in this paraand means must be provided for accomgraph (b) are not exceeded except as applishing complete penetration of the proved by the Associate Administrator. joint. The following chemical analyses are (e) Welding. Attachments to the conauthorized: tainer are authorized by fusion welding provided that such attachments are TABLE 1-AUTHORIZED MATERIALS made of weldable steel, the carbon con- 4130 Percent tent of which may not exceed 0.25 percent except in the case of 4130 steel. Carbon 0.28/0.33. (f) Wall thickness. The minimum wall Manganese 0.40/0.60. thickness must be such that the wall Phosphorus 0.040 max. Suffer 0.040 max. stress at the minimum specified test Silicon 0.15/0.35. pressure may not exceed 67 percent of 880 Pipeline and Hazardous Materials Safety Admin., DOT § 178.58 the minimum tensile strength of the cooling rate in excess of 80 percent of steel as determined from the physical the cooling rate of water, must be inand burst tests required and may not spected by the magnetic particle or dye be over 70,000 p.s.i. For any diameter penetrant method to detect the prescontainer, the minimum wall thickness ence of quenching cracks. Any cylinder is 0.040 inch. Calculations must be found to have a quench crack must be made by the formulas in (f)(1) or (f)(2) rejected and may not be requalified. of this section: (h) Openings in container. Openings in (1) Calculation for a sphere must be the container must comply with the made by the following formula: following requirements: S = PD / 4tE (1) Each opening in the container must be provided with a fitting, boss, Where: or pad of weldable steel securely at- S - wall stress in pounds psi: tached to the container by fusion weld- P = test pressure prescribed for water jacket ing. test, i.e., at least 2 times service pressure, (2) Attachments to a fitting. boss, or in psig: D = outside diameter in Inches; pad must be adequate to prevent leak- t = minimum wall thickness in inches; age. Threads must comply with the fol- E - 0.85 (provides 85 percent weld efficiency lowing: factor which must be applied in the girth (i) Threads must be clean cut, even, weld area and heat affected zones which without checks, and tapped to gauge. zone must extend a distance of 6 times wall thickness from center line of weld); (ii) Taper threads to be of length not E = 1.0 (for all other areas). less than as specified for American Standard taper pipe threads. (2) Calculation for a cylinder must be (iii) Straight threads, having at least made by the following formula: 4 engaged threads, to have tight fit and S = [P(1.3D² + 0.4d 2)] / (D² - d²) calculated shear strength at least 10 times the test pressure of the con- Where: tainer; gaskets required, adequate to S = wall stress in pounds psi; P = test pressure prescribed for water jacket prevent leakage. test, i.e., at least 2 times service pressure, (i) Hydrostatic test. Each cylinder in psig: must successfully withstand a hydro- D = outside diameter in inches; static test as follows: d = inside diameter in inches. (1) The test must be by water-jacket, (g) Heat treatment. The completed or other suitable method, operated so containers must be uniformly and as to obtain accurate data. The presproperly heat-treated prior to tests. sure gauge must permit reading to an Heat-treatment of containers of the auaccuracy of 1 percent. The expansion thorized analysis must be as follows: gauge must permit reading of total ex- (1) All containers must be quenched pansion to accuracy either of 1 percent by oil, or other suitable medium except or 0.1 cubic centimeter. as provided in paragraph (g)(4) of this (2) Pressure must be maintained for section. at least 30 seconds and sufficiently (2) The steel temperature on quenchlonger to ensure complete expansion. ing must be that recommended for the Any internal pressure applied after steel analysis, but may not exceed 1,750 heat-treatment and previous to the of- °F. ficial test may not exceed 90 percent of (3) The steel must be tempered at the the test pressure. If, due to failure of temperature most suitable for the the test apparatus, the test pressure analysis except that in no case shall cannot be maintained, the test may be the tempering temperature be less than repeated at a pressure increased by 10 1,000 F. percent or 100 psig, whichever is the (4) The steel may be normalized at a lower. temperature of 1,650 °F instead of being (3) Permanent volumetric expansion quenched, and containers so normalmay not exceed 10 percent of total volized need not be tempered. umetric expansion at test pressure. (5) All cylinders, if water quenched or (4) Each container must be tested to quenched with a liquid producing a at least 2 times service pressure. 881 $ 178.58 49 CFR Ch. I (10-1-06 Edition) (j) Burst test. One container taken at width not over 6 times thickness is aurandom out of 200 or less must be thorized when wall of sphere is not hydrostatically tested to destruction. over 3/16 inch thick. The rupture pressure must be included (3) A physical test for cylinders is reas part of the inspector's report. quired on 2 specimens cut from 1 cyl- (k) Flattening test. Spheres and cylinder taken at random out of each lot inders must be subjected to a flatof 200 or less. tening test as follows: (4) Specimens for cylinder must con- (1) Flattening test for spheres. One form to the following: sphere taken at random out of each lot (i) A gauge length of 8 inches with a of 200 or less must be subjected to a width not over 1½ inches, a gauge flattening test as follows: length of 2 inches with a width not (i) The test must be performed after over 1½ inches, a gauge length at least the hydrostatic test. 24 times thickness with a width not (ii) The test must be at the weld beover 6 times thickness is authorized tween the parallel steel plates on a when a cylinder wall is not over 3/16 press with a welded seam, at right an- Inch thick. gles to the plates. Any projecting ap- (ii) The specimen, exclusive of grip purtenances may be cut off (by meends, may not be flattened. Grip ends chanical means only) prior to crushing. may be flattened to within 1 inch of (2) Flattening test for cylinders. One each end of the reduced section. cylinder taken at random out of each (iii) Heating of a specimen for any lot of 200 or less, must be subjected to purpose is not authorized. a flattening test as follows: (5) The yield strength in tension (i) The test must be performed after must be the stress corresponding to a the hydrostatic test. permanent strain of 0.2 percent of the (ii) The test cylinder must be placed gauge length. The following conditions between wedge-shaped knife edges havapply: ing a 60° angle, rounded to a 1/2-inch ra- (i) The yield strength must be deterdius. mined by either the "offset" method or (1) Radiographic inspection. Radiothe "extension under load" method as graphic examinations is required on all prescribed in ASTM E 8 (IBR, see $171.7 welded joints which are subjected to inof this subchapter). ternal pressure, except that at the dis- (ii) In using the "extension under cretion of the disinterested inspector, load" method, the total strain (or "exopenings less than 25 percent of the tension under load") corresponding to sphere diameter need not be subjected the stress at which the 0.2 percent perto radiographic inspection. Evidence of manent strain occurs may be deterany defects likely to seriously weaken mined with sufficient accuracy by calthe container must be cause for rejecculating the elastic extension of the tion. gauge length under appropriate load (m) Physical test and specimens for and adding thereto 0.2 percent of the spheres and cylinders. Spheres and cylgauge length. Elastic extension calinders must be subjected to a physical culations must be based on an elastic test as follows: modulus of 30,000,000. In the event of (1) A physical test for a sphere is recontroversy, the entire stress-strain quired on 2 specimens cut from a flat diagram must be plotted and the yield representative sample plate of the strength determined from the 0.2 persame heat taken at random from the cent offset. steel used to produce the sphere. This (iii) For the purpose of strain measflat steel from which the 2 specimens urement, the initial strain must be set are to be cut must receive the same while the specimen is under a stress of heat-treatment as the spheres them- 12,000 psi and the strain indicator readselves. Sample plates to be taken for ing being set at the calculated coreach lot of 200 or less spheres. responding strain. (2) Specimens for spheres have a (iv) Cross-head speed of the testing gauge length of 2 inches with a width machine may not exceed 1/8 inch per not over 1½ inches, or a gauge length minute during yield strength deterat least 24 times thickness with a mination. 882 Pipeline and Hazardous Materials Safety Admin., DOT § 178.59 (n) Acceptable results for physical, flatfinished cylinder appreciably. A reatening, and burst tests. The following are sonably smooth and uniform surface acceptable results of the physical, flatfinish is required. Welding procedures tening and burst test: and operators must be qualified in ac- (1) Elongation must be at least 20 cordance with CGA Pamphlet C-3 (IBR, percent for a 2-inch gauge length or 10 see § 171.7 of this subchapter). percent in other cases. (e) Exposed bottom welds. Exposed bot- (2) Flattening is required to 50 pertom welds on cylinders over 18 inches cent of the original outside diameter long must be protected by footrings. without cracking. (f) Heat treatment. Body and heads (3) Burst pressure must be at least 3 formed by drawing or pressing must be times service pressure. uniformly and properly heat treated (o) Rejected containers. Reheat-treatprior to tests. ment of rejected cylinders is author- (g) Openings. Openings in the cylized. Subsequent thereto, containers inders must comply with the following: must pass all prescribed tests to be ac- (1) Standard taper pipe threads are ceptable. Repair of welded seams by required; welding prior to reheat-treatment is (2) Length may not be less than as authorized. specified for American Standard pipe (p) Marking. Markings on each conthreads; tapped to gauge; clean cut, tainer must be stamped plainly and even, and without checks. permanently on a permanent attach- (h) Hydrostatic test. Each cylinder ment or on a metal nameplate permamust successfully withstand a hydronently secured to the container by static test as follows: means other than soft solder. (1) The test must be by water-jacket, [Amdt. 178-114, 61 FR 25942, May 23, 1996, as or other suitable method, operated so amended at 66 FR 45386, 45388, Aug. 28, 2001; as to obtain accurate data. The pres- 67 FR 51654, Aug. 8, 2002; 67 FR 61015, Sept. 27, sure gauge must permit reading to an 2002; 68 FR 75748, Dec. 31, 2003] accuracy of 1 percent. The expansion gauge must permit reading of total ex- § 178.59 Specification 8 steel cylinders pansion to an accuracy of either 1 perwith porous fillings for acetylene. cent or 0.1 cubic centimeter. (a) Type and service pressure. A DOT 8 (2) Pressure must be maintained for cylinder is a seamless cylinder with a at least 30 seconds and sufficiently service pressure of 250 psig. The follonger to ensure complete expansion. lowing steel is authorized: Any internal pressure applied after (1) A longitudinal seam if forge lap heat-treatment and previous to the ofwelded; ficial test may not exceed 90 percent of (2) Attachment of heads by welding the test pressure. or by brazing by dipping process; or (3) Permanent volumetric expansion (3) A welded circumferential body may not exceed 10 percent of total volseam if the cylinder has no longituumetric expansion at test pressure. dinal seam. (4) One cylinder out of each lot of 200 (b) Steel. Open-hearth, electric or or less must be hydrostatically tested basic oxygen process steel of uniform to at least 750 psig. Cylinders not so quality must be used. Content percent tested must be examined under presmay not exceed the following: Carbon, sure of between 500 and 600 psig and 0.25; phosphorus, 0.045; sulphur, 0.050. show no defect. If hydrostatically test- (c) Identification of steel. Materials ed cylinder fails, each cylinder in the must be identified by any suitable lot may be hydrostatically tested and method except that plates and billets those passing are acceptable. for hot-drawn cylinders must be (i) Leakage test. Cylinders with botmarked with the heat number. toms closed in by spinning must be (d) Manufacture. Cylinders must be subjected to a leakage test by setting manufactured using equipment and the interior air or gas pressure to not processes adequate to ensure that each less than the service pressure. Cylcylinder produced conforms to the reinders which leak must be rejected. quirements of this subpart. No defect is (j) Physical test. A physical test must acceptable that is likely to weaken the be conducted as follows: 883 § 178.59 49 CFR Ch. I (10-1-06 Edition) (1) The test is required on 2 speci- (1) Porous filling. (1) Cylinders must mens cut longitudinally from 1 cylbe filled with a porous material in acinder or part thereof taken at random cordance with the following: out of each lot of 200 or less, after heat (i) The porous material may not distreatment. integrate or sag when wet with solvent (2) Specimens must conform to a or when subjected to normal service; gauge length of 8 inches with a width (ii) The porous filling material must not over 1½ inches, a gauge length of 2 be uniform in quality and free of voids, inches with width not over 1½, or a except that a well drilled into the fillgauge length at least 24 times thicking material beneath the valve is authorized if the well is filled with a maness with a width not over 6 times thickness is authorized when a cylinder terial of such type that the functions wall is not over 3/16 inch thick. of the filling material are not im- (3) The yield strength in tension paired; (iii) Overall shrinkage of the filling must be the stress corresponding to a material is authorized if the total permanent strain of 0.2 percent of the clearance between the cylinder shell gauge length. The following conditions and filling material, after solvent has apply: been added, does not exceed 1/2 of 1 per- (i) The yield strength must be detercent of the respective diameter or mined by either the "offset" method or length, but not to exceed 1/8 inch, measthe "extension under load" method as ured diametrically and longitudinally; prescribed in ASTM E 8 (IBR, see $171.7 (iv) The clearance may not impair of this subchapter). the functions of the filling material; (ii) In using the "extension under (v) The installed filling material load" method, the total strain (or "exmust meet the requirements of CGA C- tension under load") corresponding to 12 (IBR, see $171.7 of this subchapter); the stress at which the 0.2 percent perand manent strain occurs may be deter- (vi) Porosity of filling material may mined with sufficient accuracy by calnot exceed 80 percent except that fillculating the elastic extension of the ing material with a porosity of up to 92 gauge length under appropriate load percent may be used when tested with and adding thereto 0.2 percent of the satisfactory results in accordance with gauge length. Elastic extension cal- CGA Pamphlet C-12. culations must be based on an elastic (2) When the porosity of each cylmodulus of 30,000,000. In the event of inder is not known, a cylinder taken at controversy, the entire stress-strain random from a lot of 200 or less must diagram must be plotted and the yield be tested for porosity. If the test cylstrength determined from the 0.2 offinder fails, each cylinder in the lot set. may be tested individually and those (iii) For the purpose of strain meascylinders that pass the test are accepturement, the initial strain must be set able. while the specimen is under a stress of (3) For filling that is molded and 12,000 psi and the strain indicator readdried before insertion in cylinders, poing being set at the calculated corrosity test may be made on a sample responding strain. block taken at random from material (iv) Cross-head speed of the testing to be used. machine may not exceed 1/8 inch per (4) The porosity of the filling mateminute during yield strength deterrial must be determined. The amount mination. of solvent at 70 °F for a cylinder: (4) Yield strength may not exceed 73 (i) Having shell volumetric capacity percent of tensile strength. Elongation above 20 pounds water capacity (nomimust be at least 40 percent in 2 inch or nal) may not exceed the following: 20 percent in other cases. Maximum (k) Rejected cylinders. Reheat treatacetone sol- Percent porosity of filler vent percent ment of rejected cylinder is authorized. shell capac- Subsequent thereto, cylinders must ity by volume pass all prescribed tests to be acceptable. Repair by welding is authorized. 90 to 92 43.4 884 Pipeline and Hazardous Materials Safety Admin., DOT § 178.60 Maximum facture of the cylinders and, upon reacetone sol- Percent porosity of filler vent percent quest, to the purchaser. The test reshell capacports must be retained by the inspector ity by volume for fifteen years from the original test date of the cylinder. 87 to 90 42.0 83 to 87 40.0 (o) Marking. (1) Marking on each cyl- 80 to 83 38.6 inder must be stamped plainly and per- 75 to 80 36.2 manently on or near the shoulder, top 70 to 75 33.8 head, neck or valve protection collar 65 to 70 31.4 which is permanently attached to the (ii) Having volumetric capacity of 20 cylinder and forming integral part pounds or less water capacity (nomithereof. nal), may not exceed the following: (2) Tare weight of cylinder. in pounds and ounces, must be marked on the Maximum acetone solcylinder. Percent porosity of filler vent percent (3) Cylinders, not completed, when shell capacdelivered must each be marked for ity by volume identification of each lot of 200 or less. 90 to 92 41.8 [Amdt. 178-114, 61 FR 25942. May 23, 1996, as 83 to 90 38.5 amended at 66 FR 45386, Aug. 28, 2001; 67 FR 80 to 83 37.1 61016, Sept. 27, 2002; 67 FR 51654, Aug. 8, 2002; 75 to 80 34.8 32.5 68 FR 75748, 75749, Dec. 31, 2003) 70 to 75 65 to 70 30.2 $178.60 Specification 8AL steel cyl- (m) Tare weight. The tare weight is inders with porous fillings for the combined weight of the cylinder acetylene. proper, porous filling. valve, and sol- (a) Type and service pressure. A DOT vent, without removable cap. 8AL cylinder is a seamless steel cyl- (n) Duties of inspector. In addition to inder with a service pressure of 250 the requirements of $178.35, the inspecpsig. However, the attachment of heads tor is required toby welding or by brazing by dipping (1) Certify chemical analyses of steel process and a welded circumferential used, signed by manufacturer thereof; body seam is authorized. Longitudinal also verify by, check analyses of samseams are not authorized. ples taken from each heat or from 1 out (b) Authorized steel. The authorized of each lot of 200 or less, plates, shells, steel is as specified in table I of appenor tubes used. dix A to this part. (2) Verify compliance of cylinder (c) Identification of steel. Material shells with all shell requirements; inmust be identified by any suitable spect inside before closing in both ends; method except that plates and billets verify heat treatment as proper; obtain all samples for all tests and for check for hot-drawn cylinders must be marked with heat number. analyses; witness all tests; verify threads by gauge; report volumetric ca- (d) Manufacture. Cylinders must be pacity and minimum thickness of wall manufactured using equipment and noted. processes adequate to ensure that each (3) Prepare report on manufacture of cylinder produced conforms to the resteel shells in form prescribed in quirements of this subpart. No defect is § 178.35. Furnish one copy to manufacpermitted that is likely to weaken the turer and three copies to the company finished cylinder appreciably. A reathat is to complete the cylinders. sonably smooth and uniform surface (4) Determine porosity of filling and finish is required. Welding procedures tare weights; verify compliance of and operators must be qualified in acmarking with prescribed requirements; cordance with CGA Pamphlet C-3 (IBR, obtain necessary copies of steel shell see $171.7 of this subchapter). reports; and furnish complete reports (e) Footrings. Exposed bottom welds required by this specification to the on cylinders over 18 inches long must person who has completed the manube protected by footrings. 885 $ 178.60 49 CFR Ch. I (10-1-06 Edition) (f) Welding or brazing. Welding or that when brazed joints are used, heat brazing for any purpose whatsoever is treatment must follow any forming prohibited except as follows: and welding operations but may be (1) The attachment to the tops or done before, during, or after the brazbottoms of cylinders of neckrings, ing operations. Liquid quenching is not footrings, handlers, bosses, pads, and authorized. valve protecting rings is authorized (i) Openings. Standard taper pipe provided that such attachments and threads required in all openings. The the portion of the container to which length of the opening may not be less they are attached are made of weldable than as specified for American Standsteel, the carbon content of which may ard pipe threads; tapped to gauge; not exceed 0.25 percent. clean cut, even, and without checks. (2) Heat treatment is not required (j) Hydrostatic test. Each cylinder after welding or brazing weldable low must successfully withstand a hydrocarbon parts to attachments, specified static test as follows: in paragraph (f)(1) of this section, of (1) The test must be by water-jacket, similar material which have been preor other suitable method, operated so viously welded or brazed to the top or as to obtain accurate data. The presbottom of cylinders and properly heat sure gauge must permit reading to an treated, provided such subsequent accuracy of 1 percent. The expansion welding or brazing does not produce a gauge must permit reading of total extemperature in excess of 400 °F in any pansion to an accuracy of either 1 perpart of the top or bottom material. cent or 0.1 cubic centimeter. (g) Wall thickness; wall stress. The wall (2) Pressure must be maintained for thickness/wall stress of the cylinder at least 30 seconds and sufficiently must conform to the following: longer to ensure complete expansion. (1) The calculated wall stress at 750 Any internal pressure applied after psi may not exceed 35,000 psi, or oneheat-treatment and previous to the ofhalf of the minimum ultimate strength ficial test may not exceed 90 percent of of the steel as determined in paragraph the test pressure. (1) of this section, whichever value is (3) Permanent volumetric expansion the smaller. The measured wall thickmay not exceed 10 percent of total volness may not include galvanizing or umetric expansion at test pressure. other protective coating. (4) One cylinder out of each lot of 200 (i) Calculation of wall stress must be or less must be hydrostatically tested made by the formula: to at least 750 psig. Cylinders not so S = [P(1.3D² + 0.4d2)] / (D² - d²) tested must be examined under pressure of between 500 and 600 psig and Where: show no defect. If a hydrostatically S = wall stress in pounds psi: tested cylinder fails, each cylinder in P = 750 psig (minimum test pressure): the lot may be hydrostatically tested D = outside diameter in inches; and those passing are acceptable. d = inside diameter in inches. (k) Leakage test. Cylinders with bot- (ii) Either D or d must be calculated toms closed in by spinning must be from the relation D = d + 2t, where t = leakage tested by setting the interior minimum wall thickness. air or gas pressure at not less than the (2) Cylinders with a wall thickness service pressure. Any cylinder that less than 0.100 inch, the ratio of leaks must be rejected. straight side wall length to outside di- (1) Physical test. A physical test must ameter may not exceed 3.5. be conducted as follows; (3) For cylinders having outside di- (1) The test is required on 2 speciameter over 5 Inches, the minimum mens cut longitudinally from 1 cylwall thickness must be 0.087 inch. inder or part thereof taken at random (h) Heat treatment. Each cylinder out of each lot of 200 or less, after heat must be uniformly and properly heat treatment. treated, prior to tests, by any suitable (2) Specimens must conform to a method in excess of 1100 °F. Heat treatgauge length of 8 inches with a width ment must be accomplished after all not over 1½ inches, a gauge length 2 forming and welding operations, except inches with a width not over 1½ inches, 886 Pipeline and Hazardous Materials Safety Admin., DOT § 178.60 or a gauge length at least 24 times (1) Tensile test. A specimen must be thickness with a width not over 6 times cut from one cylinder of each lot of 200 thickness is authorized when a cylinder or less, or welded test plate. The speciwall is not over 3/16 inch thick. men must be taken from across the (3) The yield strength in tension major seam and must be prepared and must be the stress corresponding to a tested in accordance with and must permanent strain of 0.2 percent of the meet the requirements of CGA Pamgauge length. The following conditions phlet C-3. Should this specimen fail to apply: meet the requirements, specimens may (i) The yield strength must be deterbe taken from two additional cylinders mined by either the "offset" method or or welded test plates from the same lot the "extension under load" method as and tested. If either of the latter speciprescribed in ASTM E 8 (IBR, see $171.7 mens fail to meet the requirements, of this subchapter). the entire lot represented must be re- (ii) In using the "extension under jected. load" method, the total strain (or "ex- (2) Guided bend test. A root bend test tension under load") corresponding to specimen must be cut from the cylthe stress at which the 0.2 percent perinder or welded test plate, used for the manent strain occurs may be detertensile test specified in paragraph mined with sufficient accuracy by cal- (n)(1) of this section. Specimens must culating the elastic extension of the be prepared and tested in accordance gauge length under appropriate load with and must meet the requirements and adding thereto 0.2 percent of the of CGA Pamphlet C-3. gauge length. Elastic extension cal- (3) Alternate guided-bend test. This culations must be based on an elastic test may be used and must be as remodulus of 30,000,000. In the event of quired by CGA Pamphlet C-3. The speccontroversy, the entire stress-strain imen must be bent until the elongation diagram must be plotted and the yield at the outer surface, adjacent to the strength determined from the 0.2 offroot of the weld, between the lightly set. scribed gage lines-a to b, must be at (iii) For the purpose of strain measleast 20 percent, except that this perurement, the initial strain must be set centage may be reduced for steels havwhile the specimen is under a stress of ing a tensile strength in excess of 50,000 12,000 psi, the strain indicator reading psi, as provided in paragraph (m) of being set at the calculated corthis section. responding strain. (o) Rejected cylinders. Reheat treat- (iv) Cross-head speed of the testing ment of rejected cylinders is authormachine may not exceed 1/8 inch per ized. Subsequent thereto, cylinders minute during yield strength determust pass all prescribed tests to be acmination. ceptable. Repair by welding is author- (m) Elongation. Physical test speciized. mens must show at least a 40 percent (p) Porous filling. (1) Cylinders must elongation for a 2 inch gauge length or be filled with a porous material in acat least a 20 percent elongation in cordance with the following: other cases. Except that these elon- (i) The porous material may not disgation percentages may be reduced nuintegrate or sag when wet with solvent merically by 2 for 2 inch specimens and or when subjected to normal service; 1 in other cases for each 7,500 psi incre- (ii) The filling material must be uniment of tensile strength above 50,000 form in quality and free of voids, expsi to a maximum of four such increcept that a well drilled into the filling ments. material beneath the valve is author- (n) Weld tests. Specimens taken ized if the well is filled with a material across the circumferentially welded of such type that the functions of the seam must be cut from one cylinder filling material are not impaired: taken at random from each lot of 200 or (iii) Overall shrinkage of the filling less cylinders after heat treatment and material is authorized if the total must pass satisfactorily the following clearance between the cylinder shell tests: and filling material, after solvent has 887 § 178.60 49 CFR Ch. I (10-1-06 Edition) been added, does not exceed 1/2 of 1 perproper, porous filling, valve, and solcent of the respective diameter or vent, but without removable cap. length but not to exceed 1/8 inch, meas- (r) Duties of inspector. In addition to ured diametrically and longitudinally; the requirements of § 178.35, the inspec- (iv) The clearance may not impair tor shallthe functions of the filling material; (1) Certify chemical analyses of steel (v) The installed filling material used, signed by manufacturer thereof; must meet the requirements of CGA C- also verify by check analyses, of sam- 12 (IBR, see $171.7 of this subchapter); ples taken from each heat or from 1 out and of each lot of 200 or less plates, shells, (vi) Porosity of filling material may or tubes used. not exceed 80 percent except that fill- (2) Verify compliance of cylinder ing material with a porosity of up to 92 shells with all shell requirements, inpercent may be used when tested with spect inside before closing in both ends, satisfactory results in accordance with verify heat treatment as proper; obtain CGA Pamphlet C-12. all samples for all tests and for check (2) When the porosity of each cylanalyses, witness all tests; verify inder is not known, a cylinder taken at threads by gauge, report volumetric carandom from a lot of 200 or less must pacity and minimum thickness of wall be tested for porosity. If the test cylnoted. inder fails, each cylinder in the lot (3) Report percentage of each specimay be tested individually and those fied alloying element in the steel. Precylinders that pass the test are acceptpare report on manufacture of steel able. shells in form prescribed in $178.35. (3) For filling that is molded and Furnish one copy to manufacturer and dried before insertion in cylinders, pothree copies to the company that is to rosity test may be made on sample complete the cylinders. block taken at random from material (4) Determine porosity of filling and to be used. tare weights; verify compliance of (4) The porosity of the filling matemarking with prescribed requirements; rial must be determined; the amount of obtain necessary copies of steel shell solvent at 70 °F for a cylinder: reports prescribed in paragraph (b) of (i) Having shell volumetric capacity this section; and furnish complete test above 20 pounds water capacity (nomireports required by this specification nal) may not exceed the following: to the person who has completed the manufacturer of the cylinders and, Maximum acetone Percent porosity of filler solvent percent shell upon request, to the purchaser. The capacity by volume test reports must be retained by the in- 43.4 spector for fifteen years from the origi- 90 to 92 B7 to 90 42.0 nal test date of the cylinder. 83 to 87 40.0 (s) Marking. (1) Tare weight of cyl- 80 to 83 38.6 inder, in pounds and ounces, must be 75 to 80 36.2 70 to 75 33.8 marked on the cylinder. 65 to 70 31.4 (2) Cylinders, not completed, when delivered must each be marked for (ii) Having volumetric capacity of 20 identification of each lot of 200 or less. pounds or less water capacity (nomi- (3) Markings must be stamped plainly nal), may not exceed the following: and permanently in locations in accordance with the following: Maximum acetone Percent porosity of filler solvent percent shell (i) On shoulders and top heads not capacity by volume less than 0.087 inch thick; or 90 to 92 41.8 (ii) On neck, valve boss, valve protec- 83 to 90 38.5 tion sleeve, or similar part perma- 80 to 83 37.1 nently attached to the top end of cyl- 75 to 80 34.8 32.5 inder; or 70 to 75 65 to 70 30.2 (iii) On a plate of ferrous material attached to the top of the cylinder or (q) Tare weight. The tare weight is permanent part thereof; the plate must the combined weight of the cylinder be at least 1/16 inch thick, and must be 888 Pipeline and Hazardous Materials Safety Admin., DOT § 178.61 attached by welding, or by brazing at a footrings. Minimum thickness of heads temperature of at least 1,100 °F may not be less than 90 percent of the throughout all edges of the plate. Suffirequired thickness of the sidewall. cient space must be left on the plate to Heads must be concave to pressure. provide for stamping at least four (4) (2) Circumferential seams must be by retest dates. electric-arc welding. Joints must be [Amdt. 178-114, 61 FR 25942, May 23, 1996, as butt with one member offset (joggle amended at 66 FR 45386, 45388, Aug. 28, 2001; butt) or lap with minimum overlap of 67 FR 51654. Aug. 8, 2002; 68 FR 75748, 75749, at least four times nominal sheet Dec. 31, 2003] thickness. (3) Longitudinal seams in shells must § 178.61 Specification 4BW welded conform to the following: steel cylinders with electric-arc (i) Longitudinal electric-arc welded welded longitudinal seam. seams must be of the butt welded type. (a) Type, size and service pressure. A Welds must be made by a machine DOT 4BW cylinder is a welded type process including automatic feed and steel cylinder with a longitudinal elecwelding guidance mechanisms. Longitric-arc welded seam, a water capacity tudinal seams must have complete (nominal) not over 1,000 pounds and a joint penetration, and must be free service pressure at least 225 and not from undercuts, overlaps or abrupt over 500 psig gauge. Cylinders closed in ridges or valleys. Misalignment of matby spinning process are not authorized. ing butt edges may not exceed 1/6 of (b) Authorized steel. Steel used in the nominal sheet thickness or 1/32 inch construction of the cylinder must conwhichever is less. All joints with nomiform to the following: nal sheet thickness up to and including (1) The body of the cylinder must be 1/8 inch must be tightly butted. When constructed of steel conforming to the nominal sheet thickness is greater limits specified in table 1 of appendix A than 1/8 inch, the joint must be gapped to this part. with maximum distance equal to one- (2) Material for heads must meet the half the nominal sheet thickness or 1/32 requirements of paragraph (a) of this inch whichever is less. Joint design, section or be open hearth, electric or preparation and fit-up must be such basic oxygen carbon steel of uniform that requirements of this paragraph (d) quality. Content percent may not exare satisfied. ceed the following: Carbon 0.25, Man- (ii) Maximum joint efficiency must ganese 0.60, Phosphorus 0.045, Sulfur be 1.0 when each seam is radiographed 0.050. Heads must be hemispherical or completely. Maximum joint efficiency ellipsoidal in shape with a maximum must be 0.90 when one cylinder from ratio of 2.1. If low carbon steel is used, each lot of 50 consecutively welded cylthe thickness of such heads must be deinders is spot radiographed. In additermined by using a maximum wall tion, one out of the first five cylinders stress of 24,000 p.s.i. in the formula dewelded following a shut down of weldscribed in paragraph (f)(4) of this secing operations exceeding four hours tion. must be spot radiographed. Spot (c) Identification of material. Material radiographs, when required, must be must be identified by any suitable made of a finished welded cylinder and method. must include the girth weld for 2 (d) Manufacture. Cylinders must be inches in both directions from the manufactured using equipment and intersection of the longitudinal and processes adequate to ensure that each girth welds and include at least 6 cylinder produced conforms to the reinches of the longitudinal weld. Maxquirements of this subpart and the folimum joint efficacy of 0.75 must be perlowing: missible without radiography. (1) No defect is permitted that is (4) Welding procedures and operators likely to weaken the finished cylinder must be qualified in accordance with appreciably. A reasonably smooth and CGA Pamphlet C-3 (IBR. see $171.7 of uniform surface is required. Exposed this subchapter). bottom welds on cylinders over 18 (e) Welding of attachments. The atinches long must be protected by tachment to the tops and bottoms only 889 § 178.61 49 CFR Ch. I (10-1-06 Edition) of cylinders by welding of neckrings, (1) All openings must be in the heads footrings, handles, bosses, pads and or bases. valve protection rings is authorized (2) Openings in cylinders must be proprovided that such attachments and vided with adequate fittings, bosses, or the portion of the container to which pads, integral with or securely atthey are attached are made of weldable tached to the cylinder by welding. steel, the carbon content of which may (3) Threads must comply with the folnot exceed 0.25 percent. lowing: (f) Wall thickness. For outside diame- (i) Threads must be clean cut and to ters over 6 inches the minimum wall gauge. thickness must be 0.078 inch. For a cyl- (ii) Taper threads must be of length inder with a wall thickness less than not less than as specified for American 0.100 inch, the ratio of tangential Standard Taper Pipe threads. length to outside diameter may not ex- (iii) Straight threads, having at least ceed 4 tol (4:1). In any case the min- 4 engaged threads, to have tight fit and imum wall thickness must be such that calculated shear strength at least 10 the wall stress calculated by the fortimes the test pressure of the cylinder; mula listed in paragraph (f)(4) of this gaskets required, adequate to prevent section may not exceed the lesser value leakage. of any of the following: (4) Closure of fittings, boss or pads (1) The value referenced in paragraph must be adequate to prevent leakage. (b) of this section for the particular (1) Hydrostatic test. Cylinders must material under consideration. withstand a hydrostatic test, as fol- (2) One-half of the minimum tensile lows: strength of the material determined as (1) The test must be by water-jacket, required in paragraph (j) of this secor other suitable method, operated so tion. as to obtain accurate data. The pres- (3) 35,000 psi. sure gauge must permit readings to an (4) Stress must be calculated by the accuracy of 1 percent. The expansion following formula: gauge must permit readings of total S = [2P(1.3D² + 0.4d²)] / [E(D² - d²)] volumetric expansion to an accuracy either of 1 percent or 0.1 cubic centiwhere: meter. S = wall stress, psi; (2) Pressure must be maintained for P - service pressure, psig; at least 30 seconds and sufficiently D = outside diameter, inches; longer to ensure complete expansion. d = inside diameter, inches; Any internal pressure applied after E = joint efficiency of the longitudinal seam heat treatment and previous to the of- (from paragraph (d) of this section). ficial test may not exceed 90 percent of (g) Heat treatment. Each cylinder the test pressure. must be uniformly and properly heat (3) Permanent volumetric expansion treated prior to test by the applicable may not exceed 10 percent of the total method referenced in Table 1 of appenvolumetric expansion at test pressure. dix A to this part. Heat treatment (4) Cylinders must be tested as folmust be accomplished after all forming lows: and welding operations. Heat treat- (i) At least 1 cylinder selected at ranment is not required after welding or dom out of each lot of 200 or less must brazing of weldable low carbon parts to be tested as outlined in paragraphs attachments of similar material which (i)(1), (i)(2). and (i)(3) of this section to have been previously welded to the top at least two times service pressure. or bottom of cylinders and properly (ii) All cylinders not tested as outheat treated, provided such subsequent lined in paragraph (i)(4)(i) of this secwelding or brazing does not produce a tion must be examined under pressure temperature in excess of 400 °F in any of at least two times service pressure part of the top or bottom material. and show no defect. (h) Openings in cylinders. Openings in (5) One finished cylinder selected at the cylinder must conform to the folrandom out of each lot of 500 or less lowing: successively produced must be 890 Pipeline and Hazardous Materials Safety Admin., DOT § 178.61 hydrostatically tested to 4 times servor the "extension under load" method ice pressure without bursting. as prescribed in ASTM E 8 (IBR, see (j) Physical tests. Cylinders must be $171.7 of this subchapter). subjected to a physical test as follows: (ii) In using the "extension under (1) Specimens must be taken from load" method, the total strain (or "exone cylinder after heat treatment and tension under load"), corresponding to chosen at random from each lot of 200 the stress at which the 0.2-percent peror less, as follows: manent strain occurs may be deter- (i) Body specimen. One specimen mined with sufficient accuracy by calmust be taken longitudinally from the culating the elastic extension of the body section at least 90 degrees away gauge length under appropriate load from the weld. and adding thereto 0.2 percent of the (ii) Head specimen. One specimen must be taken from either head on a gauge length. Elastic extension calculations must be based on an elastic cylinder when both heads are made of modulus of 30,000,000. In the event of the same material. However, if the two heads are made of differing materials, controversy, the entire stress-strain a specimen must be taken from each diagram must be plotted and the yield head. strength determined from the 0.2-per- (iii) If due to welded attachments on cent offset. the top head there is insufficient sur- (iii) For the purpose of strain measface from which to take a specimen, it urement, the initial strain reference may be taken from a representative must be set while the specimen is head of the same heat treatment as the under a stress of 12,000 psi and the test cylinder. strain indicator reading being set at (2) Specimens must conform to the the calculated corresponding strain. following: (iv) Cross-head speed of the testing (i) A gauge length of 8 inches with a machine may not exceed 1/8 inch per width not over 1½ inches, a gauge minute during yield strength deterlength of 2 inches with a width not mination. over 1½ inches, or a gauge length at (k) Elongation. Physical test specileast 24 times thickness with a width mens must show at least a 40 percent not over 6 times thickness is authorelongation for a 2-inch gauge length or ized when a cylinder wall is not over 3/16 at least a 20 percent elongation in inch thick. other cases. Except that these elon- (ii) The specimen, exclusive of grip gation percentages may be reduced nuends, may not be flattened. Grip ends merically by 2 for 2-inch specimens and may be flattened to within 1 inch of by 1 in other cases for each 7,500 psi ineach end of the reduced section. crement of tensile strength above 50,000 (iii) When size of the cylinder does psi to a maximum of four increments. not permit securing straight speci- (1) Tests of welds. Welds must be submens, the specimens may be taken in jected to the following tests: any location or direction and may be straightened or flattened cold, by pres- (1) Tensile test. A specimen must be sure only, not by blows when specicut from one cylinder of each lot of 200 mens are so taken and prepared, the inor less. The specimen must be taken spector's report must show in connecfrom across the longitudinal seam and tion with record of physical tests demust be prepared and tested in accordtailed information in regard to such ance with and must meet the requirespecimens. ments of CGA Pamphlet C-3. (iv) Heating of a specimen for any (2) Guided bend test. A root test specipurpose is not authorized. men must be cut from the cylinder (3) The yield strength in tension used for the tensile test specified in must be the stress corresponding to a paragraph (1)(1) of this section. Specipermanent strain of 0.2 percent of the mens must be taken from across the gauge length. The following conditions longitudinal seam and must be preapply: pared and tested in accordance with (i) The yield strength must be deterand must meet the requirements of mined by either the "off-set" method CGA Pamphlet C-3. 891 § 178.65 49 CFR Ch. I (10-1-06 Edition) (3) Alternate guided bend test. This tached by welding, or by brazing. The test may be used and must be as rebrazing rod is to melt at a temperature quired by CGA Pamphlet C-3. The specof 1100 °F Welding or brazing must be imen must be bent until the elongation along all the edges of the plate. at the outer surface, adjacent to the (3) On the neck, valve boss, valve proroot of the weld, between the lightly tection sleeve, or similar part permascribed gauge lines a to b, must be at nently attached to the top of the cylleast 20 percent, except that this perinder. centage may be reduced for steels hav- (4) On the footring permanently ating a tensile strength in excess of 50,000 tached to the cylinder, provided the psi, as provided in paragraph (k) of this water capacity of the cylinder does not section. exceed 25 pounds. (m) Radiographic examination. Welds (p) Inspector's report. In addition to of the cylinders must be subjected to a the information required by $178.35, the radiographic examination as follows: inspector's report must indicate the (1) Radiographic inspection must type and amount of radiography. conform to the techniques and accept- [Amdt. 178-114, 61 FR 25942, May 23, 1996, as ability criteria set forth in CGA Pamamended at 64 FR 51919. Sept. 27, 1999: 66 FR phlet C-3. When fluoroscopic inspection 45386, 45388, Aug. 28, 2001; 67 FR 51654, Aug. 6, is used, permanent film records need 2002; 67 FR 61016, Sept. 27, 2002; 68 FR 57633, not be retained. Oct. 6, 2003; 68 FR 75748, Dec. 31, 2003) (2) Should spot radiographic examination fail to meet the requirements § 178.65 Specification 39 non-reusable of paragraph (m)(1) of this section, two (non-refillable) cylinders. additional welds from the same lot of (a) Type, size, service pressure, and test 50 cylinders or less must be examined, pressure. A DOT 39 cylinder is a seamand if either of these fail to meet the less, welded, or brazed cylinder with a requirements, each cylinder must be service pressure not to exceed 80 perexamined as previously outlined; only cent of the test pressure. Spherical those passing are acceptable. pressure vessels are authorized and (n) Rejected cylinders. (1) Unless othcovered by references to cylinders in erwise stated, if a sample cylinder or this specification. specimen taken from a lot of cylinders (1) Size limitation. Maximum water cafails the prescribed test, then two addipacity may not exceed: (i) 55 pounds tional specimens must be selected from (1,526 cubic inches) for a service presthe same lot and subjected to the presure of 500 p.s.i.g. or less, and (ii) 10 scribed test. If either of these fails the pounds (277 cubic inches) for a service test, then the entire lot must be repressure in excess of 500 p.s.i.g. jected. (2) Test pressure. The minimum test (2) Reheat treatment of rejected cylpressure is the maximum pressure of inders is authorized. Subsequent therecontents at 130 °F or 180 p.s.i.g. whichto, cylinders must pass all prescribed ever is greater. tests to be acceptable. Repair of welded (3) Pressure of contents. The term seams by welding is authorized pro- "pressure of contents" as used in this vided that all defective metal is cut specification means the total pressure away and the joint is rewelded as preof all the materials to be shipped in the scribed for original welded joints. cylinder. (o) Markings. Markings must be (b) Material: steel or aluminum. The stamped plainly and permanently in cylinder must be constructed of either any of the following locations on the steel or aluminum conforming to the cylinder: following requirements: (1) On shoulders and top heads when (1) Steel. (i) The steel analysis must they are not less than 0.087-inch thick. conform to the following: (2) On a metal plate attached to the Ladle Check top of the cylinder or permanent part analysis analysis thereof; sufficient space must be left on the plate to provide for stamping at Carbon, maximum percent 0.12 0.15 least six retest dates; the plate must be Phosphorus, maximum percent .04 .05 Sulfur, maximum percent .05 .06 at least 1/16-inch thick and must be at- 892 Pipeline and Hazardous Materials Safety Admin., DOT § 178.65 (ii) For a cylinder made of seamless minimum strength of the shell matesteel tubing with integrally formed rial in the finished cylinder. ends, hot drawn, and finished, content (3) Attachments to the cylinder are percent for the following may not expermitted by any means which will not ceed: Carbon, 0.55; phosphorous, 0.045; be detrimental to the integrity of the sulfur, 0.050. cylinder. Welding or brazing of attach- (iii) For non-heat treated welded ments to the cylinder must be comsteel cylinders, adequately killed deep pleted prior to all pressure tests. drawing quality steel is required. (4) Welding procedures and operators (iv) Longitudinal or helical welded must be qualified in accordance with cylinders are not authorized for service CGA Pamphlet C-3 (IBR, see $171.7 of pressures in excess of 500 p.s.i.g. this subchapter). (2) Aluminum. Aluminum is not au- (d) Wall thickness. The minimum wall thorized for service pressures in excess thickness must be such that the wall of 500 psig. The analysis of the alustress at test pressure does not exceed minum must conform to the Aluminum the yield strength of the material of Association standard for alloys 1060, the finished cylinder wall. Calculations 1100, 1170, 3003, 5052, 5086, 5154, 6061, and must be made by the following for- 6063, as specified in its publication enmulas: titled "Aluminum Standards and (1) Calculation of the stress for cyl- Data" (IBR, see $171.7 of this subinders must be made by the following chapter). formula: (3) Material with seams, cracks, lam- S = [P(1.3D² + 0.4d2)] / (D² - d²) inations, or other injurious defects not permitted. Where: (4) Material used must be identified S = Wall stress, in psi; by any suitable method. P = Test pressure in psig: (c) Manufacture. (1) General manufac- D = Outside diameter, in inches; d = Inside diameter, in inches. turing requirements are as follows: (i) The surface finish must be uni- (2) Calculation of the stress for form and reasonably smooth. spheres must be made by the following (ii) Inside surfaces must be clean, formula: dry, and free of loose particles. S = PD / 4t (iii) No defect of any kind is permitted if it is likely to weaken a fin- Where: ished cylinder. S = Wall stress. in psi: (2) Requirements for seams: P = Test pressure 1 psig: (i) Brazing is not authorized on alu- D = Outside diameter, in inches; t = Minimum wall thickness, in inches. minum cylinders. (ii) Brazing material must have a (e) Openings and attachments. Openmelting point of not lower than 1,000 ings and attachments must conform to °F. the following: (iii) Brazed seams must be assembled (1) Openings and attachments are with proper fit to ensure complete penpermitted on heads only. etration of the brazing material (2) All openings and their reinforcethroughout the brazed joint. ments must be within an imaginary (iv) Minimum width of brazed joints circle, concentric to the axis of the cylmust be at least four times the thickinder. The diameter of the circle may ness of the shell wall. not exceed 80 percent of the outside di- (v) Brazed seams must have design ameter of the cylinder. The plane of strength equal to or greater than 1.5 the circle must be parallel to the plane times the minimum strength of the of a circumferential weld and normal shell wall. to the long axis of the cylinder. (vi) Welded seams must be properly (3) Unless a head has adequate thickaligned and welded by a method that ness, each opening must be reinforced provides clean, uniform joints with by a securely attached fitting, boss, adequate penetration. pad, collar, or other suitable means. (vii) Welded joints must have a (4) Material used for welded openings strength equal to or greater than the and attachments must be of weldable 893 $ 178.65 49 CFR Ch. I (10-1-06 Edition) quality and compatible with the mate- (4) Cylinders and test rings may not rial of the cylinder. crack when flattened so that their (f) Pressure tests. (1) Each cylinder outer surfaces are not more than six must be tested at an internal pressure times wall thickness apart when made of at least the test pressure and must of steel or not more than ten times be held at that pressure for at least 30 wall thickness apart when made of aluseconds. minum. (i) The leakage test must be con- (5) If any cylinder or ring cracks ducted by submersion under water or when subjected to the specified flatby some other method that will be tening test, the lot of cylinders repequally sensitive. resented by the test must be rejected (ii) If the cylinder leaks, evidences (see paragraph (h) of this section). visible distortion, or any other defect, (h) Rejected cylinders. Rejected cylwhile under test, it must be rejected inders must conform to the following (see paragraph (h) of this section). requirements: (2) One cylinder taken from the be- (1) If the cause for rejection of a lot ginning of each lot, and one from each is determinable, and if by test or in- 1,000 or less successively produced spection defective cylinders are elimiwithin the lot thereafter, must be nated from the lot, the remaining cylhydrostatically tested to destruction. inders must be qualified as a new lot The entire lot must be rejected (see under paragraphs (f) and (g) of this secparagraph (h) of this section) if: tion. (i) A failure occurs at a gage pressure (2) Repairs to welds are permitted. less than 2.0 times the test pressure; Following repair, a cylinder must pass (ii) A failure initiates in a braze or a the pressure test specified in paragraph weld or the heat affected zone thereof; (f) of this section. (iii) A failure is other than in the (3) If a cylinder made from seamless sidewall of a cylinder longitudinal with steel tubing fails the flattening test deits long axis; or scribed in paragraph (g) of this section, (iv) In a sphere. a failure occurs in suitable uniform heat treatment must any opening, reinforcement. or at a be used on each cylinder in the lot. All point of attachment. prescribed tests must be performed (3) A "lot" is defined as the quantity subsequent to this heat treatment. of cylinders successively produced per (i) Markings. (1) The markings reproduction shift (not exceeding 10 quired by this section must be durable hours) having identical size, design, and waterproof. The requirements of construction, material, heat treat- $178.35(h) do not apply to this section. ment, finish, and quality. (2) Required markings are as follows: (g) Flattening test. One cylinder must (i) DOT-39. be taken from the beginning of produc- (ii) NRC. tion of each lot (as defined in para- (iii) The service pressure. graph (f)(3) of this section) and sub- (iv) The test pressure. jected to a flattening test as follows: (v) The registration number (M****) (1) The flattening test must be made of the manufacturer. on a cylinder that has been tested at (vi) The lot number. test pressure. (vii) The date of manufacture if the (2) A ring taken from a cylinder may lot number does not establish the date be flattened as an alternative to a test of manufacture. on a complete cylinder. The test ring (viii) With one of the following statemay not include the heat affected zone ments: or any weld. However, for a sphere, the (A) For cylinders manufactured prior test ring may include the circumferento October 1, 1996: "Federal law forbids tial weld if it is located at a 45 degree transportation if refilled-penalty up to angle to the ring, ±5 degrees. $25,000 fine and 5 years imprisonment (3) The flattening must be between 60 (49 U.S.C. 1809)" or "Federal law fordegrees included-angle, wedge shaped bids transportation if refilled-penalty knife edges, rounded to a 0.5 inch raup to $500,000 fine and 5 years imprisondius. ment (49 U.S.C. 5124)." 894 Pipeline and Hazardous Materials Safety Admin., DOT § 178.68 (B) For cylinders manufactured on or TABLE 1-AUTHORIZED MATERIALS-Continued after October 1, 1996: "Federal law for- Chemical analysis-limits in bids transportation if refilled-penalty Designation percent 5154 up to $500,000 fine and 5 years imprisonment (49 U.S.C. 5124)." Aluminum remainder. (3) The markings required by para- 1 Analysis must regularly be made only for the elements graphs (i)(2)(i) through (i)(2)(v) of this specifically mentioned in this table. If, however, the presence of other elements is indicated in the course of routine analsection must be in numbers and letters ysis, further analysis should be made to determine conformat least 1/8 inch high and displayed seance with the limits specified for other elements. quentially. For example: (c) Identification. Material must be DOT-39 NRC 250/500 M1001. identified by any suitable method that will identify the alloy and manufactur- (4) No person may mark any cylinder er's lot number. with the specification identification (d) Manufacture. Cylinders must be "DOT-39" unless it was manufactured manufactured using equipment and in compliance with the requirements of this section and its manufacturer has a processes adequate to ensure that each registration number (M****) from the cylinder produced conforms to the re- Associate Administrator. quirements of this subpart. No defect is permitted that is likely to weaken the [Amdt. 178-114, 61 FR 25942, May 23, 1996, as finished cylinder appreciably. A reaamended at 65 FR 58631, Sept. 29. 2000; 66 FR sonably smooth and uniform surface 45389, Aug. 28. 2001; 67 FR 51654, Aug. 8, 2002: finish is required. All welding must be 68 FR 75748, 75749, Dec. 31, 2003] by the gas shielded arc process. § 178.68 Specification 4E welded alu- (e) Welding. The attachment to the minum cylinders. tops and bottoms only of cylinders by (a) Type, size and service pressure. A welding of neckrings or flanges, DOT 4E cylinder is a welded aluminum footrings, handles, bosses and pads and cylinder with a water capacity (nomivalve protection rings is authorized. nal) of not over 1,000 pounds and a serv- However, such attachments and the ice pressure of at least 225 to not over portion of the cylinder to which it is 500 psig. The cylinder must be conattached must be made of weldable alustructed of not more than two seamless minum alloys. drawn shells with no more than one (f) Wall thickness. The wall thickness circumferential weld. The circumferenof the cylinder must conform to the tial weld may not be closer to the point following: of tangency of the cylindrical portion (1) The minimum wall thickness of with the shoulder than 20 times the the cylinder must be 0.140 inch. In any cylinder wall thickness. Cylinders or case, the minimum wall thickness shells closed in by spinning process and must be such that calculated wall cylinders with longitudinal seams are stress at twice service pressure may not authorized. not exceed the lesser value of either of (b) Authorized material. The cylinder the following: must be constructed of aluminum of (i) 20,000 psi. uniform quality. The following chem- (ii) One-half of the minimum tensile ical analyses are authorized: strength of the material as required in TABLE 1-AUTHORIZED MATERIALS paragraph (j) of this section. (2) Calculation must be made by the Designation Chemical analysis-limits in percent 51541 following formula: S = [P(1.3D² + 0.4d²)] / (D² - d²) Iron plus silicon 0.45 maximum. Copper 0.10 maximum. Where: Manganese 0.10 maximum. Magnesium 3.10/3.90. S = wall stress in psi; Chromium 0.15/0.35. P = minimum test pressure prescribed for Zinc 0.20 maximum. water jacket test; Titanium 0.20 maximum. D = outside diameter in inches; Others, each 0.05 maximum. d - inside diameter in inches. Others, total 0.15 maximum. 895 § 178.68 49 CFR Ch. I (10-1-06 Edition) (3) Minimum thickness of heads and (i) At least one cylinder selected at bottoms may not be less than the minrandom out of each lot of 200 or less imum required thickness of the side must be tested in accordance with wall. paragraphs (h)(1). (h)(2), and (h)(3) of (g) Opening in cylinder. Openings in this section. cylinders must conform to the fol- (ii) All cylinders not tested as prolowing: vided in paragraph (h)(4)(i) of this sec- (1) All openings must be in the heads tion must be examined under pressure or bases. of at least 2 times service pressure and (2) Each opening in cylinders, except show no defect. those for safety devices, must be pro- (5) One finished cylinder selected at vided with a fitting, boss, or pad, serandom out of each lot of 1,000 or less curely attached to cylinder by welding must be hydrostatically tested to 4 by inert gas shielded arc process or by times the service pressure without threads. If threads are used, they must bursting. Inability to meet this recomply with the following: quirement must result in rejection of (i) Threads must be clean-cut, even, the lot. without checks and cut to gauge. (i) Flattening test. After hydrostatic (ii) Taper threads to be of length not testing, a flattening test is required on less than as specified for American one section of a cylinder, taken at ran- Standard taper pipe threads. dom out of each lot of 200 or less as fol- (iii) Straight threads, having at least lows: 4 engaged threads, to have tight fit and (1) If the weld is not at midlength of calculated shear strength at least 10 the cylinder, the test section must be times the test pressure of the cylinder; no less in width than 30 times the cylgaskets required, adequate to prevent inder wall thickness. The weld must be leakage. in the center of the section. Weld rein- (3) Closure of a fitting, boss, or pad forcement must be removed by machinmust be adequate to prevent leakage. ing or grinding so that the weld is flush (h) Hydrostatic test. Each cylinder with the exterior of the parent metal. must successfully withstand a hydro- There must be no evidence of cracking static test, as follows: in the sample when it is flattened be- (1) The test must be by water jacket, tween flat plates to no more than 6 or other suitable method, operated so times the wall thickness. as to obtain accurate data. The pres- (2) If the weld is at midlength of the sure gauge must permit reading to an cylinder, the test may be made as specaccuracy of 1 percent. The expansion ified in paragraph (i)(f) of this section gauge must permit a reading of the or must be made between wedge shaped total expansion to an accuracy either knife edges (60° angle) rounded to a 1/2 of 1 percent or 0.1 cubic centimeter. inch radius. There must be no evidence (2) Pressure of 2 times service presof cracking in the sample when it is sure must be maintained for at least 30 flattened to no more than 6 times the seconds and sufficiently longer to inwall thickness. sure complete expansion. Any internal (j) Physical test. A physical test must pressure applied previous to the official be conducted to determine yield test may not exceed 90 percent of the strength, tensile strength, elongation, test pressure. If, due to failure of the and reduction of area of material as test apparatus, the test pressure canfollows: not be maintained, the test may be re- (1) The test is required on 2 specipeated at a pressure increased by 10 mens cut from one cylinder or part percent over the pressure otherwise thereof taken at random out of each specified. lot of 200 or less. (3) Permanent volumetric expansion (2) Specimens must conform to the may not exceed 12 percent of total volfollowing: umetric expansion at test pressure. (i) A gauge length of 8 inches with a (4) Cylinders having a calculated wall width not over 1½ inches, a gauge stress of 18,000 psi or less at test preslength of 2 inches with a width not sure may be tested as follows: over 1½ inches. 896 Pipeline and Hazardous Materials Safety Admin., DOT § 178.69 (ii) The specimen, exclusive of grip ments, the entire lot represented must ends, may not be flattened. Grip ends be rejected. may be flattened to within 1 inch of (2) Guided bend test. A bend test specieach end of the reduced section. men must be cut from the cylinder (iii) When size of cylinder does not used for the physical tests specified in permit securing straight specimens, paragraph (j) of this section. Specimen the specimens may be taken in any lomust be taken across the seam, must cation or direction and may be be 1½ inches wide, edges must be parstraightened or flattened cold, by presallel and rounded with a file, and backsure only, not by blows; when speciup strip, if used, must be removed by mens are so taken and prepared, the inmachining. The specimen must be bent spector's report must show in connecto refusal in the guided bend test jig iltion with record of physical test delustrated in paragraph 6.10 of CGA tailed information in regard to such Pamphlet C-3 (IBR, see § 171.7 of this specimens. subchapter). The root of the weld (in- (iv) Heating of a specimen for any side surface of the cylinder) must be lopurpose is not authorized. cated away from the ram of the jig. No (3) The yield strength in tension specimen must show a crack or other must be the stress corresponding to a open defect exceeding 1/8 inch in any dipermanent strain of 0.2 percent of the rection upon completion of the test. gauge length. The following conditions Should this specimen fall to meet the apply: requirements, specimens may be taken (i) The yield strength must be deterfrom each of 2 additional cylinders mined by the "offset" method as prefrom the same lot and tested. If either scribed in ASTM E 8 (IBR, see $171.7 of of the latter specimens fail to meet rethis subchapter). quirements, the entire lot represented (ii) Cross-head speed of the testing must be rejected. machine may not exceed 1/8 inch per (m) Rejected cylinders. Repair of weldminute during yield strength detered seams is authorized. Acceptable cylmination. inders must pass all prescribed tests. (k) Acceptable results for physical tests. (n) Inspector's report. In addition to An acceptable result of the physical the information required by $178.35, the test requires an elongation to at least record of chemical analyses must also 7 percent and yield strength not over 80 include applicable information on iron, percent of tensile strength. titanium, zinc, and magnesium used in (1) Weld tests. Welds of the cylinder the construction of the cylinder. are required to successfully pass the following tests: [Amdt. 178-114, 61 FR 25942, May 23, 1996, as (1) Reduced section tensile test. A speciamended at 62 FR 51561, Oct. 1, 1997; 66 FR men must be cut from the cylinder 45386, Aug. 28, 2001: 67 FR 51654, Aug. 8, 2002; used for the physical tests specified in 68 FR 75748. Dec. 31. 2003; 69 FR 54046, Sept. paragraph (j) of this section. The speci- 7. 2004] men must be taken from across the § 178.69 Responsibilities and requireseam, edges must be parallel for a disments for manufacturers of UN tance of approximately 2 inches on eipressure receptacles. ther side of the weld. The specimen must be fractured in tension. The ap- (a) Each manufacturer of a UN presparent breaking stress calculated on sure receptacle marked with "USA" as the minimum wall thickness must be a country of approval must comply at least equal to 2 times the stress calwith the requirements in this section. culated under paragraph (f)(2) of this The manufacturer must maintain a section, and in addition must have an quality system, obtain an approval for actual breaking stress of at least 30,000 each initial pressure receptacle design psi. Should this specimen fail to meet type, and ensure that all production of the requirements, specimens may be UN pressure receptacles meets the aptaken from 2 additional cylinders from plicable requirements. the same lot and tested. If either of the (1) Quality system. The manufacturer latter specimens fails to meet requireof a UN pressure receptacle must have 897 § 178.70 49 CFR Ch. I (10-1-06 Edition) its quality system approved by the Asity system as approved by the Assosociate Administrator. The quality sysciate Administrator. The manufacturer tem will initially be assessed through shall notify the Associate Adminisan audit by the Associate Administrator of any intended changes to the trator or his or her representative to approved quality system prior to makdetermine whether it meets the Γe- ing the change. The Associate Adminisquirements of this section. The Assotrator will evaluate the proposed clate Administrator will notify the change to determine whether the manufacturer in writing of the results amended quality system will satisfy of the audit. The notification will conthe requirements. The Associate Adtain the conclusions of the audit and ministrator will notify the manufacany corrective action required. The Asturer of the findings. sociate Administrator may perform (b) Design type approvals. The manuperiodic audits to ensure that the manfacturer must have each pressure reufacturer operates in accordance with ceptacle design type reviewed by an IIA the quality system. Reports of periodic and approved by the Associate Adminaudits will be provided to the manufacistrator in accordance with $178.70. A turer. The manufacturer must bear the cylinder is considered to be of a new cost of audits. design, compared with an existing ap- (2) Quality system documentation. The proved design, as stated in the applicamanufacturer must be able to demble ISO design, construction and testonstrate a documented quality system. ing standard. Management must review the adequacy (c) Production inspection and certifiof the quality system to assure that it cation. The manufacturer must ensure is effective and conforms to the rethat each UN pressure receptacle is inquirements in $178.70. The quality sysspected and certified in accordance tem records must be in English and with $178.71. must include detailed descriptions of [71 FR 33885, June 12, 2006] the following: (i) The organizational structure and § 178.70 Approval of UN pressure reresponsibilities of personnel with receptacles. gard to design and product quality; (a) Initial design-type approval. The (ii) The design control and design manufacturer of a UN pressure recepverification techniques, processes, and tacle must obtain an initial design procedures used when designing the type approval from the Associate Adpressure receptacles; ministrator. The initial design type ap- (iii) The relevant procedures for presproval must be of the pressure recepsure receptacle manufacturing, quality tacle design as it is intended to be procontrol, quality assurance, and process duced. The manufacturer must arrange operation instructions; for an IIA, approved by the Associate (iv) Inspection and testing meth- Administrator in accordance with subodologies, measuring and testing equippart I of part 107 of this chapter, to ment, and calibration data; perform a pre-audit of its pressure re- (v) The process for meeting customer ceptacle manufacturing operation prior requirements; to having an audit conducted by the (vi) The process for document control Associate Administrator or his desand document revision; ignee. (vii) The system for controlling non- (b) IIA pre-audit. The manufacturer conforming material and records, inmust submit an application for initial cluding procedures for identification, design type approval to the IIA for resegregation, and disposition; view. The IIA will examine the manu- (viii) Production, processing and fabfacturer's application for initial design rication, including purchased compotype approval for completeness. An innents, in-process and final materials; complete application will be returned and to the manufacturer with an expla- (ix) Training programs for relevant nation. If an application is complete, personnel. the IIA will review all technical docu- (3) Maintenance of quality system. The mentation, including drawings and calmanufacturer must maintain the qualculations, to verify that the design 898 Pipeline and Hazardous Materials Safety Admin., DOT § 178.70 meets all requirements of the applica- (4) Details of any refusal of approval ble UN pressure receptacle standard of a similar application by a designated and specification requirements. If the approval agency of another country. technical documentation shows that (5) The name and address of the prothe pressure receptacle prototype deduction IIA that will perform the funcsign conforms to the applicable standtions prescribed in paragraph (e) of this ards and requirements in $178.70, the section. The IIA must be approved in manufacturer will fabricate a protowriting by the Associate Administrator type lot of pressure receptacles in conin accordance with subpart I of part 107 formance with the technical docuof this chapter. mentation representative of the design. (6) Documentation on the manufac- The IIA will verify that the prototype turing facility as specified in $178.69. lot conforms to the applicable require- (7) Design specifications and manuments by selecting pressure receptacles facturing drawings, showing compoand witnessing their testing. After pronents and subassemblies if relevant, detotype testing has been satisfactorily sign calculations, and material specicompleted, showing the pressure recepfications necessary to verify complitacles fully conform to all applicable ance with the applicable pressure respecification requirements, the certiceptacle design standard. fying IIA must prepare a letter of rec- (8) Manufacturing procedures and any applicable standards that describe ommendation and a design type apin detail the manufacturing processes proval certificate. The design type apand control. proval certificate must contain the (9) Design type approval test reports name and address of the manufacturer detailing the results of examinations and the ILA certifying the design type, and tests conducted in accordance with the test results, chemical analyses, lot the relevant pressure receptacle standidentification, and all other supporting ard, to include any additional data, data specified in the applicable ISO desuch as suitability for underwater apsign, construction and testing standplications or compatibility with hydroard. The IIA must provide the certifigen embrittlement gases. cate and documentation to the manu- (d) Modification of approved pressure facturer. receptacle design type. Modification of (c) Application for initial design type an approved UN pressure receptacle deapproval. If the pre-audit is found satissign type is not authorized without the factory by the IIA, the manufacturer approval of the Associate Adminiswill submit the letter of recommendatrator. A manufacturer seeking modition from the IIA and an application fication of an approved UN pressure refor design type approval to the Assoceptacle design type may be required clate Administrator. An application for to submit design qualification test initial design type approval must be data to the Associate Administrator submitted for each manufacturing fabefore production. An audit may be recility. The application must be in quired as part of the process to modify English and, at a minimum, contain an approval. the following information: (e) Responsibilities of the production (1) The name and address of the man- IIA. The production IIA is responsible ufacturing facility. If the application is for ensuring that each pressure recepsubmitted by an authorized representatacle conforms to the design type aptive on behalf of the manufacturer, the proval. The production IIA must perform the following functions: application must include the represent- (1) Witness all inspections and tests ative's name and address. specified in the UN pressure receptacle (2) The name and title of the indistandard to ensure compliance with the vidual responsible for the manufacturstandard and that the procedures er's quality system, as required by adopted by the manufacturer meet the $178.69. requirements of the standard; (3) The designation of the pressure (2) Verify that the production inspecreceptacle and the relevant pressure retions were performed in accordance ceptacle standard. with this section; 899 § 178.70 49 CFR Ch. I (10-1-06 Edition) (3) Select UN pressure receptacles (g) Recordkeeping. The production IIA from a prototype production lot and and the manufacturer must retain a witness testing as required for the decopy of the design type approval cersign type approval; tificate and certificate of compliance (4) Ensure that the various design records for at least 20 years. type approval examinations and tests (h) Denial of design type application. If are performed accurately; the design type application is denied, (5) Verify that each pressure recepthe Associate Administrator will notacle is marked in accordance with the tify the applicant in writing and proapplicable requirements in $178.72; and vide the reason for the denial. The (6) Furnish complete test reports to manufacturer may request that the Asthe manufacturer and upon request to sociate Administrator reconsider the the purchaser. The test reports and decision. The application request certificate of compliance must be remust- tained by the IIA for at least 20 years (1) Be written in English and filed from the original test date of the preswithin 60 days of receipt of the decisure receptacles. sion; (f) Production inspection audit and cer- (2) State in detail any alleged errors tification. (1) If the application, design of fact and law; and drawing and quality control documents (3) Enclose any additional informaare found satisfactory, PHMSA will tion needed to support the request to schedule an on-site audit of the presreconsider. sure receptacle manufacturer's quality (i) Appeal. (1) A manufacturer whose system, manufacturing processes, inreconsideration request is denied may spections, and test procedures. appeal to the PHMSA Administrator. (2) During the audit, the manufac- The appeal mustturer will be required to produce pres- (i) Be written in English and filed sure receptacles to the technical standwithin 60 days of receipt of the Assoards for which approval is sought. clate Administrator's decision on re- (3) The production IIA must witness consideration; the required inspections and verifications on the pressure recep- (ii) State in detail any alleged errors of fact and law; tacles during the production run. The IIA selected by the manufacturer for (iii) Enclose any additional informaproduction inspection and testing may tion needed to support the appeal; and be different from the IIA who per- (iv) State in detail the modification formed the design type approval of the final decision sought. verifications. (2) The PHMSA Administrator will (4) If the procedures and controls are grant or deny the relief and inform the deemed acceptable, test sample presappellant in writing of the decision. sure receptacles will be selected at ran- PHMSA Administrator's decision is the dom from the production lot and sent final administrative action. to a laboratory designated by the Asso- (j) Termination of a design type apciate Administrator for verification proval certificate. (1) The Associate Adtesting. ministrator may terminate an approval (5) If the pressure receptacle test certificate issue under this section if it samples are found to conform to all the is determined that, because of a change applicable requirements, the Associate in circumstances, the approval no Administrator will issue approvals to longer is needed or no longer would be the manufacturer and the production granted if applied for; information IIA to authorize the manufacture of upon which the approval was based is the pressure receptacles. The approved fraudulent or substantially erroneous; design type approval certificate will be or termination of the approval is necreturned to the manufacturer. essary to adequately protect against (6) Upon the receipt of the approved risks to life and property. design type approval certificate from (2) Before an approval is terminated, the Associate Administrator, the presthe Associate Administrator will prosure receptacle manufacturer must vide the manufacturer and the apsign the certificate. proval agency- 900 Pipeline and Hazardous Materials Safety Admin., DOT § 178.71 (i) Written notice of the facts or con- (1) Following the final heat treatduct believed to warrant the withment, all cylinders, except those sedrawal; lected for batch testing must be sub- (ii) Opportunity to submit oral and jected to a hydraulic volumetric expanwritten evidence, and sion test. (iii) Opportunity to demonstrate or (2) The standard requirements appliachieve compliance with the applicacable to UN pressure receptacles may tion requirement. be varied only if approved in writing by (3) If the Associate Administrator dethe Associate Administrator. termines that a certificate of approval (3) The test pressure of UN cylinders, must be withdrawn to preclude a sigtubes, and bundles of cylinders must nificant and imminent adverse affect conform to the requirements in part on public safety, the procedures in 178 of this subchapter. paragraph (j)(2)(ii) and (iii) of this sec- (d) Service equipment. (1) Except for tion need not be provided prior to withdrawal of the approval, but shall be pressure relief devices, UN pressure receptacle equipment, including valves, provided as soon as practicable thereafter. piping, fittings, and other equipment subjected to pressure must be designed [71 FR 33886, June 12, 2006, as amended at 71 and constructed to withstand at least FR 54397, Sept. 14, 2006) 1.5 times the test pressure of the pressure receptacle. § 178.71 Specifications for UN pressure receptacles. (2) Service equipment must be configured or designed to prevent damage (a) General. Each UN pressure recepthat could result in the release of the tacle must meet the requirements of pressure receptacle contents during this section. Requirements for apnormal conditions of handling and proval, qualification, maintenance, and transport. Manifold piping leading to testing are contained in $178.70, and shut-off valves must be sufficiently subpart C of part 180 of this subchapter. flexible to protect the valves and the (b) Definitions. The following definipiping from shearing or releasing the tions apply for the purposes of design pressure receptacle contents. The filland construction of UN pressure receping and discharge valves and any protacles under this subpart: tective caps must be secured against Alternative arrangement means an approval granted by the Associate Adunintended opening. The valves must ministrator for a MEGC that has been conform to ISO 10297 (IBR, see $171.7 of designed, constructed or tested to the this subchapter) and be protected as technical requirements or testing specified in § 173.301b(f) of this submethods other than those specified for chapter. UN pressure receptacles in part 178 or (3) UN pressure receptacles that canpart 180 of this subchapter. not be handled manually or rolled, Bundle of cylinders. See $171.8 of this must be equipped with devices (e.g. subchapter. skids, rings, straps) ensuring that they Design type means a pressure recepcan be safely handled by mechanical tacle design as specified by a particular means and so arranged as not to impair pressure receptacle standard. the strength of, nor cause undue Design type approval means an overall stresses, in the pressure receptacle. approval of the manufacturer's quality (4) Pressure receptacles filled by volsystem and design type of each presume must be equipped with a level insure receptacle to be produced within dicator. the manufacturer's facility. (e) Bundles of cylinders. UN pressure UN tube. See $171.8 of this subreceptacles assembled in bundles must chapter. be structurally supported and held to- (c) General design and construction. gether as a unit and secured in a man- UN pressure receptacles and their cloner that prevents movement in relasures must be designed, manufactured, tion to the structural assembly and tested and equipped in accordance with movement that would result in the the requirements contained in this secconcentration of harmful local tion. stresses. The frame design must ensure 901 $ 178.71 49 CFR Ch. I (10-1-06 Edition) stability under normal operating conother means that will not become disditions. lodged by operational impact loads. (1) The frame must securely retain Valves that need to be operated in norall the components of the bundle and mal service or in an emergency must must protect them from damage during be accessible. conditions normally incident to trans- (f) [Reserved] portation. The method of cylinder re- (g) Design and construction requirestraint must prevent any vertical or ments for UN refillable seamless steel cylhorizontal movement or rotation of the inders. In addition to the general recylinder that could cause undue strain quirements of this section, UN refillon the manifold. The total assembly able seamless steel cylinders must conmust be able to withstand rough hanform to the following ISO standards, as dling, including being dropped or overapplicable: turned. (1) ISO 9809-1: Gas cylinders-Refill- (2) The frame must include features able seamless steel gas cylinders-Dedesigned for the handling and transporsign, construction and testing-Part 1: tation of the bundle. The lifting rings Quenched and tempered steel cylinders must be designed to withstand a design with tensile strength less than 1 100 load of 2 times the maximum gross MPa. (IBR, see $171.7 of this subweight. Bundles with more than one chapter). lifting ring must be designed such that (2) ISO 9809-2: Gas cylinders-Refill- a minimum sling angle of 45 degrees to able seamless steel gas cylinders-Dethe horizontal can be achieved during sign, construction and testing-Part 2: lifting using the lifting rings. If four Quenched and tempered steel cylinders lifting rings are used, their design with tensile strength greater than or must be strong enough to allow the equal to 1 100 MPa. (IBR, see $171.7 of bundle to be lifted by two rings. Where this subchapter). two or four lifting rings are used, dia- (3) ISO 9809-3: Gas cylinders-Refillmetrically opposite lifting rings must able seamless steel gas cylinders-Debe aligned with each other to allow for sign, construction and testing-Part 3: correct lifting using shackle pins. If Normalized steel cylinders. (IBR, see the bundle is filled with forklift pock- $171.7 of this subchapter). ets, it must contain two forklift pock- (h) Design and construction requireets on each side from which it is to be ments for UN refillable seamless aluminum lifted. The forklift pockets must be poalloy cylinders. In addition to the gensitioned symmetrically consistent with eral requirements of this section, UN the bundle center of gravity. refillable seamless aluminum cylinders (3) The frame structural members must conform to ISO 7866: Gas cylmust be designed for a vertical load of inders-Refillable seamless aluminum 2 times the maximum gross weight of alloy gas cylinders-Design, constructhe bundle. Design stress levels may tion and testing. (IBR, see $171.7 of this not exceed 0.9 times the yield strength subchapter). The use of Aluminum of the material. alloy 6351-T6 or equivalent is prohib- (4) The frame may not contain any ited. protrusions from the exterior frame (i) Design and construction requirestructure that could cause a hazardous ments for UN non-refillable metal cylcondition. inders. In addition to the general re- (5) The frame design must prevent quirements of this section, UN non-recollection of water or other debris that fillable metal cylinders must conform would increase the tare weight of bunto ISO 11118: Gas cylinders-Non-refilldles filled by weight. able metallic gas cylinders-Specifica- (6) The floor of the bundle frame tion and test methods. (IBR, see $ 171.7 must not buckle during normal operof this subchapter.) ating conditions and must allow for the (j) Design and construction requiredrainage of water and debris from ments for UN refillable seamless steel around the base of the cylinders. tubes. In addition to the general re- (7) If the frame design includes movquirements of this section, UN refillable doors or covers, they must be caable seamless steel tubes must conform pable of being secured with latches or to ISO 11120: Gas cylinders-Refillable 902 Pipeline and Hazardous Materials Safety Admin., DOT § 178.71 seamless steel tubes of water capacity in the UN pressure receptacle design between 150 L and 3000 L-Design, conand construction ISO standards, and struction and testing. (IBR, see $171.7 any restrictions specified in part 173 of this subchapter). for the gases to be transported, the re- (k) Design and construction requirequirements of the following standards ments for UN acetylene cylinders. In admust be applied with respect to matedition to the general requirements of rial compatibility: this section, UN acetylene cylinders (1) ISO 11114-1: Transportable gas cylmust conform to the following ISO inders-Compatibility of cylinder and standards, as applicable: valve materials with gas contents- (1) For the cylinder shell: Part 1: Metallic materials. (IBR, see (i) ISO 9809-1: Gas cylinders-Refillable seamless steel gas cylinders-De- $171.7 of this subchapter). sign, construction and testing-Part 1: (2) ISO 11114-2: Transportable gas cyl- Quenched and tempered steel cylinders inders-Compatibility of cylinder and with tensile strength less than 1 100 valve materials with gas contents- MPa. Part 2: Non-metallic materials. (IBR, (ii) ISO 9809-3: Gas cylinders-Refillsee § 171.7 of this subchapter). able seamless steel gas cylinders-De- (n) Protection of closures. Closures and sign, construction and testing-Part 3: their protection must conform to the Normalized steel cylinders. requirements in $173.301(f) of this sub- (2) The porous mass in an acetylene chapter. cylinder must conform to ISO 3807-2: (o) Marking of UN refillable pressure re- Cylinders for acetylene-Basic requireceptacles. UN refillable pressure recepments-Part 2: Cylinders with fusible tacles must be marked clearly and legplugs. (IBR, see $171.7 of this subibly. The required markings must be chapter). permanently affixed by stamping, en- (1) Design and construction requiregraving, or other equivalent method, ments for UN composite cylinders. (1) In on the shoulder, top end or neck of the addition to the general requirements of pressure receptacle or on a permathis section, UN composite cylinders nently affixed component of the presmust be designed for unlimited service life and conform to the following ISO sure receptacle, such as a welded colstandards, as applicable: lar. Except for the "UN" mark, the minimum size of the marks must be 5 (i) ISO 11119-1: Gas cylinders of composite construction-Specification and mm for pressure receptacles with a ditest methods-Part 1: Hoop-wrapped ameter greater than or equal to 140 mm composite gas cylinders. (IBR, see and 2.5 mm for pressure receptacles $171.7 of this subchapter). with a diameter less than 140 mm. The (ii) ISO 11119-2: Gas cylinders of comminimum size of the "UN" mark must posite construction-Specification and be 5 mm for pressure receptacles with a test methods-Part 2: Fully-wrapped diameter less than 140 mm and 10 mm fibre reinforced composite gas cylfor pressure receptacles with a diameinders with load-sharing metal liners. ter of greater than or equal to 140 mm. (IBR, see $171.7 of this subchapter). The depth of the markings must not (iii) ISO 11119-3: Gas cylinders of create harmful stress concentrations. composite construction-Specification A refillable pressure receptacle conand test methods-Part 3: Fully forming to the UN standard must be wrapped fibre reinforced composite gas marked as follows: cylinders with non-load sharing metal- (1) The UN packaging symbol. lic or non-metallic liners. (IBR, see $171.7 of this subchapter). (2) ISO 11119-2 and ISO 11119-3 gas cylinders of composite construction manufactured in accordance with the requirements for underwater use must bear the "UW" mark. (m) Material compatibility. In addition to the material requirements specified 903 $ 178.71 49 CFR Ch. I (10-1-06 Edition) to the last digit. For acetylene cylinders, the tare weight must be marked on the cylinders in kilograms (KG). The tare weight is the sum of the empty weight, mass of the valve, any coating and all permanently attached parts (e.g. fittings and accessories) that are not removed during filling. The tare weight must be expressed to two significant figures rounded down to the last digit. The tare weight does not include the cylinder cap or any outlet cap or plug not permanently attached to the cylinder. (2) The ISO standard, for example (8) The minimum wall thickness of ISO 9809-1, used for design, constructhe pressure receptacle in millimeters tion and testing. Acetylene cylinders followed by the letters "MM". This must be marked to indicate the porous mark is not required for pressure remass and the steel shell, for example: ceptacles with a water capacity less "ISO 3807-2/ISO 9809-1." than or equal to 1.0 L or for composite (3) The mark of the country where cylinders. the approval is granted. The letters (9) For pressure receptacles intended "USA" must be marked on UN pressure for the transport of compressed gases receptacles approved by the United and UN 1001 acetylene, dissolved, the States. The manufacturer must obtain working pressure in bar, proceeded by an approval number from the Associate the letters "PW". Administrator. The manufacturer ap- (10) For liquefied gases, the water caproval number must follow the country pacity in liters expressed to three sigof approval mark, separated by a slash nificant digits rounded down to the (for example, USA/MXXXX). Pressure last digit, followed by the letter "L". If receptacles approved by more than one the value of the minimum or nominal national authority may contain the water capacity is an integer, the digits mark of each country of approval, sepafter the decimal point may be omitarated by a comma. ted. (4) The identity mark or stamp of the (11) Identification of the cylinder IIA. thread type (e.g., 25E). (5) The date of the initial inspection, (12) The country of manufacture. The the year (four digits) followed by the letters "USA" must be marked on cylmonth (two digits) separated by a inders manufactured in the United slash, for example "2006/04". States. (6) The test pressure in bar, preceded (13) The serial number assigned by by the letters "PH" and followed by the manufacturer. the letters "BAR". The test pressure must be obtained from the results of a (14) For steel pressure receptacles, hydraulic volumetric expansion test. the letter "H" showing compatibility (7) The empty or tare weight. Except of the steel, as specified in ISO 11114-1. for acetylene cylinders, empty weight (15) Identification of aluminum alloy, is the mass of the pressure receptacle if applicable. in kilograms, including all integral (16) Stamp for nondestructive testparts (e.g., collar, neck ring, foot ring, ing, if applicable. etc.), followed by the letters "KG". The (17) Stamp for underwater use of empty weight does not include the composite cylinders, if applicable. mass of the valve, valve cap or valve (p) Marking sequence. The marking reguard or any coating. The empty quired by paragraph (o) of this section weight must be expressed to three sigmust be placed in three groups as nificant figures rounded up to the last shown in the example below: digit. For cylinders of less than 1 kg, (1) The top grouping contains manuthe empty weight must be expressed to facturing marks and must appear contwo significant figures rounded down secutively in the sequence given in 904 Pipeline and Hazardous Materials Safety Admin., DOT $ 178.71 paragraphs (o)(11) through (17) of this (3) The bottom grouping contains section. certification marks and must appear (2) The middle grouping contains consecutively in the sequence given in operational marks described in paraparagraph (o)(1) through (5) of this secgraphs (o)(6) through (10) of this section. tion. (11) (12) (13) (14) (15) (16) (17) 25E USA 765432 H UW (9) (6) (7) (10) (8) PW200 PH300BAR 62.1KG 50L 5.8MM (1) (2) (3) (4) (5) u n ISO 9809-1 USA/MXXXX IB 2005/12 (q) Other markings. Other markings graphs (o)(7), (8), (11) and (17) are not are allowed in areas other than the side applicable. The required serial number wall, provided they are made in low marking in paragraph (o)(13) may be stress areas and are not of a size and replaced by the batch number. depth that will create harmful stress (2) Each receptacle must be marked concentrations. Such marks must not with the words "DO NOT REFILL" in conflict with required marks. letters of at least 5 mm in height. (r) Marking of UN non-refillable pres- (3) A non-refillable pressure recepsure receptacles. Unless otherwise specitacle, because of its size, may subfied in this paragraph, each UN non-restitute the marking required by this fillable pressure receptacle must be paragraph with a label. Reduction in clearly and legibly marked as premarking size is authorized only as prescribed in paragraph (o) of this section. scribed in ISO 7225, Gas cylinders-Pre- In addition, permanent stenciling is cautionary labels. (IBR, see $171.7 of authorized. Except when stenciled, the this subchapter). marks must be on the shoulder, top end (4) Each non-refillable pressure reor neck of the pressure receptacle or on ceptacle must also be legibly marked a permanently affixed component of by stenciling the following statement: the pressure receptacle, for example a "Federal law forbids transportation if welded collar. refilled-penalty up to $500,000 fine and 5 (1) The marking requirements and seyears in imprisonment (49 U.S.C. quence listed in paragraphs (o)(1) 5124)." through (17) of this section are re- (5) No person may mark a non-refillquired, except the markings in paraable pressure receptacle as meeting the 905 § 178.74 49 CFR Ch. I (10-1-06 Edition) requirements of this section unless it ing all drawings and calculations, to was manufactured in conformance with ensure that the design of the MEGC this section. meets all requirements of the relevant [7] FR 33887, June 12, 2006, as amended at 71 specification and to determine whether FR 54397, Sept. 14, 2006) it is complete and conforms to the requirements of this section. An incom- § 178.74 Approval of MEGCs. plete application will be returned to (a) Application for design type apthe applicant with the reasons why the proval. (1) Each new MEGC design type application was returned. If the applimust have a design approval certification is complete and all applicable cate. An owner or manufacturer must requirements of this section are met, apply to an approval agency that is apthe approval agency must prepare a proved by the Associate Administrator MEGC design approval certificate conin accordance with subpart E of part taining the manufacturer's name and 107 of this chapter +to obtain approval address, results and conclusions of the of a new design. When a series of examination and necessary data for MEGCs is manufactured without identification of the design type. If the change in the design, the certificate is Associate Administrator approves the valid for the entire series. The design Design Type Approval Certificate apapproval certificate must refer to the plication, the approval agency and the prototype test report, the materials of manufacturer must each maintain a construction of the manifold, the copy of the approved drawings, calculastandards to which the pressure receptions, and test data for at least 20 tacles are made and an approval numyears. ber. The compliance requirements or (c) Approval agency's responsibilities. test methods applicable to MEGCs as The approval agency is responsible for specified in this subpart may be varied ensuring that the MEGC conforms to when the level of safety is determined the design type approval. The approval to be equivalent to or exceed the reagency must: quirements of this subchapter and is (1) Witness all tests required for the approved in writing by the Associate approval of the MEGC specified in this Administrator. A design approval may section and $ 178.75. serve for the approval of smaller (2) Ensure, through appropriate in- MEGCs made of materials of the same spection, that each MEGC is fabricated type and thickness, by the same fabin all respects in conformance with the rication techniques and with identical approved drawings, calculations, and supports, equivalent closures and other test data. appurtenances. (3) Determine and ensure that the (2) Each application for design ap- MEGC is suitable for its intended use proval must be in English and contain and that it conforms to the requirethe following information: ments of this subchapter. (i) Two complete copies of all engi- (4) Apply its name, identifying mark neering drawings, calculations, and or identifying number, and the date the test data necessary to ensure that the approval was issued, to the metal idendesign meets the relevant specificatification marking plate attached to tion. the MEGC upon successful completion (ii) The manufacturer's serial number of all requirements of this subpart. that will be assigned to each MEGC. Any approvals by the Associate Admin- (iii) A statement as to whether the istrator authorizing design or condesign type has been examined by any struction alternatives (Alternate Arapproval agency previously and judged rangements) of the MEGC (see paraunacceptable. Affirmative statements graph (a) of this section) must be indimust be documented with the name of cated on the metal identification plate the approval agency, reason for non-acas specified in $178.75(j). ceptance, and the nature of modifica- (5) Prepare an approval certificate tions made to the design type. for each MEGC or, in the case of a se- (b) Actions by the approval agency. The ries of identical MEGCs manufactured approval agency must review the applito a single design type, for each series cation for design type approval, includof MEGCs. The approval certificate 906 Pipeline and Hazardous Materials Safety Admin., DOT $ 178.74 must include all of the following infor- (e) Denial of application for approval. mation: If the Associate Administrator finds (i) The information displayed on the that the MEGC will not be approved for metal identification plate required by any reason, the Associate Adminis- $178.75(j): trator will notify the applicant in writ- (ii) The results of the applicable ing and provide the reason for the deframework test specified in ISO 1496-3 nial. The manufacturer may request (IBR, see $171.7 of this subchapter); that the Associate Administrator re- (iii) The results of the initial inspecconsider the decision. The application tion and test specified in paragraph (h) request mustof this section; (1) Be written in English and filed (iv) The results of the impact test within 90 days of receipt of the decispecified in § 178.75(i) (4): sion; (v) Certification documents verifying (2) State in detail any alleged errors that the cylinders and tubes conform of fact and law; and to the applicable standards; and (3) Enclose any additional informa- (vi) A statement that the approval tion needed to support the request to agency certifies the MEGC in accordreconsider. ance with the procedures in this sec- (f) Appeal. (1) A manufacturer whose tion and that the MEGC is suitable for reconsideration request is denied may its intended purpose and meets the reappeal to the PHMSA Administrator. quirements of this subchapter. When a The appeal mustseries of MEGCs is manufactured with- (i) Be in writing and filed within 90 out change in the design type, the ceΓ- days of receipt of the Associate Admintificate may be valid for the entire seistrator S decision on reconsideration; ries of MEGCs representing a single de- (ii) State in detail any alleged errors sign type. The approval number must of fact and law; consist of the distinguishing sign or (iii) Enclose any additional informamark of the country ("USA" for the tion needed to support the appeal; and United States of America) where the (iv) State in detail the modification approval was granted and a registraof the final decision sought. tion number. (2) The Administrator will grant or (6) Retain on file a copy of each apdeny the relief and inform the appelproval certificate for at least 20 years. lant in writing of the decision. The Ad- (d) Manufacturers' responsibilities. The ministrator's decision is the final admanufacturer is responsible for compliministrative action. ance with the applicable specifications (g) Modifications to approved MEGCs. for the design and construction of (1) Prior to modification of any ap- MEGCs. The manufacturer of a MEGC proved MEGC that may affect conformmust: ance and safe use, and that may in- (1) Comply with all the requirements volve a change to the design type or afof the applicable ISO standard specified fect its ability to retain the hazardous in $178.71; material in transportation. the (2) Obtain and use an approval agen- MEGC's owner must inform the apcy to review the design, construction proval agency that prepared the initial and certification of the MEGC; approval certificate for the MEGC or, if (3) Provide a statement in the manuthe initial approval agency is unavailfacturers' data report certifying that able, another approval agency, of the each MEGC manufactured complies nature of the modification and request with the relevant specification and all certification of the modification. The the applicable requirements of this owner must supply the approval agency subchapter; and with all revised drawings, calculations, (4) Retain records for the MEGCs for and test data relative to the intended at least 20 years. When required by the modification. The MEGC's owner must specification, the manufacturer must also provide a statement as to whether provide copies of the records to the apthe intended modification has been exproval agency, the owner or lessee of amined and determined to be unacceptthe MEGC, and to a representative of able by any approval agency. The writ- DOT, upon request. ten statement must include the name 907 § 178.75 49 CFR Ch. I (10-1-06 Edition) of the approval agency, the reason for (iii) Termination of the approval is non-acceptance, and the nature of necessary to adequately protect changes made to the modification since against risks to life and property: or its original rejection. (iv) The MEGC does not meet the (2) The approval agency must review specification. the request for modification. If the ap- (2) Before an approval is terminated, proval agency determines that the prothe Associate Administrator will proposed modification does not conform to vide the personthe relevant specification, the approval (i) Written notice of the facts or conduct believed to warrant the termiagency must reject the request in acnation; cordance with paragraph (d) of this sec- (ii) An opportunity to submit oral tion. If the approval agency determines and written evidence; and that the proposed modification con- (3) An opportunity to demonstrate or forms fully with the relevant specificaachieve compliance with the applicable tion, the request is accepted. If modirequirements. fication to an approved MEGC alters (i) Imminent Danger. If the Associate any information on the approval cer- Administrator determines that a certificate, the approval agency must pretificate of approval must be terminated pare a new approval certificate for the to preclude a significant and imminent modified MEGC and submit the certifiadverse effect on public safety, the Ascate to the Associate Administrator for sociate Administrator may terminate approval. After receiving approval the certificate immediately. In such from the Associate Administrator, the circumstances, the opportunities of approval agency must ensure that any paragraphs (h)(2) and (3) of this section necessary changes are made to the need not be provided prior to termimetal identification plate. A copy of nation of the approval, but must be each newly issued approval certificate provided as soon as practicable theremust be retained by the approval agenafter. cy and the MEGC's owner for at least [71 FR 33890, June 12, 2006] 20 years. The approval agency must perform the following activities: § 178.75 Specifications for MEGCs. (i) Retain a set of the approved re- (a) General. Each MEGC must meet vised drawings, calculations, and data the requirements of this section. In a as specified in § 178.69(b) (4) for at least MEGC that meets the definition of a 20 years; "container" within the terms of the (ii) Ensure through appropriate in- International Convention for Safe Conspection that all modifications containers (CSC) must meet the requireform to the revised drawings, calculaments of the CSC as amended and 49 tions, and test data; and CFR parts 450 through 453, and must (iii) Determine the extent to which have a CSC approval plate. retesting of the modified MEGC is nec- (b) Alternate Arrangements. The techessary based on the nature of the pronical requirements applicable to posed modification, and ensure that all MEGCs may be varied when the level of required retests are satisfactorily persafety is determined to be equivalent formed. to or exceed the requirements of this (h) Termination of Approval Certificate. subchapter. Such an alternate arrangement must be approved in writing by (1) The Associate Administrator may the Associate Administrator. MEGCs terminate an approval issued under approved to an Alternate Arrangement this section if he or she determines must be marked as required by parathat--- graph (j) of this section. (i) Because of a change in cir- (c) Definitions. The following definicumstances, the approval no longer is tions apply: needed or no longer would be granted if Leakproofness test means a test using applied for; gas subjecting the pressure receptacles (ii) Information upon which the apand the service equipment of the MEGC proval was based is fraudulent or subto an effective internal pressure of not stantially erroneous; less than 20% of the test pressure. 908 Pipeline and Hazardous Materials Safety Admin., DOT § 178.75 Manifold means an assembly of piping Quenched and tempered steel cylinders and valves connecting the filling and/or with tensile strength greater than or discharge openings of the pressure reequal to 1 100 MPa. (IBR, see $171.7 of ceptacles. this subchapter); Maximum permissible gross mass or (iii) ISO 9809-3: Gas cylinders-Refill- MPGM means the heaviest load authorable seamless steel gas cylinders-Deized for transport (sum of the tare sign, construction and testing-Part 3: mass of the MEGC, service equipment Normalized steel cylinders. (IBR, see and pressure receptacle). $171.7 of this subchapter); or Service equipment means manifold sys- (iv) ISO 11120: Gas cylinders-Refilltem (measuring instruments, piping able seamless steel tubes of water caand safety devices). pacity between 150 L and 3000 L-De- Shut-off valve means a valve that sign, construction and testing. (IBR, stops the flow of gas. see $171.7 of this subchapter). Structural equipment means the rein- (4) Pressure receptacles of MEGCs, forcing, fastening, protective and stabifittings, and pipework must be conlizing members external to the presstructed of a material that is compatsure receptacles. ible with the hazardous materials in- (d) General design and construction retended to be transported, as specified quirements. (1) The MEGC must be capain this subchapter. ble of being loaded and discharged (5) Contact between dissimilar metwithout the removal of its structural als that could result in damage by galequipment. It must possess stabilizing vanic action must be prevented by apmembers external to the pressure repropriate means. ceptacles to provide structural integ- (6) The materials of the MEGC, inrity for handling and transport. MEGCs cluding any devices, gaskets, and acmust be designed and constructed with cessories, must have no adverse effect supports to provide a secure base duron the gases intended for transport in ing transport and with lifting and tiethe MEGC. down attachments that are adequate (7) MEGCs must be designed to withfor lifting the MEGC including when stand, without loss of contents, at loaded to its maximum permissible least the internal pressure due to the gross mass. The MEGC must be decontents, and the static, dynamic and signed to be loaded onto a transport vethermal loads during normal condihicle or vessel and equipped with skids, tions of handling and transport. The mountings or accessories to facilitate design must take into account the efmechanical handling. fects of fatigue, caused by repeated ap- (2) MEGCs must be designed, manuplication of these loads through the exfactured and equipped to withstand, pected life of the MEGC. without loss of contents, all normal (8) MEGCs and their fastenings must, handling and transportation condiunder the maximum permissible load, tions. The design must take into acbe capable of withstanding the folcount the effects of dynamic loading lowing separately applied static forces and fatigue. (for calculation purposes, acceleration (3) Each pressure receptacle of a due to gravity (g) = 9.81 m/s2): MEGC must be of the same design type, (1) In the direction of travel: 2g seamless steel, and constructed and (twice the MPGM multiplied by the actested according to one of the following celeration due to gravity); ISO standards: (ii) Horizontally at right angles to (1) ISO 9809-1: Gas cylinders-Refillthe direction of travel: 1g (the MPGM able seamless steel gas cylinders-Demultiplied by the acceleration due to sign, construction and testing-Part 1: gravity. When the direction of travel is Quenched and tempered steel cylinders not clearly determined. the forces must with tensile strength less than 1 100 be equal to twice the MPGM); MPa. (IBR, see $171.7 of this sub- (iii) Vertically upwards: 1g (the chapter); MPGM multiplied by the acceleration (ii) ISO 9809-2: Gas cylinders-Refilldue to gravity): and able seamless steel gas cylinders-De- (iv) Vertically downwards: 2g (twice sign, construction and testing-Part 2: the MPGM (total loading including the 909 § 178.75 49 CFR Ch. I (10-1-06 Edition) effect of gravity) multiplied by the acsion 2.3 liquefied gases must be deceleration due to gravity. signed so that each pressure receptacle (9) Under each of the forces specified can be filled separately and be kept in paragraph (d)(8) of this section, the isolated by a valve capable of being stress at the most severely stressed closed during transit. For Division 2.1 point of the pressure receptacles must gases, the pressure receptacles must be not exceed the values given in the apisolated by an individual shut-off valve plicable design specifications (e.g., ISO into assemblies of not more than 3,000 11120). L. (10) Under each of the forces specified (3) For MEGC filling and discharge in paragraph (d)(8) of this section, the openings: safety factor for the framework and (i) Two valves in series must be fastenings must be as follows: placed in an accessible position on each (i) For steels having a clearly defined discharge and filling pipe. One of the yield point, a safety factor of 1.5 in revalves may be a backflow prevention lation to the guaranteed yield valve. (ii) The filling and discharge destrength; or vices may be equipped to a manifold. (ii) For steels with no clearly defined (iii) For sections of piping which can yield point, a safety factor of 1.5 in rebe closed at both ends and where a liqlation to the guaranteed 0.2 percent uid product can be trapped, a pressureproof strength and, for austenitic relief valve must be provided to presteels, the 1 percent proof strength. vent excessive pressure build-up. (11) MEGCs must be capable of being (iv) The main isolation valves on a electrically grounded to prevent elec- MEGC must be clearly marked to inditrostatic discharge when intended for cate their directions of closure. All flammable gases. shutoff valves must close by a clock- (12) The pressure receptacles of a wise motion of the handwheel. MEGC must be secured in a manner to (v) Each shut-off valve or other prevent movement that could result in means of closure must be designed and damage to the structure and conconstructed to withstand a pressure centration of harmful localized equal to or greater than 1.5 times the stresses. test pressure of the MEGC. (e) Service equipment. (1) Service (vi) All shut-off valves with screwed equipment must be arranged so that it spindles must close by a clockwise mois protected from mechanical damage tion of the handwheel. For other shutby external forces during handling and off valves, the open and closed positransportation. When the connections tions and the direction of closure must between the frame and the pressure rebe clearly shown. ceptacles allow relative movement be- (vii) All shut-off valves must be detween the subassemblies, the equipsigned and positioned to prevent uninment must be fastened to allow movetentional opening. ment to prevent damage to any work- (viii) Ductile metals must be used in ing part. The manifolds, discharge fltthe construction of valves or accestings (pipe sockets, shut-off devices), sories. and shut-off valves must be protected (4) The piping must be designed, confrom damage by external forces. Manistructed and installed to avoid damage fold piping leading to shut-off valves due to expansion and contraction, memust be sufficiently flexible to protect chanical shock and vibration. Joints in the valves and the piping from sheartubing must be brazed or have an ing, or releasing the pressure recepequally strong metal union. The melttacle contents. The filling and dising point of brazing materials must be charge devices, including flanges or no lower than 525 °C (977 °F). The rated threaded plugs, and any protective caps pressure of the service equipment and must be capable of being secured of the manifold must be not less than against unintended opening. two-thirds of the test pressure of the (2) Each pressure receptacle intended pressure receptacles. for the transport of Division 2.3 gases (f) Pressure relief devices. Each presmust be equipped with an individual sure receptacle must be equipped with shut-off valve. The manifold for Divione or more pressure relief devices as 910 Pipeline and Hazardous Materials Safety Admin., DOT § 178.75 specified in $ 173.301(f) of this subcaping gas must be directed away from chapter. When pressure relief devices the pressure receptacle in such a manare installed, each pressure receptacle ner that it cannot impinge upon the or group of pressure receptacles of a other pressure receptacles. Heat resist- MEGC that can be isolated must be ant protective devices that deflect the equipped with one or more pressure reflow of gas are permissible provided the lief devices. Pressure relief devices required pressure relief device capacity must be of a type that will resist dyis not reduced. Arrangements must be namic forces including liquid surge and made to prevent access to the pressure must be designed to prevent the entry relief devices by unauthorized persons of foreign matter, the leakage of gas and to protect the devices from damage and the development of any dangerous caused by rollover. excess pressure. (g) Gauging devices. When a MEGC is (1) The size of the pressure relief deintended to be filled by mass, it must vices: CGA S-1.1, 2003 edition (IBR, see be equipped with one or more gauging $171.7 of this subchapter) must be used devices. Glass level-gauges and gauges to determine the relief capacity of inmade of other fragile material are prodividual pressure receptacles. hibited. (2) Connections to pressure-relief de- (h) MEGC supports, frameworks, lifting vices: Connections to pressure relief and tie-down attachments. (1) MEGCs devices must be of sufficient size to enmust be designed and constructed with able the required discharge to pass un- a support structure to provide a secure restricted to the pressure relief device. base during transport. MEGCs must be A shut-off valve installed between the protected against damage to the prespressure receptacle and the pressure resure receptacles and service equipment lief device is prohibited, except where resulting from lateral and longitudinal duplicate devices are provided for impact and overturning. The forces maintenance or other reasons, and the specified in paragraph (d)(8) of this secshut-off valves serving the devices action, and the safety factor specified in tually in use are locked open, or the paragraph (d)(10) of this section must shut-off valves are interlocked so that be considered in this aspect of the deat least one of the duplicate devices is sign. Skids, frameworks, cradles or always operable and capable of meeting other similar structures are acceptthe requirements of paragraph (f)(1) of able. If the pressure receptacles and this section. No obstruction is perservice equipment are so constructed mitted in an opening leading to or as to withstand impact and overleaving from a vent or pressure-relief turning, additional protective support device that might restrict or cut-off structure is not required (see parathe flow from the pressure receptacle graph (h)(4) of this section). to that device. The opening through all (2) The combined stresses caused by piping and fittings must have at least pressure receptacle mountings (e.g. the same flow area as the inlet of the cradles, frameworks, etc.) and MEGC pressure relief device to which it is lifting and tie-down attachments must connected. The nominal size of the disnot cause excessive stress in any prescharge piping must be at least as large sure receptacle. Permanent lifting and as that of the pressure relief device. tie-down attachments must be (3) Location of pressure-relief deequipped to all MEGCs. Any welding of vices: For liquefied gases, each presmountings or attachments onto the sure relief device must, under maxpressure receptacles is prohibited. imum filling conditions, be in commu- (3) The effects of environmental cornication with the vapor space of the rosion must be taken into account in pressure receptacles. The devices, when the design of supports and frameworks. installed, must be arranged to ensure (4) When MEGCs are not protected the escaping vapor is discharged upduring transport as specified in parawards and unrestrictedly to prevent graph (h)(1) of this section, the presimpingement of escaping gas or liquid sure receptacles and service equipment upon the MEGC, its pressure recepmust be protected against damage retacles or personnel. For flammable, sulting from lateral or longitudinal impyrophoric and oxidizing gases, the espact or overturning. External fittings 911 § 178.75 49 CFR Ch. I (10-1-06 Edition) must be protected against release of transport. A listing of acceptable the pressure receptacles' contents upon methods for performing the impact test impact or overturning of the MEGC on is provided in the UN Recommendaits fittings. Particular attention must tions (IBR. see $171.7 of this subbe paid to the protection of the manichapter). fold. Examples of protection include: (j) Marking. (1) Each MEGC must be (i) Protection against lateral impact, equipped with a corrosion resistant which may consist of longitudinal bars; metal plate permanently attached to (ii) Protection against overturning. the MEGC in a conspicuous place readwhich may consist of reinforcement ily accessible for inspection. The presrings or bars fixed across the frame; sure receptacles must be marked ac- (iii) Protection against rear impact, cording to this section. Affixing the which may consist of a bumper or metal plate to a pressure receptacle is frame; prohibited. At a minimum, the fol- (iv) Protection of the pressure receplowing information must be marked on tacles and service equipment against the plate by stamping or by any other damage from impact or overturning by equivalent method: use of an ISO frame according to the relevant provisions of ISO 1496-3. (IBR, Country of manufacture see $171.7 of this subchapter). UN (i) Initial inspection and test. The pressure receptacles and items of equipment of each MEGC must be inspected and tested before being put into service for the first time (initial inspection and test). This initial inspection and test of an MEGC must include the following: (1) A check of the design characteristics. (2) An external examination of the MEGC and its fittings, taking into account the hazardous materials to be transported. (3) A pressure test performed at the Approval Country test pressures specified in Approval Number §173.304b(b)(1) and (2) of this subchapter. The pressure test of the mani- Alternate Arrangements (see $178.75(b)) fold may be performed as a hydraulic MEGC Manufacturer's name or mark test or by using another liquid or gas. MEGC's serial number A leakproofness test and a test of the satisfactory operation of all service Approval agency (Authorized body for equipment must also be performed bethe design approval) fore the MEGC is placed into service. Year of manufacture When the pressure receptacles and Test pressure: bar gauge their fittings have been pressure-tested Design temperature range °C to separately, they must be subjected to a °C leakproof test after assembly. (4) An MEGC that meets the defini- Number of pressure receptacles tion of "container" in the CSC (see 49 Total water capacity liters CFR 450.3(a) must be subjected to an Initial pressure test date and identiimpact test using a prototype repfication of the Approval Agency resenting each design type. The prototype MEGC must be shown to be capa- Date and type of most recent periodic tests ble of absorbing the forces resulting from an impact not less than 4 times (4 Year Month Type g) the MPGM of the fully loaded (e.g. 2004-05, AE/UE, where "AE" rep- MEGC, at a duration typical of the meresents acoustic emission and "UE" chanical shocks experienced in rail represents ultrasonic examination) 912 Pipeline and Hazardous Materials Safety Admin., DOT Pt. 178, Subpt. C, App. A Stamp of the approval agency who Maximum permissible load mass performed or witnessed the most recent kg test Working pressure at 15 °C: bar (2) The following information must gauge be marked on a metal plate firmly se- Maximum permissible gross mass cured to the MEGC: (MPGM) kg Name of the operator Unladen (tare) mass kg [71 FR 33892, June 12. 2006] APPENDIX A TO SUBPART C OF PART 178-ILLUSTRATIONS: CYLINDER TENSILE SAMPLE The following figures illustrate the recommended locations for test specimens taken from welded cylinders: 913 Pt. 178, Subpt. C, App. A 49 CFR Ch. I (10-1-06 Edition) 1 4 2 SEAMLESS BODY SECTIONS REQUIRE ONLY 3 ONE PARENT METAL TEST 5 OPTIONAL CONVEX HEAD PARENT MATERIAL TEST SAMPLE 1 & 3 & 5 WELD TENSILE TEST И SAMPLE 4 WELD BEND TEST SAMPLE 2 THIS FIGURE ILLUSTRATES THE PROPER TENSILE LOCATION FOR A 3 PIECE CYLINDER WITH THE HEADS HAVING STRAIGHT SIDEWALL. FIGURE #1 914 Pipeline and Hazardous Materials Safety Admin., DOT Pf. 178, Subpt. C, App. A 1 4 2 3 OPTIONAL CONVEX HEAD PARENT MATERIAL TEST SAMPLE 1 & 3 WELD TENSILE TEST a SAMPLE 4 WELD BEND TEST SAMPLE 2 THIS FIGURE ILLUSTRATES THE PROPER TENSILE LOCATION FOR A 2 PIECE CYLINDER WITH THE HEADS HAVING STRAIGHT SIDEWALLS. FIGURE #2 915 Pt. 178, Subpt. C, App. A 49 CFR Ch. I (10-1-06 Edition) 1 1 3 ALTERNATIVE LOCATIONS 2 5 4 5 OPTIONAL, CONVEX HEAD SAMPLE TO BE TAKEN FROM HEAD PARENT MATERIAL TEST SAMPLE 1 & 3 & 5 WELD TENSILE TEST SAMPLE 4 WELD BEND TEST SAMPLE 2 THIS FIGURE ILLUSTRATES THE PROPER TENSILE LOCATION FOR A 2 PIECE CYLINDER THAT HAVE DEEP DRAWN HEADS. FIGURE #3 916 Pipeline and Hazardous Materials Safety Admin., DOT Pt. 178, Subpt. C, App. A 1 4 1 3 2 3 SEAMLESS SIDEWALL TWO PIECE CONSTRUCTION CONSTRUCTION PARENT MATERIAL TEST SAMPLE 1 & 3 WELD TENSILE TEST И SAMPLE 4 WELD BEND TEST SAMPLE 2 THIS FIGURE ILLUSTRATES THE PROPER TENSILE LOCATION FOR A 2 PIECE CYLINDER THAT HAVE DEEP DRAWN HEADS. FIGURE #4 917 Pt. 178, Subpt. C, App. A 49 CFR Ch. I (10-1-06 Edition) 1 4 2 3 PARENT MATERIAL TEST SAMPLE 1 & 3 WELD TENSILE TEST a SAMPLE 4 WELD BEND TEST SAMPLE 2 THIS FIGURE ILLUSTRATES THE PROPER TENSILE LOCATION FOR A 2 PIECE CYLINDER. FIGURE #5 [67 FR 51654, Aug. 8, 2002] 918 Pipeline and Hazardous Materials Safety Admin., DOT $ 178.255-6 Subparts D-G [Reserved] § 178.255-3 Expansion domes. (a) Expansion domes, if applied, must Subpart H-Specifications for have a minimum capacity of one per- Portable Tanks cent of the combined capacity of the tank and dome. SOURCE: 29 FR 18972, Dec. 29, 1964, unless (b) [Reserved] otherwise noted. Redesignated at 32 FR 5606, Apr. 5, 1967. § 178.255-4 Closures for manholes and domes. §§ 178.251-178.253-5 [Reserved] (a) The manhole cover shall be de- § 178.255 Specification 60; steel portsigned to provide a secure closure of able tanks. the manhole. All covers, not hinged to the tanks, shall be attached to the out- § 178.255-1 General requirements. side of the dome by at least 1/8 inch chain or its equivalent. Closures shall (a) Tanks must be of fusion welded be made tight against leakage of vapor construction, cylindrical in shape with and liquid by use of gaskets of suitable seamless heads concave to the presmaterial. sure. Tank shells may be of seamless construction. (b) [Reserved] (b) Tanks must be designed, con- § 178.255-5 Bottom discharge outlets. structed, certified, and stamped in accordance with Section VIII of the (a) Bottom discharge outlets prohib- ASME Code (IBR, see § 171.7 of this subited, except on tanks used for shipchapter). ments of sludge acid and alkaline cor- (c) Tanks including all permanent atrosive liquids. tachments must be postweld heat (b) If installed, bottom outlets or treated as a unit. bottom washout chambers shall be of (d) Requirements concerning types of metal not subject to rapid deterioravalves, retesting. and qualification of tion by the lading, and each shall be portable tanks contained in §§ 173.32 provided with a valve or plug at its and 173.315 of this chapter must be obupper end and liquid-tight closure at it served. lower end. Each valve or plug shall be designed to insure against unseating [29 FR 18972, Dec. 29, 1964. Redesignated at 32 due to stresses or shocks incident to FR 5606. Apr. 5, 1967. and amended by Amdt. 178-7, 34 FR 18250, Nov. 14, 1969; 68 FR 75750, transportation. Bottom outlets shall be Dec. 31, 2003) adequately protected against handling damage and outlet equipment must not § 178.255-2 Material. extend to within less than one inch of the bottom bearing surface of the skids (a) Material used in the tank must be steel of good weldable quality and conor tank mounting. form with the requirements in Sections [29 FR 18972, Dec. 29, 1964. Redesignated at 32 V, VIII, and IX of the ASME Code (IBR, FR 5606, Apr. 5, 1967. as amended by Amdt. see $171.7 of this subchapter). 178-104, 59 FR 49135, Sept. 26, 1994] (b) The minimum thickness of metal, exclusive of lining material, for shell § 178.255-6 Loading and unloading accessories. and heads of tanks shall be as follows: (a) When installed, gauging, loading Minimum and air inlet devices, including their Tank capacity thickness (inch) valves, shall be provided with adequate means for their secure closure; and Not more than 1,200 gallons 1/4 Over 1,200 to 1,800 gallons 5/16 means shall also be provided for the Over 1,800 gallons 3/8 closing of pipe connections of valves. (b) Interior heater coils, if installed, [29 FR 18972. Dec. 29, 1964. Redesignated at 32 must be of extra heavy pipe and so con- FR 5606, Apr. 5, 1967, and amended by Amdt. structed that breaking off of exterior 178-7, 34 FR 18250, Nov. 14, 1969; 68 FR 75750, connections will not cause leakage of Dec. 31, 2003) tanks. 919 § 178.255-7 49 CFR Ch. I (10-1-06 Edition) § 178.255-7 Protection of valves and devices shall be deemed to comply with accessories. this requirement. (a) All valves, fittings, accessories, (b) All tank mountings such as skids, safety devices, gauging devices, and the fastenings, brackets, cradles, lifting like shall be adequately protected lugs, etc., intended to carry loadings against mechanical damage by a housshall be permanently secured to tanks ing closed with a cover plate. in accordance with the requirements (b) Protective housing shall comply under which the tanks are fabricated, with the requirements under which the and shall be designed with a factor of tanks are fabricated with respect to desafety of four, and built to withstand sign and construction, and shall be deloadings in any direction equal to two signed with a minimum factor of safety times the weight of the tanks and atof four to withstand loadings in any ditachments when filled to the maximum rection equal to two times the weight permissible loaded weight. of the tank and attachments when (c) Lifting lugs or side hold-down filled with water. lugs shall be provided on the tank mountings in a manner suitable for at- § 178.255-8 Safety devices. taching lifting gear and hold-down de- (a) See § 173.315(i) of this subchapter. vices. Lifting lugs and hold-down lugs (b) [Reserved] welded directly to the tank shall be of the pad-eye type. Doubling plates weld- [Amdt. 178-83, 50 FR 11066, Mar. 19, 1985] ed to the tank and located at the § 178.255-9 Compartments. points of support shall be deemed to comply with this requirement. (a) When the interior of the tank is (d) All tank mountings shall be so dedivided into compartments, each comsigned as to prevent the concentration partment shall be designed, conof excessive loads on the tank shell. structed and tested as a separate tank. Thickness of shell and compartment § 178.255-12 Pressure test. heads shall be determined on the basis of total tank capacity. (a) Each completed portable tank (b) [Reserved] prior to application of lining shall be tested before being put into transpor- § 178.255-10 Lining. tation service by completely filling the (a) If a lining is required, the matetank with water or other liquid having rial used for lining the tank shall be a similar viscosity, the temperature of homogeneous, nonporous, imperforate which shall not exceed 100 °F during when applied, not less elastic than the the test, and applying a pressure of 60 metal of the tank proper. It shall be of psig. The tank shall be capable of holdsubstantially uniform thickness, not ing the prescribed pressure for at least less than 1/32 inch thick if metallic, and 10 minutes without leakage, evidence not less than 1/16 inch thick if nonof impending failure, or failure. All clometallic, and shall be directly bonded sures shall be in place while the test is or attached by other equally satisfacmade and the pressure shall be gauged tory means. Rubber lining shall be not at the top of the tank. Safety devices less than 3/16 inch thick. Joints and and/or vents shall be plugged during this test. seams in the lining shall be made by fusing the material together or by (b) [Reserved] other equally satisfactory means. The [29 FR 18972. Dec. 29, 1964. Redesignated at 32 interior of the tank shall be free from FR 5606, Apr. 5, 1967, as amended by Amdt. scale, oxidation, moisture and all for- 178-104, 59 FR 49135, Sept. 26, 1994] eign matter during the lining operation. § 178.255-13 Repair of tanks. (b) [Reserved] (a) Tanks failing to meet the test may be repaired and retested, provided § 178.255-11 Tank mountings. that repairs are made in complete com- (a) Tanks shall be designed and fabpliance with the requirements of this ricated with mountings to provide a sespecification. cure base in transit. "Skids" or similar (b) [Reserved] 920 Pipeline and Hazardous Materials Safety Admin., DOT § 178.270-12 $ 178.255-14 Marking. § 178.270-12 Valves, nozzles, piping, (a) In addition to markings required and gauging devices. by Section VIII of the ASME Code (a) All tank nozzles, except those pro- (IBR, see $171.7 of this subchapter), vided for filling and discharge connecevery tank shall bear permanent marks tions below the normal liquid level of at least 1/8-inch high stamped into the the tank, relief devices, thermometer metal near the center of one of the wells, and inspection openings, must be tank heads or stamped into a plate perfitted with manually operated stop manently attached to the tank by valves located as near the shell as pracmeans of brazing or welding or other ticable either internal or external to suitable means as follows: the shell. Each filling and discharge Manufacturer's name Serial connection located below the normal No. liquid level of the tank must be DOT specification equipped with an internal discharge Nominal capacity (gallons) valve. A tank nozzle installed in the Tare weight (pounds) Date of manufacture vapor space to provide a filling or cleaning opening, which is closed by a (b) [Reserved] blank flange or other suitable means, [29 FR 18972, Dec. 29, 1964. Redesignated at 32 need not be provided with a manually FR 5606, Apr. 5, 1967, and amended by Amdt. operated stop valve. A tank nozzle in- 178-67, 46 FR 49906, Oct. 8. 1981; 68 FR 75750, stalled for a thermometer well or in- Dec. 31, 2003] spection opening need not be provided § 178.255-15 Report. with a manually operated stop valve. (b) Each valve must be designed and (a) A copy of the manufacturer's data report required by Section VIII of the constructed to a rated pressure not less ASME Code (IBR, see $171.7 of this subthan the MAWP of the tank. Each stop chapter) under which the tank is fabvalve with a screwed spindle must be ricated must be furnished to the owner closed by a clockwise motion of the for each new tank. handwheel. All valves must be constructed to prevent unintentional Place opening. Date Portable tank (c) Each internal discharge valve Manufactured for Company shall be self-closing, located inside the Location tank, within the welded flange or with- Manufactured by Company in its companion flange. Location (d) A shear section must be located Consigned to Company Location outboard of each internal discharge Size feet outside diameter by valve seat and within 10.2 cm (4 inches) long. of the vessel. The shear section must Marks on tank as prescribed by $178.255-14 of break under strain without affecting this specification are as follows: the product retention capabilities of Manufacturer's name Serial number the tank and any attachments. Owner's serial number (e) All piping must be of suitable ma- DOT specification terial. Welded joints must be used ASME Code Symbol (par U-201) wherever practicable. The bursting Date of manufacture strength of all piping and pipe fittings Nominal capacity gallons. must be at least 4 times the MAWP of It is hereby certified that this tank is in complete compliance with the requirements the tank. Piping must be supported in of DOT specification No. 60. such a manner as to prevent damage (Signed) due to thermal stresses, jarring or vi- Manufacturer or owner bration. (b) [Reserved] (f) All nozzles and tank shell penetrations for nozzles shall be designed and [29 FR 18972, Dec. 29, 1964. Redesignated at 32 FR 5606, Apr. 5, 1967, and amended by Amdt. constructed in accordance with Section 178-83, 50 FR 11066, Mar. 19, 1985; 68 FR 75750, VIII of the ASME Code (IBR, see § 171.7 Dec. 31, 2003) of this subchapter). 921 § 178.270-13 49 CFR Ch. I (10-1-06 Edition) (g) Glass liquid level gauges, or port at the lower end of the base strucgauges of other easily destructible mature providing vertical and lateral reterial, which are in direct communicastraint and by support at the upper end tion with the contents of the tank are of the base structure providing lateral prohibited. restraint only. [Amdt. 178-65, 46 FR 9898. Jan. 29. 1981; 46 FR (2) Lateral inertia. The tank loaded to 24184, Apr. 30, 1981, as amended by Amdt. 178- its maximum gross weight must be po- 117. 61 FR 50628. Sept. 26, 1996; 66 FR 45386, sitioned for five minutes with its trans- Aug. 28. 2001; 68 FR 75751, Dec. 31, 2003) verse axis vertical. It shall be held in this position for five minutes by sup- § 178.270-13 Testing. port at the lower side of the base struc- (a) Hydrostatic test. Each portable ture providing vertical and lateral retank and all piping. valves, and other straint and by support at the upper attachments which are subject to the side of the base structure providing latpressure of the contents of the tank, eral restraint only. except pressure relief devices, must be (d) Approval of smaller tanks of the hydrostatically tested by completely same design. Design approval must infilling the tank (including domes, if clude the prototype testing of at least any) with water or other liquid having one tank of each design and each size; a similar density and viscosity and aphowever, a set of tests made on a tank plying a pressure of at least 150 percent of one size may serve for the approval of the MAWP. The pressure shall be of smaller tanks with equal or lesser maintained for at least 10 minutes. diameter and length) made of the same While under pressure, the tank shall be material and thickness by the same inspected for leakage, undue distorfabrication technique and with idention, or other conditions which inditical supports and equivalent closures cate weakness or which might render and other appurtenances. the tank unsafe for transportation (e) Pressure and vacuum relief devices. service. Failure to successfully meet Each spring loaded relief device must the test criteria shall be deemed evibe tested for the accuracy of the setdence of failure to meet the requireting prior to installation on a tank and ments of this specification. Tanks failmust be effectively sealed to maintain ing to pass the test shall be suitably the required setting. repaired and must successfully pass the (Amdt. 178-65, 46 FR 9898, Jan. 29, 1981; 46 FR prescribed tests prior to use for trans- 24184, Apr. 30, 1981, as amended by 66 FR porting any hazardous material. 45387, Aug. 28, 2001] (b) Testing of internal coils. Internal coils, if installed, must be § 178.270-14 Marking of tanks. hydrostatically tested to an internal (a) General. Each tank must bear a pressure of 13.8 bar (200 psig) or 150 percorrosion resistant metal identificacent of the rated pressure of the coils, tion plate that is permanently atwhichever is greater. tached to the portable tank and readily (c) Tank container qualification test. accessible for inspection. The informa- For each tank design, a prototype tion required in paragraph (b), and, tank, using a framework for containerwhen appropriate, paragraph (c) of this ized transport, must fulfill the requiresection must be stamped, embossed or ments of parts 450-453 of this title for otherwise marked by an equally duracompliance with the requirements of ble method on the plate in characters Annex II of the International Convenat least 3 mm (0.118 inches) high. The tion for Safe Containers. In addition, plate must not be painted. the following tests must be completed (b) Required information. At least the without leakage or deformation that following information must appear on would render the tank unsuitable for the metal identification plate for each use: tank: (1) Longitudinal inertia. The tank (1) US DOT Specification number. loaded to its maximum gross weight (2) Country of manufacture. must be positioned with its longitu- (3) Manufacturer's name. dinal axis vertical. It shall be held in (4) Date of manufacture. this position for five minutes by sup- (5) Manufacturer's serial number. 922 Pipeline and Hazardous Materials Safety Admin., DOT § 178.273 (6) Identification of USA/DOT apapproval agency previously and judged proval agency and approval number. unacceptable. Affirmative statements (7) MAWP, in bar or psig. must be documented with the name of (8) Test pressure, in bar or psig. the approval agency, reason for non- (9) Total measured water capacity at acceptance, and the nature of modifica- 20 °C (68 °F), in liters or gallons. tions made to the design type. (10) Maximum allowable gross (b) Action by approval agency. The apweight, in kg or lbs. proval agency must perform the fol- (11) Equivalent minimum shell thicklowing activities: ness in mild steel, in mm or Inches. (12) Tank material and specification (1) Review the application for apnumber. proval to determine whether it is com- (13) Metallurgical design temperature plete and conforms with the requirerange, in °C or °F. ments of paragraph (a) of this section. (c) Additional information. The fol- If an application is incomplete, it will lowing additional information must apbe returned to the applicant with an pear on the metal identification plate explanation as to why the application when applicable: is incomplete. (1) Lining material. (2) Review all drawings and calcula- (2) Heating coil MAWP in bar and tions to ensure that the design is in psig. compliance with all requirements of (3) Corrosion allowance, in mm or in. the relevant specification. If the appli- (d) In addition to the markings recation is approved, one set of the apquired above, each tank used in interproved drawings, calculations, and test national transport must have a Safety data shall be returned to the applicant. Approval Plate containing the informa- The second (inspector's copy) set of aption required in §§ 451.21 through 451.25 proved drawings, calculations, and test of this title. data shall be retained by the approval (e) Nothing in this section shall be agency. Maintain drawings and apdeemed to preclude the display of other proval records for as long as the portpertinent information on the required able tank remains in service. The drawmetal identification plate. ings and records must be provided to the Department of Transportation [Amdt. 178-65, 46 FR 9899, Jan. 29, 1981, as (DOT) upon request. amended at 62 FR 51561, Oct. 1. 1997; 66 FR 45387, Aug. 28, 2001] (3) Witness all tests required for the approval of the portable tank specified § 178.273 Approval of Specification IM in this section and part 180, subpart G portable tanks and UN portable of this subchapter. tanks. (4) Ensure, through appropriate in- (a) Application for approval. (1) An spection that each portable tank is fabowner or manufacturer of a portable ricated in all respects in conformance tank shall apply for approval to a deswith the approved drawings, calculaignated approval agency authorized to tions, and test data. approve the portable tank in accord- (5) Determine and ensure that the ance with the procedures in subpart E, portable tank is suitable for its inpart 107 of this subchapter. tended use and that it conforms to the (2) Each application for approval requirements of this subchapter. must contain the following informa- (6) For UN portable tanks intended tion: for non-refrigerated and refrigerated (i) Two complete copies of all engiliquefied gases and Division 6.1 liquids neering drawings, calculations, and which meet the inhalation toxicity critest data necessary to ensure that the teria (Zone A or B) as defined in design meets the relevant specifica- $173.132 of this subchapter, or that are tion. designated as toxic by inhalation mate- (ii) The manufacturer's serial number rials in the $172.101 Table of this subthat will be assigned to each portable chapter, the approval agency must entank. sure that: (iii) A statement as to whether the (i) The portable tank has been dedesign type has been examined by any signed, constructed, certified, and 923 § 178.273 49 CFR Ch. I (10-1-06 Edition) stamped in accordance with the retype, the certificate may be valid for quirements in Division 1 of Section the entire series of portable tanks rep- VIII of the ASME Code (IBR, see $171.7 resenting a single design type. For UN of this subchapter). Other design codes portable tanks, the certificate must may be used if approved by the Assorefer to the prototype test report, the ciate Administrator (see §178.274(b)(1); hazardous material or group of haz- (ii) All applicable provisions of the ardous materials allowed to be transdesign and construction have been met ported, the materials of construction of to the satisfaction of the designated the shell and lining (when applicable) approval agency in accordance with the and an approval number. The approval rules established in the ASME Code number must consist of the distinand that the portable tank meets the guishing sign or mark of the country requirements of the ASME Code and all ("USA" for the United States of Amerthe applicable requirements specified ica) where the approval was granted in this subchapter; and a registration number. (iii) The inspector has carried out all (iii) Retain a copy of each approval the inspections specified by the rules certificate. established in the ASME Code; and (8) For UN portable tanks, the ap- (iv) The portable tank is marked proval certificate must also include the with a U stamp code symbol under the following: authority of the authorized independent inspector. (i) The results of the applicable (7) Upon successful completion of all framework and rail impact test specirequirements of this subpart, the apfied in part 180, subpart G, of this subproval agency must: chapter; and (i) Apply its name, identifying mark (ii) The results of the initial inspecor identifying number, and the date tion and test in $178.274(j). upon which the approval was issued, to (9) The approval agency shall be indethe metal identification marking plate pendent from the manufacturer. The attached to the portable tank. Any apapproval agency and the authorized inprovals for UN portable tanks authorspector may be the same entity. izing design or construction alter- (c) Manufacturers' responsibilities. The natives (Alternate Arrangements) apmanufacturer is responsible for compliproved by the Associate Administrator ance with the applicable specifications (see $178.274(a)(2)) must be indicated on for the design and construction of portthe plate as specified in $ 178.274(i). able tanks. In addition to responsi- (ii) Issue an approval certificate for bility for compliance, manufacturers each portable tank or, in the case of a are responsible for ensuring that the series of identical portable tanks mancontracted approval agency and auufactured to a single design type, for thorized inspector, if applicable, are each series of portable tanks. The apqualified, reputable and competent. proval certificate must include all the The manufacturer of a portable tank information required to be displayed on shallthe required metal identification plate (1) Comply with all the applicable Γe- required by $178.270-14 of this subquirements of the ASME Code and of chapter for IM portable tanks, $178.245- this subpart including, but not limited 6 for Specification 51 steel portable to, ensuring that the quality control, tanks, or $178.274(i) for UN portable design calculations and required tests tanks. The approval certificate must are performed and that all aspects of certify that the approval agency desthe portable tank meet the applicable ignated to approve the portable tank requirements. has approved the portable tank in ac- (2) Obtain and use a designated apcordance with the procedures in subproval agency, If applicable, and obtain part E of part 107 of this subchapter and use a DOT-designated approval and that the portable tank is suitable agency to approve the design, construcfor its intended purpose and meets the tion and certification of the portable requirements of this subchapter. When tank. a series of portable tanks is manufac- (3) Provide a statement in the manutured without change in the design facturers' data report certifying that 924 Pipeline and Hazardous Materials Safety Admin., DOT § 178.273 each portable tank that is manufacapproved and the approval agency shall tured complies with the relevant speciperform the following activities: fication and all the applicable require- (i) Return one set of the approved rements of this subchapter. vised drawings, calculations, and test (4) Maintain records of the qualificadata to the applicant. The second and tion of portable tanks for at least 5 third sets of the approved revised drawyears and provide copies to the apings, calculations, and data shall be reproval agency, the owner or lessee of tained by the approval agency as rethe tank. Upon request, provide these quired in § 107.404(a)(3) of this subrecords to a representative of DOT. chapter. (d) Denial of application for approval. (ii) Ensure through appropriate in- If an approval agency finds that a portspection that all modifications conable tank cannot be approved for any form to the revised drawings, calculareason, it shall notify the applicant in tions, and test data. writing and shall provide the applicant (iii) Determine the extent to which with the reasons for which the apretesting of the modified tank is necproval is denied. A copy of the notificaessary based on the nature of the protion letter shall be provided to the Asposed modification, and ensure that all sociate Administrator. An applicant required retests are satisfactorily peraggrieved by a decision of an approval formed. agency may appeal the decision in (iv) If modification to an approved writing, within 90 days of receipt, to tank alters any information on the apthe Associate Administrator. proval certificate, issue a new approval (e) Modifications to approved portable certificate for the modified tank and tanks. (1) Prior to modification of any ensure that any necessary changes are approved portable tank which may afmade to the metal identification plate. fect conformance and the safe use of an A copy of each newly issued approval IM or UN portable tank, which may incertificate shall be retained by the apvolve a change to the design type or proval agency and by the owner of each which may affect its ability to retain portable tank. the hazardous material in transpor- (4) If the approval agency determines tation, the person desiring to make that the proposed modification is not such modification shall inform the apin compliance with the relevant DOT proval agency that issued the initial specification, the approval agency approval of the portable tank (or if unshall deny the request in accordance available another approval agency) of with paragraph (d) of this section. the nature of the modification and re- (f) Termination of Approval Certificate. quest approval of the modification. The (1) The Associate Administrator may person desiring to modify the tank terminate an approval issued under must supply the approval agency with this section if he determines thatthree sets of all revised drawings, cal- (i) Information upon which the apculations, and test data relative to the proval was based is fraudulent or subintended modification. stantially erroneous; or (2) A statement as to whether the in- (ii) Termination of the approval is tended modification has been examined necessary to adequately protect and determined to be unacceptable by against risks to life and property; or any approval agency. The written (iii) The approval was not issued by statement must include the name of the approval agency in good faith; or the approving agency, the reason for (iv) The portable tank does not meet nonacceptance, and the nature of the specification. changes made to the modification since (2) Before an approval is terminated, its original rejection. the Associate Administrator gives the (3) The approval agency shall review interested party(ies): the request for modification, and If it (i) Written notice of the facts or conis determined that the proposed modiduct believed to warrant the termification is in full compliance with the nation; relevant DOT specification, including a (ii) Opportunity to submit oral and UN portable tank, the request shall be written evidence; and 925 § 178.274 49 CFR Ch. I (10-1-06 Edition) (iii) Opportunity to demonstrate or Alternate Arrangement portable tank achieve compliance with the applicable means a UN portable tank that has requirements. been approved to alternative technical (3) If the Associate Administrator derequirements or testing methods other termines that a certificate of approval than those specified for UN portable must be terminated to preclude a sigtanks in part 178 or part 180 of this subnificant and imminent adverse affect chapter. on public safety, he may terminate the Approval agency means the descertificate immediately. In such cirignated approval agency authorized to cumstances, the opportunities of paraapprove the portable tank in accordgraphs (f)(2) (ii) and (iii) of this section ance with the procedures in subpart E need not be provided prior to termiof part 107 of this subchapter. nation of the approval, but shall be Design pressure is defined according provided as soon as practicable thereto the hazardous materials intended to after. be transported in the portable tank. See SS 178.275, 178.276 and 178.277, as ap- [66 FR 33439, June 21, 2001, as amended at 67 plicable. FR 61016, Sept. 27, 2002; 68 FR 75748, 75751, Design type means a portable tank or Dec. 31, 2003] series of portable tanks made of mate- § 178.274 Specifications for UN portrials of the same material specificaable tanks. tions and thicknesses, manufactured by a single manufacturer, using the (a) General. (1) Each UN portable same fabrication techniques (for examtank must meet the requirements of ple, welding procedures) and made with this section. In addition to the requireequivalent structural equipment, cloments of this section, requirements sures, and service equipment. specific to UN portable tanks used for Fine grain steel means steel that has a liquid and solid hazardous materials, ferritic grain size of 6 or finer when denon-refrigerated liquefied gases and retermined in accordance with ASTM E frigerated liquefied gases are provided 112-96 (IBR, see $171.7 of this subin $ 178.275, 178.276 and 178.277, respecchapter). tively. Requirements for approval, Fusible element means a non-reclosing maintenance, inspection, testing and pressure relief device that is thermally use are provided in 178.273 and part activated and that provides protection 180, subpart G, of this subchapter. Any against excessive pressure buildup in portable tank which meets the definithe portable tank developed by expotion of a "container" within the terms sure to heat, such as from a fire (see of the International Convention for $178.275(g)). Safe Containers (CSC) must meet the Jacket means the outer insulation requirements of the CSC as amended cover or cladding which may be part of and 49 CFR parts 450 through 453 and the insulation system. must have a CSC safety approval plate. Leakage test means a test using gas to (2) In recognition of scientific and subject the shell and its service equiptechnological advances, the technical ment to an internal pressure. requirements applicable to UN portable Maximum allowable working pressure tanks may be varied if approved by the (MAWP) is defined according to the Associate Administrator and the porthazardous materials intended to be able tank is shown to provide a level of transported in the portable tank. See safety equal to or exceeding the re- SS 178.275, 178.276 and 178.277, as applicaquirements of this subchapter. Portble. able tanks approved to alternative Maximum permissible gross mass technical requirements must be (MPGM) means the sum of the tare marked "Alternative Arrangement" as mass of the portable tank and the specified in paragraph (i) of this secheaviest hazardous material authorized tion. for transportation. (3) Definitions. The following defini- Mild steel means a steel with a guartions apply for the purposes of design anteed minimum tensile strength of 360 and construction of UN portable tanks N/mm2 to 440 N/mm2 and a guaranteed under this subpart: minimum elongation at fracture as 926 Pipeline and Hazardous Materials Safety Admin., DOT § 178.274 specified in paragraph (c)(10) of this ture must not be less than the maxsection. imum temperature of the hazardous Offshore portable tank means a portmaterial during filling, discharge or able tank specially designed for retransportation. More severe design peated use in the transportation of haztemperatures must be considered for ardous materials to, from and between portable tanks subjected to severe clioffshore facilities. An offshore portable matic conditions (for example, portable tank is designed and constructed in actanks transported in arctic regions). cordance with the Guidelines for the Shells must be designed and con- Approval of Containers Handled in structed in accordance with the re- Open Seas specified in the IMDG Code quirements in Section VIII of the (IBR, see $171.7 of this subchapter). ASME Code (IBR, see $171.7 of this sub- Reference steel means a steel with a chapter), except as limited or modified tensile strength of 370 N/mm2 and an in this subchapter. For portable tanks elongation at fracture of 27%. used for liquid or solid hazardous mate- Service equipment means measuring rials, a design code other than the instruments and filling, discharge, ASME Code may be used if approved by venting, safety, heating, cooling and the Associate Administrator. Portable insulating devices. tanks used for non-refrigerated and re- Shell means the part of the portable frigerated liquified compressed gases tank which retains the hazardous marequire an ASME certification and U terials intended for transportation, instamp. Shells must be made of metallic cluding openings and closures, but does materials suitable for forming. Nonnot include service equipment or extermetallic materials may be used for the nal structural equipment. attachments and supports between the Structural equipment means the reinshell and jacket, provided their mateforcing, fastening, protective and stabirial properties at the minimum and lizing members external to the shell. maximum design temperatures are Test pressure means the maximum proven to be sufficient. For welded gauge pressure at the top of the shell shells, only a material whose during the hydraulic pressure test weldability has been fully demequal to not less than 1.5 times the deonstrated may be used. Welds must be sign pressure for liquids and 1.3 for liqof high quality and conform to a level uefied compressed gases and refrigof integrity at least equivalent to the erated liquefied gases. In some inwelding requirements specified in Secstances a pneumatic test is authorized tion VIII of the ASME Code for the as an alternative to the hydraulic test. welding of pressure vessels. When the The minimum test pressures for portmanufacturing process or the materials able tanks intended for specific liquid make it necessary, the shells must be and solid hazardous materials are specsuitably heat-treated to guarantee adeified in the applicable portable tank T quate toughness in the weld and in the codes (such as T1-T23) assigned to heat-affected zones. In choosing the these hazardous materials in the material. the design temperature range § 172.101 Table of this subchapter. must be taken into account with re- (b) General design and construction respect to risk of brittle fracture, stress quirements. (1) The design temperature corrosion cracking, resistance to imrange for the shell must be -40 °C to -50 pact, and suitability for the hazardous °C (-40 °F to 122 °F) for hazardous matematerials intended for transportation rials transported under normal condiin the portable tank. When fine grain tions of transportation, except for steel is used, the guaranteed value of portable tanks used for refrigerated the yield strength must be not more liquefied gases where the minimum dethan 460 N/mm2 and the guaranteed sign temperature must not be higher value of the upper limit of the tensile than the lowest (coldest) temperature strength must be not more than 725 N/ (for example, service temperature) of mm² according to the material specithe contents during filling, discharge fication. Aluminum may not be used as or transportation. For hazardous mate- a construction material for the shells rials handled under elevated temperaof portable tanks intended for the ture conditions, the design temperatransport of non-refrigerated liquefied 927 $ 178.274 49 CFR Ch. I (10-1-06 Edition) gases. For portable tanks intended for (6) The construction materials of the the transport of liquid or solid hazportable tank, including any devices, ardous materials, aluminum may only gaskets, linings and accessories, must be used as a construction material for not adversely affect or react with the portable tank shells if approved by the hazardous materials intended to be Associate Administrator. Portable transported in the portable tank. tank materials must be suitable for the (7) Portable tanks must be designed external environment where they will and constructed with supports that be transported. taking into account the provide a secure base during transpordetermined design temperature range. tation and with suitable lifting and tie- Portable tanks shall be designed to down attachments. withstand, without loss of contents, at (c) Design criteria. (1) Portable tanks least the Internal pressure due to the and their fastenings must, under the contents and the static, dynamic and maximum permissible loads and maxthermal loads during normal condiimum permissible working pressures, tions of handling and transportation. be capable of absorbing the following The design must take into account the separately applied static forces (for effects of fatigue, caused by repeated calculation purposes, acceleration due application of these loads through the to gravity (g) =9.81m/s²): expected life of the portable tank. (i) In the direction of travel: 2g (2) Portable tank shells, fittings, and (twice the MPGM multiplied by the acpipework shall be constructed from celeration due to gravity); materials that are: (ii) Horizontally at right angles to (i) Compatible with the hazardous the direction of travel: 1g (the MPGM materials intended to be transported; multiplied by the acceleration due to or gravity): (ii) Properly passivated or neutral- (iii) Vertically upwards: 1g (the ized by chemical reaction, if applica- MPGM multiplied by the acceleration ble; or due to gravity); and (iii) For portable tanks used for liq- (iv) Vertically downwards: 2g (twice uid and solid materials, lined with corthe MPGM multiplied by the accelerarosion-resistant material directly tion due to gravity). bonded to the shell or attached by (2) Under each of the forces specified equivalent means. in paragraph (c)(1) of this section, the (3) Gaskets and seals shall be made of safety factor must be as follows: materials that are compatible with the (i) For metals having a clearly dehazardous materials intended to be fined yield point, a design margin of 1.5 transported. in relation to the guaranteed yield (4) When shells are lined, the lining strength: or must be compatible with the hazardous (ii) For metals with no clearly dematerials intended to be transported, fined yield point, a design margin of 1.5 homogeneous, non-porous, free from in relation to the guaranteed 0.2% perforations, sufficiently elastic and proof strength and, for austenitic compatible with the thermal expansion steels. the 1% proof strength. characteristics of the shell. The lining (3) The values of yield strength or of every shell, shell fittings and piping proof strength must be the values acmust be continuous and must extend cording to recognized material standaround the face of any flange. Where ards. When austenitic steels are used, external fittings are welded to the the specified minimum values of yield tank, the lining must be continuous strength or proof strength according to through the fitting and around the face the material standards may be inof external flanges. Joints and seams in creased by up to 15% for portable tanks the lining must be made by fusing the used for liquid and solid hazardous mamaterial together or by other equally terials, other than toxic by inhalation effective means. liquids meeting the criteria of Hazard (5) Contact between dissimilar met- Zone A or Hazard Zone B (see § 173.133 als which could result in damage by of this subchapter), when these greater galvanic action must be prevented by values are attested in the material inappropriate measures. spection certificate. 928 Pipeline and Hazardous Materials Safety Admin., DOT § 178.274 (4) Portable tanks must be capable of the construction of welded shells. The being electrically grounded to prevent values of Re and Rm to be used in dedangerous electrostatic discharge when termining this ratio must be the values they are used for Class 2 flammable specified in the material inspection gases or Class 3 flammable liquids, incertificate. cluding elevated temperature mate- (10) Steels used in the construction of rials transported at or above their shells must have an elongation at fracflash point. ture, in percentage, of not less than (5) For shells of portable tanks used 10,000/Rm with an absolute minimum of for liquefied compressed gases, the 16% for fine grain steels and 20% for shell must consist of a circular cross other steels. section. Shells must be of a design ca- (11) For the purpose of determining pable of being stress-analyzed matheactual values for materials for sheet matically or experimentally by resistmetal, the axis of the tensile test speciance strain gauges as specified in UGmen must be at right angles (trans- 101 of Section VIII of the ASME Code, versely) to the direction of rolling. The or other methods approved by the Aspermanent elongation at fracture must sociate Administrator. be measured on test specimens of rec- (6) Shells must be designed and contangular cross sections in accordance structed to withstand a hydraulic test with ISO 6892 (IBR, see $171.7 of this pressure of not less than 1.5 times the subchapter), using a 50 mm gauge design pressure for portable tanks used length. for liquids and 1.3 times the design (d) Minimum shell thickness. (1) The pressure for portable tanks used for liqminimum shell thickness must be the uefied compressed gases. Specific regreatest thickness of the following: quirements are provided for each haz- (i) the minimum thickness deterardous material in the applicable T mined in accordance with the require- Code or portable tank special provision ments of paragraphs (d)(2) through specified in the $172.101 Table of this (d)(7) of this section; subchapter. The minimum shell thick- (ii) the minimum thickness deterness requirements must also be taken mined in accordance with Section VIII into account. of the ASME Code or other approved (7) For metals exhibiting a clearly pressure vessel code: or defined yield point or characterized by (iii) the minimum thickness specified a guaranteed proof strength (0.2% proof in the applicable T code or portable strength, generally, or 1% proof tank special provision indicated for strength for austenitic steels). the prieach hazardous material in the $172.101 mary membrane stress σ (sigma) in the Table of this subchapter. shell must not exceed 0.75 Re or 0.50 (2) Shells (cylindrical portions, heads Rm, whichever is lower, at the test and manhole covers) not more than 1.80 pressure, where: m in diameter may not be less than 5 mm thick in the reference steel or of Re = yield strength in N/mm2, or 0.2% proof strength or, for austenitic equivalent thickness in the metal to be used. Shells more than 1.80 m in diamesteels, 1% proof strength; Rm = minimum tensile strength in N/ ter may not be less than 6 mm (0.2 inches) thick in the reference steel or mm². of equivalent thickness in the metal to (8) The values of Re and Rm to be be used. For portable tanks used only used must be the specified minimum for the transportation of powdered or values according to recognized mategranular solid hazardous materials of rial standards. When austenitic steels Packing Group II or III, the minimum are used, the specified minimum values thickness requirement may be reduced for Re and Rm according to the mateto 5 mm in the reference steel or of rial standards may be increased by up equivalent thickness in the metal to be to 15% when greater values are atused regardless of the shell diameter. tested in the material inspection cer- For vacuum-insulated tanks, the agtificate. gregate thickness of the jacket and the (9) Steels which have a Re/Rm ratio shell must correspond to the minimum of more than 0.85 are not allowed for thickness prescribed in this paragraph, 929 § 178.274 49 CFR Ch. I (10-1-06 Edition) with the thickness of the shell itself (d)(3) and (d)(4) of this section. This not less than the minimum thickness thickness must be exclusive of any corprescribed in paragraph (d)(3) of this rosion allowance. section. (7) There must be no sudden change (3) When additional protection of plate thickness at the attachment of against shell damage is provided in the the heads to the cylindrical portion of case of portable tanks used for liquid the shell. and solid hazardous materials requir- (e) Service equipment. (1) Service ing test pressures less than 2.65 bar equipment must be arranged so that it (265.0 kPa), subject to certain limitais protected against the risk of metions specified in the UN Recommendachanical damage by external forces tions (IBR, see $171.7 of this subduring handling and transportation. chapter), the Associate Administrator When the connections between the may approve a reduced minimum shell frame and the shell allow relative thickness. movement between the sub-assemblies, (4) The cylindrical portions, heads the equipment must be fastened to and manhole covers of all shells must allow such movement without risk of not be less than 3 mm (0.1 inch) thick damage to any working part. The exregardless of the material of constructernal discharge fittings (pipe sockets, tion, except for portable tanks used for shut-off devices) and the internal stopliquefied compressed gases where the valve and its seating must be protected cylindrical portions, ends (heads) and manhole covers of all shells must not against mechanical damage by external forces (for example, by using shear be less than 4 mm (0.2 inch) thick regardless of the material of construcsections). Each internal self-closing tion. stop-valve must be protected by a shear section or sacrificial device lo- (5) When steel is used, that has charcated outboard of the valve. The shear acteristics other than that of reference section or sacrificial device must break steel, the equivalent thickness of the at no more than 70% of the load that shell and heads must be determined acwould cause failure of the Internal selfcording to the following formula: closing stop valve. The filling and dis- 21.4e₀d₁ charge devices (including flanges or e₁ = threaded plugs) and any protective X A1 caps must be capable of being secured Where: against unintended opening. e₁ = required equivalent thickness (in mm) of (2) Each filling or discharge opening the metal to be used; of a portable tank must be clearly eo = minimum thickness (in mm) of the refmarked to indicate its function. erence steel specified in the applicable T (3) Each stop-valve or other means of code or portable tank special provision inclosure must be designed and condicated for each material in the $172.101 structed to a rated pressure not less Table of this subchapter; di = 1.8m, unless the formula is used to dethan the MAWP of the shell taking termine the equivalent minimum thickinto account the temperatures exness for a portable tank shell that is repected during transport. All stopquired to have a minimum thickness of valves with screwed spindles must 8mm or 10mm according to the applicable close by a clockwise motion of the T code indicated in the $172.101 Table of handwheel. For other stop-valves, the this subchapter. When reference steel position (open and closed) and directhicknesses of 8mm or 10mm are specified, d, is equal to the actual diameter of the tion of closure must be clearly indishell but not less than 1.8m; cated. All stop-valves must be designed Rm, = guaranteed minimum tensile strength to prevent unintentional opening. (in N/mm²) of the metal to be used; (4) Piping must be designed, con- A, = guaranteed minimum elongation at structed and installed to avoid the risk fracture (in %) of the metal to be used acof damage due to thermal expansion cording to recognized material standards. and contraction, mechanical shock and (6) The wall and all parts of the shell vibration. All piping must be of a suitmay not have a thickness less than able metallic material. Welded pipe that prescribed in paragraphs (d)(2), joints must be used wherever possible. 930 Pipeline and Hazardous Materials Safety Admin., DOT § 178.274 (5) Joints in copper tubing must be use. There must be no obstruction in brazed or have an equally strong metal an opening leading to a vent or presunion. The melting point of brazing sure relief device which might restrict materials must be no lower than 525 °C or cut-off the flow from the shell to (977 °F). The joints must not decrease that device. Vents or pipes from the the strength of the tubing, such as may pressure relief device outlets, when happen when cutting threads. Brazed used, must deliver the relieved vapor or joints are not authorized for portable liquid to the atmosphere in conditions tanks intended for refrigerated liqueof minimum back-pressure on the refied gases. lieving devices. (6) The burst pressure of all piping (3) Location of pressure relief devices. and pipe fittings must be greater than (i) Each pressure relief device inlet the highest of four times the MAWP of must be situated on top of the shell in the shell or four times the pressure to a position as near the longitudinal and which it may be subjected in service by transverse center of the shell as reathe action of a pump or other device sonably practicable. All pressure relief (except pressure relief devices). device inlets must, under maximum (7) Ductile metals must be used in filling conditions, be situated in the the construction of valves and accesvapor space of the shell and the devices sories. must be so arranged as to ensure that (f) Pressure relief devices-(1) Marking any escaping vapor is not restricted in of pressure relief devices. Every pressure any manner. For flammable hazardous relief device must be clearly and permaterials, the escaping vapor must be manently marked with the following: directed away from the shell in such a (i) the pressure (in bar or kPa) or manner that it cannot impinge upon temperature for fusible elements (in the shell. For refrigerated liquefied °C) at which it is set to discharge; gases, the escaping vapor must be di- (ii) the allowable tolerance at the rected away from the tank and in such discharge pressure for reclosing de- a manner that it cannot impinge upon vices; the tank. Protective devices which de- (iii) the reference temperature corflect the flow of vapor are permissible responding to the rated pressure for provided the required relief-device cafrangible discs; pacity is not reduced. (iv) the allowable temperature toler- (ii) Provisions must be implemented ance for fusible elements; to prevent unauthorized persons from (v) The rated flow capacity of the access to the pressure relief devices spring loaded pressure relief devices, and to protect the devices from damage frangible disc or fusible elements in caused by the portable tank overstandard cubic meters of air per second turning. (m³/s). For spring loaded pressure relief (g) Gauging devices. Unless a portable device the rated flow capacity shall be tank is intended to be filled by weight, determined according to ISO 4126-1 it must be equipped with one or more (IBR, see § 171.7 of this subchapter); and gauging devices. Glass level-gauges and (vi) when practicable, the device gauges made of other fragile material, must show the manufacturer's name which are in direct communication and product number. with the contents of the tank are pro- (2) Connections to pressure relief dehibited. A connection for a vacuum vices. Connections to pressure relief degauge must be provided in the jacket of vices must be of sufficient size to en- a vacuum-insulated portable tank. able the required discharge to pass un- (h) Portable tank supports, frameworks, restricted to the safety device. No stoplifting and tie-down attachments. (1) valve may be installed between the Portable tanks must be designed and shell and the pressure relief devices exconstructed with a support structure to cept where duplicate devices are proprovide a secure base during transport. vided for maintenance or other reasons The forces and safety factors specified and the stop-valves serving the devices in paragraphs (c)(1) and (c)(2) of this actually in use are locked open or the section, respectively, must be taken stop-valves are interlocked so that at into account in this aspect of the deleast one of the devices is always in sign. Skids, frameworks, cradles or 931 $ 178.274 49 CFR Ch. I (10-1-06 Edition) other similar structures are acceptof reinforcement rings or bars fixed able. across the frame; (2) The combined stresses caused by (iii) Protection against rear impact portable tank mountings (for example, which may consist of a bumper or cradles, framework, etc.) and portable frame; tank lifting and tie-down attachments (iv) Protection of the shell against must not cause stress that would damdamage from impact or overturning by age the shell in a manner that would use of an ISO frame in accordance with compromise its lading retention capa- ISO 1496-3 (IBR, see § 171.7 of this subbility. Permanent lifting and tie-down chapter); and attachments must be fitted to all port- (v) Protection of the portable tank able tanks. Preferably they should be from impact or damage that may refitted to the portable tank supports sult from overturning by an insulation but may be secured to reinforcing jacket. plates located on the shell at the (i) Marking. (1) Every portable tank points of support. Each portable tank must be fitted with a corrosion resistmust be designed so that the center of ant metal plate permanently attached gravity of the filled tank is approxito the portable tank in a conspicuous mately centered within the points of place and readily accessible for inspecattachment for lifting devices. tion. When the plate cannot be perma- (3) In the design of supports and nently attached to the shell, the shell frameworks, the effects of environmust be marked with at least the informental corrosion must be taken into mation required by Section VIII of the account. ASME Code. At a minimum, the fol- (4) Forklift pockets must be capable lowing information must be marked on of being closed off. The means of closthe plate by stamping or by any other ing forklift pockets must be a permaequivalent method: nent part of the framework or perma- Country of manufacture nently attached to the framework. Sin- UN gle compartment portable tanks with a Approval Country length less than 3.65 m (12 ft.) need not Approval Number have forklift pockets that are capable Alternative Arrangements (see $178.274(a)(2)) of being closed off provided that: "AA" Manufacturer's name or mark (i) The shell, including all the fit- Manufacturer's serial number tings, are well protected from being hit Approval Agency (Authorized body for the by the forklift blades; and design approval) (ii) The distance between forklift Owner's registration number pockets (measured from the center of Year of manufacture each pocket) is at least half of the Pressure vessel code to which the shell is demaximum length of the portable tank. signed (5) During transport, portable tanks Test pressure bar gauge. MAWP bar gauge. must be adequately protected against External design pressure (not required for damage to the shell, and service equipportable tanks used for refrigerated liquement resulting from lateral and longified gases) bar gauge. tudinal impact and overturning, or the Design temperature range °C shell and service equipment must be to °C. (For portable tanks used for constructed to withstand the forces rerefrigerated liquefied gases, the minimum sulting from impact or overturning. design temperature must be marked.) Water capacity at 20 °C/ liters. External fittings must be protected so Water capacity of each compartment at 20 as to preclude the release of the shell °C liters. contents upon impact or overturning of Initial pressure test date and witness identithe portable tank on its fittings. Exfication. amples of protection include: MAWP for heating/cooling system bar (i) Protection against lateral impact gauge. which may consist of longitudinal bars Shell material(s) and material standard reference(s). protecting the shell on both sides at Equivalent thickness in reference the level of the median line; steel mm. (ii) Protection of the portable tank Lining material (when applicable). against overturning which may consist Date and type of most recent periodic test(s). 932 Pipeline and Hazardous Materials Safety Admin., DOT $ 178.274 Month Year Test (5) A test of the satisfactory operpressure bar gauge. ation of all service equipment includ- Stamp of approval agency that performed or ing pressure relief devices must also be witnessed the most recent test. performed. When the shell and its fit- For portable tanks used for refrigerated tings have been pressure-tested sepaliquefied gases: rately, they must be subjected to a Either "thermally insulated" or "vacuum inleakage test after reassembly. All sulated" welds, subject to full stress level in the Effectiveness of the insulation system (heat influx) Watts (W). shell, must be inspected during the ini- Reference holding time days or hours tial test by radiographic, ultrasonic, or and initial pressure bar/kPa gauge another suitable non-destructive test and degree of filling in kg for each method. This does not apply to the refrigerated liquefied gas permitted for jacket. transportation. (6) A UN portable tank that meets the definition of "container" in the (2) The following information must be marked either on the portable tank CSC (see 49 CFR 450.3(a) must be itself or on a metal plate firmly sesubjected to an impact test using a cured to the portable tank: prototype representing each design type. The prototype portable tank Name of the operator. must be shown to be capable of absorb- Name of hazardous materials being transing the forces resulting from an impact ported and maximum mean bulk temperanot less than 4 times (4 g) the maxture (except for refrigerated liquefied imum permissible gross mass of the gases, the name and temperature are only required when the maximum mean bulk fully loaded portable tank at a duratemperature is higher than 50 °C). tion typical of the mechanical shocks Maximum permissible gross mass experienced in rail transportation. A (MPGM) kg. listing of standards describing methods Unladen (tare) mass kg. acceptable for performing the impact test are provided in the UN Rec- NOTE TO PARAGRAPH (1)(2): For the identification of the hazardous materials being ommendations. UN portable tanks used transported refer to part 172 of this subfor the dedicated transportation of chapter. "Helium, refrigerated liquid," UN1963 and "Hydrogen, refrigerated liquid," (3) If a portable tank is designed and UN1966 that are marked "NOT FOR approved for open seas operations, such RAIL TRANSPORT" in letters of a as offshore oil exploration, in accordminimum height of 10 cm (4 inches) on ance with the IMDG Code, the words at least two sides of the portable tank "OFFSHORE PORTABLE TANK" must are excepted from the 4 g impact test. be marked on the identification plate. (7) The following tests must be com- (j) Initial inspection and test. The inipleted on a portable tank or a series of tial inspection and test of a portable portable tanks designed and contank must include the following: structed to a single design type that is (1) A check of the design characterisalso a CSC container without leakage tics. or deformation that would render the (2) An internal and external examinaportable tank unsafe for transportation tion of the portable tank and its fitand use: tings, taking into account the haz- (i) Longitudinal Inertia. The portable ardous materials to be transported. For tank loaded to its maximum gross UN portable tanks used for refrigerated weight must be positioned with its lonliquefied gases, a pressure test using an gitudinal axis vertical. It shall be held inert gas may be conducted instead of in this position for five minutes by sup- a hydrostatic test. An internal inspecport at the lower end of the base struction is not required for a portable tank ture providing vertical and lateral reused for the dedicated transportation straint and by support at the upper end of refrigerated liquefied gases that are of the base structure providing lateral not filled with an inspection opening. restraint only. (3) A pressure test as specified in (ii) Lateral inertia. The portable tank paragraph (i) of this section. loaded to its maximum gross weight (4) A leakage test. must be positioned for five minutes 933 § 178.275 49 CFR Ch. I (10-1-06 Edition) with its transverse axis vertical. It (i) The maximum effective gauge shall be held in this position for five pressure allowed in the shell during minutes by support at the lower side of filling or discharge; or the base structure providing vertical (ii) The maximum effective gauge and lateral restraint and by support at pressure to which the shell is designed the upper side of the base structure which must be not less than the design providing lateral restraint only. pressure. [66 FR 33440, June 21, 2001, as amended at 67 (c) Service equipment. (1) In addition FR 15744, Apr. 3, 2002; 68 FR 45041, July 31. to the requirements specified in 2003; 68 FR 57633, Oct. 6, 2003; 68 FR 75751, $178.274, for service equipment, all Dec. 31, 2003; 69 FR 76185, Dec. 20, 2004; 70 FR openings in the shell, intended for fill- 34399. June 14, 2005] ing or discharging the portable tank EDITORIAL NOTE: At 68 FR 57633, Oct. 6, must be fitted with a manually oper- 2003, $178.274 was amended in paragraph ated stop-valve located as close to the (b)(1); however, the amendment could not be shell as reasonably practicable. Other incorporated due to inaccurate amendatory openings, except for openings leading instruction. to venting or pressure relief devices, must be equipped with either a stop- § 178.275 Specification for UN Portable valve or another suitable means of clo- Tanks intended for the transporsure located as close to the shell as tation of liquid and solid hazardous materials. reasonably practicable. (2) All portable tanks must be fitted (a) In addition to the requirements of with a manhole or other inspection $178.274, this section sets forth definiopenings of a suitable size to allow for tions and requirements that apply to internal inspection and adequate ac- UN portable tanks intended for the cess for maintenance and repair of the transportation of liquid and solid hazinterior. Compartmented portable ardous materials. tanks must have a manhole or other (b) Definitions and requirements-(1) inspection openings for each compart- Design pressure means the pressure to ment. be used in calculations required by the (3) For insulated portable tanks, top recognized pressure vessel code. The fittings must be surrounded by a spill design pressure must not be less than collection reservoir with suitable the highest of the following pressures: drains. (i) The maximum effective gauge (4) Piping must be designed, conpressure allowed in the shell during structed and installed to avoid the risk filling or discharge; or of damage due to thermal expansion (ii) The sum ofand contraction, mechanical shock and (A) The absolute vapor pressure (in vibration. All piping must be of a suitbar) of the hazardous material at 65 °C, able metallic material. Welded pipe minus 1 bar (149 °F, minus 100 kPa); joints must be used wherever possible. (B) The partial pressure (in bar) of (d) Bottom openings. (1) Certain hazair or other gases in the ullage space, ardous materials may not be transresulting from their compression durported in portable tanks with bottom ing filling without pressure relief by a openings. When the applicable T code maximum ullage temperature of 65 °C or portable tank special provision, as (149 °F) and a liquid expansion due to referenced for materials in the $172.101 an increase in mean bulk temperature Table of this subchapter, specifies that of 35 °C (95 °F); and bottom openings are prohibited, there (C) A head pressure determined on must be no openings below the liquid the basis of the forces specified in level of the shell when it is filled to its $ 178.274(c) of this subchapter, but not maximum permissible filling limit. less than 0.35 bar (35 kPa). When an existing opening is closed, it (2) Maximum allowable working presmust be accomplished by internally sure (MAWP) means a pressure that and externally welding one plate to the must not be less than the highest of shell. the following pressures measured at (2) Bottom discharge outlets for portthe top of the shell while in operating able tanks carrying certain solid, crysposition: tallizable or highly viscous hazardous 934 Pipeline and Hazardous Materials Safety Admin., DOT § 178.275 materials must be equipped with at 6.1, PG I or II, the remote means of cloleast two serially fitted and mutually sure must be capable of thermal actiindependent shut-off devices. Use of vation. The thermal means of activaonly two shut-off devices is only aution must activate at a temperature of thorized when this paragraph is refnot more than 250 °F (121 °C). erenced in the applicable T Code indi- (e) Pressure relief devices. All portable cated for each hazardous material in tanks must be fitted with at least one the $172.101 Table of this subchapter. pressure relief device. All relief devices The design of the equipment must be to must be designed, constructed and the satisfaction of the approval agency marked in accordance with the requireand must include: ments of this subchapter. (i) An external stop-valve fitted as (f) Vacuum-relief devices. (1) A shell close to the shell as reasonably pracwhich is to be equipped with a vacuumticable; and relief device must be designed to with- (ii) A liquid tight closure at the end stand, without permanent deformation, of the discharge pipe, which may be a an external pressure of not less than bolted blank flange or a screw cap. 0.21 bar (21.0 kPa). The vacuum-relief (3) Except as provided in paragraph device must be set to relieve at a vacu- (c) (2) of this section, every bottom disum setting not greater than -0.21 bar (- charge outlet must be equipped with 21.0 kPa) unless the shell is designed three serially fitted and mutually indefor a higher external over pressure, in pendent shut-off devices. The design of which case the vacuum-relief pressure the equipment must include: of the device to be fitted must not be (i) A self-closing internal stop-valve, greater than the tank design vacuum which is a stop-valve within the shell pressure. A shell that is not fitted with or within a welded flange or its com- a vacuum-relief device must be depanion flange, such that: signed to withstand, without perma- (A) The control devices for the opernent deformation, an external pressure ation of the valve are designed to preof not less than 0.4 bar (40.0 kPa). vent any unintended opening through (2) Vacuum-relief devices used on impact or other inadvertent act; portable tanks intended for the trans- (B) The valve is operable from above portation of hazardous materials meetor below; ing the criteria of Class 3. including (C) If possible, the setting of the elevated temperature hazardous matevalve (open or closed) must be capable rials transported at or above their of being verified from the ground; flash point, must prevent the imme- (D) Except for portable tanks having diate passage of flame into the shell or a capacity less than 1,000 liters (264.2 the portable tank must have a shell cagallons), it must be possible to close pable of withstanding, without leakthe valve from an accessible position age, an internal explosion resulting on the portable tank that is remote from the passage of flame into the from the valve itself within 30 seconds shell. of actuation: and (g) Pressure relief devices. (1) Each (E) The valve must continue to be efportable tank with a capacity not less fective in the event of damage to the than 1,900 liters (501.9 gallons) and external device for controlling the opevery independent compartment of a eration of the valve; portable tank with a similar capacity, (ii) An external stop-valve fitted as must be provided with one or more close to the shell as reasonably pracpressure relief devices of the reclosing ticable; type. Such portable tanks may, in ad- (iii) A liquid tight closure at the end dition, have a frangible disc or fusible of the discharge pipe, which may be a element in parallel with the reclosing bolted blank flange or a screw cap; and devices, except when the applicable T (iv) For UN portable tanks, with botcode assigned to a hazardous material tom outlets, used for the transporrequires that the frangible disc precede tation of liquid hazardous materials the pressure relief device, according to that are Class 3, PG I or II, or PG III paragraph (g)(3) of this section, or with a flash point of less than 100 °F (38 when no bottom openings are allowed. °C); Division 5.1, PG I or II; or Division The pressure relief devices must have 935 $ 178.275 49 CFR Ch. I (10-1-06 Edition) sufficient capacity to prevent rupture temperature. The shell must not be of the shell due to over pressurization subject to undue fluctuations of presor vacuum resulting from filling, dissure during normal conditions of transcharging, heating of the contents or portation. fire. (ii) The required pressure relief de- (2) Pressure relief devices must be device must be set to start to discharge signed to prevent the entry of foreign at a nominal pressure of five-sixths of matter, the leakage of liquid and the the test pressure for shells having a development of any dangerous excess test pressure of not more than 4.5 bar pressure. (450 kPa) and 110% of two-thirds of the (3) When required for certain haztest pressure for shells having a test ardous materials by the applicable T pressure of more than 4.5 bar (450 kPa). code or portable tank special provision A self-closing relief device must close specified for a hazardous material in at a pressure not more than 10% below the $172.101 Table of this subchapter, the pressure at which the discharge portable tanks must have a pressure starts. The device must remain closed relief device consistent with the reat all lower pressures. This requirequirements of this subchapter. Except ment does not prevent the use of vacufor a portable tank in dedicated service um-relief or combination pressure rethat is fitted with an approved relief lief and vacuum-relief devices. device constructed of materials com- (h) Fusible elements. Fusible elements patible with the hazardous material, must operate at a temperature between the relief device system must include a 110 °C (230 °F) and 149 °C (300.2 °F) profrangible disc preceding (such as, bevided that the pressure in the shell at tween the lading and the reclosing the fusing temperature will not exceed pressure relief device) a reclosing presthe test pressure. They must be placed sure relief device. A pressure gauge or at the top of the shell with their inlets suitable tell-tale indicator for the dein the vapor space and in no case may tection of disc rupture, pin-holing or they be shielded from external heat. leakage must be provided in the space Fusible elements must not be utilized between the frangible disc and the on portable tanks with a test pressure pressure relief device to allow the portwhich exceeds 2.65 bar (265.0 kPa). Fusiable tank operator to check to deterble elements used on portable tanks inmine if the disc is leak free. The frantended for the transport of elevated gible disc must rupture at a nominal temperature hazardous materials must pressure 10% above the start-to-disbe designed to operate at a temperacharge pressure of the reclosable presture higher than the maximum temsure relief device. perature that will be experienced dur- (4) Every portable tank with a capacing transport and must be designed to ity less than 1,900 liters (501.9 gallons) the satisfaction of the approval agency. must be fitted with a pressure relief de- (i) Capacity of pressure relief devices. vice which, except as provided in para- (1) The reclosing pressure relief device graph (g)(3) of this section, may be a required by paragraph (g)(1) of this secfrangible disc when this disc is set to tion must have a minimum cross secrupture at a nominal pressure equal to tional flow area equivalent to an orithe test pressure at any temperature fice of 31.75 mm (1.3 inches) diameter. within the design temperature range. Vacuum-relief devices, when used. (5) When the shell is fitted for presmust have a cross sectional flow area sure discharge, a suitable pressure renot less than 284 mm² (11.2 inches2). lief device must provide the inlet line (2) The combined delivery capacity of to the portable tank and set to operate the pressure relief system (taking into at a pressure not higher than the account the reduction of the flow when MAWP of the shell, and a stop-valve the portable tank is fitted with franmust be fitted as close to the shell as gible-discs preceding spring-loaded practicable to minimize the potential pressure-relief devices or when the for damage. spring-loaded pressure-relief devices (6) Setting of pressure relief devices. (i) are provided with a device to prevent Pressure relief devices must operate the passage of the flame), in condition only in conditions of excessive rise in of complete fire engulfment of the 936 Pipeline and Hazardous Materials Safety Admin., DOT § 178.276 portable tank must be sufficient to (A) Without insulation or sun shield: limit the pressure in the shell to 20% 60 °C (140 °F); above the start to discharge pressure (B) With sun shield: 55 °C (131 °F); and limiting device (pressure relief device). (C) With insulation: 50 °C (122 °F). The total required capacity of the re- (3) Filling density means the average lief devices may be determined using mass of liquefied compressed gas per the formula in paragraph (i)(2)(i)(A) of liter of shell capacity (kg/1). this section or the table in paragraph (4) Maximum allowable working pres- (i)(2)(iii) of this section. sure (MAWP) means a pressure that (j) Approval, inspection and testing. must be not less than the highest of Approval procedures for UN portable the following pressures measured at tanks are specified in $178.273. Inspecthe top of the shell while in operating tion and testing requirements are specposition, but in no case less than 7 bar ified in § 180.605 of this subchapter. (700 kPa): [66 FR 33445, June 21, 2001, as amended at 68 (i) The maximum effective gauge FR 32414, May 30, 2003; 69 FR 76185, Dec. 20, pressure allowed in the shell during 2004) filling or discharge; or (ii) The maximum effective gauge § 178.276 Requirements for the design, pressure to which the shell is designed, construction, inspection and testing which must be: of portable tanks intended for the (A) Not less than the pressure specitransportation of non-refrigerated fied for each liquefied compressed gas liquefied compressed gases. listed in the UN Portable Tank Table (a) In addition to the requirements of for Liquefied Compressed Gases in § 178.274 applicable to UN portable § 173.313; and tanks, the following requirements (B) Not less than the sum of: apply to UN portable tanks used for (1) The absolute vapor pressure (in non-refrigerated liquefied compressed bar) of the liquefied compressed gas at gases. In addition to the definitions in the design reference temperature $178.274, the following definitions minus 1 bar; and apply: (2) The partial pressure (in bar) of air (1) Design pressure means the pressure or other gases in the ullage space to be used in calculations required by which is determined by the design refthe ASME Code, Section VIII (IBR, see erence temperature and the liquid $171.7 of this subchapter). The design phase expansion due to the increase of pressure must be not less than the the mean bulk temperature of (t, highest of the following pressures: = filling temperature, usually 15 °C, t, = (i) The maximum effective gauge 50 °C maximum mean bulk temperapressure allowed in the shell during ture). filling or discharge; or (b) General design and construction re- (ii) The sum of: quirements. (1) Shells must be of seam- (A) The maximum effective gauge less or welded steel construction, or pressure to which the shell is designed combination of both, and have a water as defined in this paragraph under capacity greater than 450 liters (118.9 "MAWP"; and gallons). Shells must be designed. con- (B) A head pressure determined on structed, certified and stamped in acthe basis of the dynamic forces specicordance with the ASME Code, Section fied in paragraph (h) of this section, VIII. but not less than 0.35 bar (35 kPa). (2) Portable tanks must be postweld (2) Design reference temperature means heat-treated and radiographed as prethe temperature at which the vapor scribed in Section VIII of the ASME pressure of the contents is determined Code, except that each portable tank for the purpose of calculating the constructed in accordance with part MAWP. The value for each portable UHT of the ASME Code must be tank type is as follows: postweld heat-treated. Where postweld (i) Shell with a diameter of 1.5 meters heat treatment is required, the port- (4.9 ft.) or less: 65 °C (149 °F); or able tank must be treated as a unit (ii) Shell with a diameter of more after completion of all the welds in than 1.5 meters (4.9 ft.): and/or to the shell and heads. The 937 § 178.276 49 CFR Ch. I (10-1-06 Edition) method must be as prescribed in the must satisfy the following require- ASME Code. Welded attachments to ments: pads may be made after postweld heat (1) consist of a shield covering not treatment is made. A portable tank less than the upper third, but not more used for anhydrous ammonia must be than the upper half of the surface of postweld heat-treated. The postweld the shell, and separated from the shell heat treatment must be as prescribed by an air space of approximately 40 mm in the ASME Code, but in no event at (1.7 inches) across; or less than 1050 °F tank metal tempera- (ii) consist of a complete cladding of ture. Additionally, portable tanks coninsulating materials. The insulation structed in accordance with part UHT must be of adequate thickness and conof the ASME Code must conform to the structed to prevent the ingress of moisfollowing requirements: ture and damage to the insulation. The (i) Welding procedure and welder perinsulation and cladding must have a formance tests must be made annually thermal conductance of not more than in accordance with Section IX of the 0.67 (W.m⁻².K⁻¹) under normal condi- ASME Code. In addition to the essentions of transportation. tial variables named therein, the fol- (c) Service equipment. (1) Each opening lowing must be considered to be essenwith a diameter of more than 1.5 mm tial variables: number of passes, thick- (0.1 inch) in the shell of a portable ness of plate, heat input per pass, and tank, except openings for pressure-remanufacturer's identification of rod lief devices, inspection openings and and flux. The number of passes, thickclosed bleed holes, must be fitted with ness of plate and heat input per pass at least three mutually independent may not vary more than 25 percent shut-off devices in series: the first from the qualified procedure. Records being an internal stop-valve, excess of the qualification must be retained flow valve, integral excess flow valve, for at least 5 years by the portable or excess flow feature (see $178.337- tank manufacturer or his designated 1(g)), the second being an external agent and, upon request, made availstop-valve and the third being a blank able to a representative of the Departflange. thread cap, plug or equivalent ment of Transportation or the owner of tight liquid closure device. the tank. (2) When a portable tank is fitted (ii) Impact tests must be made on a with an excess flow valve, the excess lot basis. A lot is defined as 100 tons or flow valve must be so fitted that its less of the same heat and having a seating is inside the shell or inside a thickness variation no greater than welded flange or, when fitted exterplus or minus 25 percent. The minimum nally, its mountings must be designed impact required for full-sized speciso that in the event of impact it mainmens shall be 20 foot-pounds (or 10 tains its effectiveness. The excess flow foot-pounds for half-sized specimens) at valves must be selected and fitted so as 0 °F (-17.8 °F) Charpy V-Notch in both to close automatically when the rated the longitudinal and transverse direcflow, specified by the manufacturer, is tion. If the lot test does not pass this reached. Connections and accessories requirement, individual plates may be leading to or from such a valve must accepted if they individually meet this have a capacity for a flow more than impact requirement. the excess flow valve's rated flow. (3) When the shells intended for the (3) For filling and discharge openings transportation of non-refrigerated liqthat are located below the liquid level, uefied compressed gases are equipped the first shut-off device must be an inwith thermal insulation, a device must ternal stop-valve and the second must be provided to prevent any dangerous be a stop-valve placed in an accessible pressure from developing in the insuposition on each discharge and filling lating layer in the event of a leak, pipe. when the protective covering is closed (4) For filling and discharge openings it must be gas tight. The thermal insulocated below the liquid level of portlation must not inhibit access to the able tanks intended for the transporfittings and discharge devices. In additation of flammable and/or toxic liquetion, the thermal insulation systems fied compressed gases, the internal 938 Pipeline and Hazardous Materials Safety Admin., DOT § 178.276 stop-valve must be a self-closing safety (ii) One plugged opening of 2-inch Nadevice that fully closes automatically tional Pipe Thread or less provided for during filling or discharge in the event maintenance purposes may be located of fire engulfment. The device shall elsewhere; fully close within 30 seconds of actu- (iii) An opening of 3-inch National ation and the thermal means of closure Pipe Size or less may be provided at must actuate at a temperature of not another location, when necessary, to more than 121 °C (250 °F). Except for facilitate installation of condensing portable tanks having a capacity less coils. than 1,000 liters (264.2 gallons), this de- (9) Filling and discharge connections vice must be operable by remote conare not required to be grouped and may trol. be installed below the normal liquid (5) In addition to filling, discharge level of the tank if: and gas pressure equalizing orifices, (i) The portable tank is permanently shells may have openings in which mounted in a full framework for congauges, thermometers and manometers tainerized transport; can be fitted. Connections for such in- (ii) For each portable tank design, a struments must be made by suitable prototype portable tank, meets the rewelded nozzles or pockets and may not be connected by screwed connections quirements of parts 450 through 453 of this title for compliance with the rethrough the shell. (6) All portable tanks must be fitted quirements of Annex II of the International Convention for Safe Conwith manholes or other inspection tainers; and openings of suitable size to allow for internal inspection and adequate ac- (iii) Each filling and discharge outlet cess for maintenance and repair of the meets the requirements of paragraph interior. (c)(4) of this section. (7) Inlets and discharge outlets on chlo- (d) Bottom openings. Bottom openings rine portable tanks. The inlet and disare prohibited on portable tanks when charge outlets on portable tanks used the UN Portable Tank Table for Liqueto transport chlorine must meet the refied Compressed Gases in $173.313 of quirements of § 178.337-1(c)(2) and must this subchapter indicates that bottom be fitted with an internal excess flow openings are not allowed. In this case, valve. In addition to the internal exthere may be no openings located cess flow valve, the inlet and discharge below the liquid level of the shell when outlets must be equipped with an exit is filled to its maximum permissible ternal stop valve (angle valve). Excess filling limit. flow valves must conform to the stand- (e) Pressure relief devices. (1) Portable ards of The Chlorine Institute, Inc. tanks must be provided with one or (IBR, see $171.7 of this subchapter) as more reclosing pressure relief devices. follows: The pressure relief devices must open (i) A valve conforming to Drawing automatically at a pressure not less 101-7, dated July 1993, must be installed than the MAWP and be fully open at a under each liquid angle valve. pressure equal to 110% of the MAWP. (ii) A valve conforming to Drawing These devices must, after discharge, 106-6, dated July 1993, must be installed close at a pressure not less than 10% under each gas angle valve. For portbelow the pressure at which discharge able tanks used to transport non-restarts and must remain closed at all frigerated liquefied gases. lower pressures. The pressure relief de- (8) External fittings must be grouped vices must be of a type that will resist together as close as reasonably pracdynamic forces including liquid surge. ticable. The following openings may be A frangible disc may only be used in seinstalled at locations other than on the ries with a reclosing pressure relief detop or end of the tank: vice. (i) The openings for liquid level gaug- (2) Pressure relief devices must be deing devices, pressure gauges, or for signed to prevent the entry of foreign safety devices, may be installed sepamatter, the leakage of gas and the derately at the other location or in the velopment of any dangerous excess side of the shell; pressure. 939 § 178.277 49 CFR Ch. I (10-1-06 Edition) (3) A portable tank intended for the ery capacity must consider the additransportation of certain liquefied tional thermodynamic properties of the compressed gases identified in the UN gas, for example see CGA S-1.2 (IBR, Portable Tank Table for Liquefied see § 171.7 of this subchapter). Compressed Gases in $173.313 of this subchapter must have a pressure relief [66 FR 33448, June 21, 2001, as amended at 68 FR 75748, 75752, Dec. 31, 2003; 69 FR 54046, device which conforms to the require- Sept. 7, 2004; 69 FR 76185, Dec. 20, 2004) ments of this subchapter. Unless a portable tank, in dedicated service, is § 178.277 Requirements for the design, fitted with a relief device constructed construction, inspection and testing of materials compatible with the hazof portable tanks intended for the ardous material, the relief device must transportation of refrigerated liquebe comprised of a frangible disc prefied gases. ceded by a reclosing device. The space (a) In addition to the requirements of between the frangible disc and the de- § 178.274 applicable to UN portable vice must be provided with a pressure tanks, the following requirements and gauge or a suitable tell-tale indicator. definitions apply to UN portable tanks This arrangement must facilitate the used for refrigerated liquefied gases: detection of disc rupture, pinholing or Design pressure For the purpose of leakage which could cause a malfuncthis section the term "design pressure" tion of the pressure relief device. The is consistent with the definition for defrangible disc must rupture at a nomisign pressure in the ASME Code, Secnal pressure 10% above the start-to-distion VIII (IBR, see $171.7 of this subcharge pressure of the relief device. (4) In the case of portable tanks used chapter). for more than one gas, the pressure re- Holding time is the time, as deterlief devices must open at a pressure inmined by testing, that will elapse from dicated in paragraph (e)(1) of this secloading until the pressure of the contion for the gas having the highest tents, under equilibrium conditions, maximum allowable pressure of the reaches the lowest set pressure of the gases allowed to be transported in the pressure limiting device(s) (for examportable tank. ple, pressure control valve or pressure (f) Capacity of relief devices. The comrelief device). Holding time must be debined delivery capacity of the relief determined as specified in § 178.338-9. vices must be sufficient so that, in the Maximum allowable working pressure event of total fire engulfment, the (MAWP) means the maximum effective pressure inside the shell cannot exceed gauge pressure permissible at the top 120% of the MAWP. Reclosing relief deof the shell of a loaded portable tank in vices must be used to achieve the full its operating position including the relief capacity prescribed. In the case highest effective pressure during filling of portable tanks used for more than and discharge; gas, the combined delivery capacity of Minimum design temperature means the pressure relief devices must be the temperature which is used for the taken for the liquefied compressed gas design and construction of the shell which requires the highest delivery canot higher than the lowest (coldest) pacity of the liquefied compressed service temperature of the contents gases allowed to be transported in the during normal conditions of filling, disportable tank. The total required cacharge and transportation. pacity of the relief devices must be de- Shell means the part of the portable termined according to the requiretank which retains the refrigerated liqments in § 178.275(i). These requireuefied gas intended for transport, inments apply only to liquefied comcluding openings and their closures, pressed gases which have critical tembut does not include service equipment peratures well above the temperature or external structural equipment. at the accumulating condition. For Tank means a construction which gases that have critical temperatures normally consists of either: near or below the temperature at the (1) A jacket and one or more Inner accumulating condition, the calculashells where the space between the tion of the pressure relief device delivshell(s) and the jacket is exhausted of 940 Pipeline and Hazardous Materials Safety Admin., DOT § 178.277 air (vacuum insulation) and may incorto be sufficient. In choosing the mateporate a thermal insulation system; or rial, the minimum design temperature (2) A jacket and an inner shell with must be taken into account with rean intermediate layer of solid therspect to risk of brittle fracture, to hymally insulating material (for examdrogen embrittlement, to stress corrople, solid foam). sion cracking and to resistance to im- (b) General design and construction repact. quirements. (1) Portable tanks must be (5) Any part of a portable tank, inof seamless or welded steel construccluding fittings, gaskets and pipetion and have a water capacity of more work, which can be expected normally than 450 liters (118.9 gallons). Portable to come into contact with the refrigtanks must be designed, constructed, erated liquefied gas transported must certified and stamped in accordance be compatible with that refrigerated with Section VIII of the ASME Code. liquefied gas. (2) Portable tanks must be postweld (6) The thermal insulation system heat treated and radiographed as premust include a complete covering of scribed in Sections V and VIII of the the shell with effective insulating ma- ASME Code except that each tank conterials. External insulation must be structed in accordance with part UHT protected by a jacket so as to prevent in Section VIII of the ASME Code must the ingress of moisture and other dambe postweld heat treated. Where age under normal transport conditions. postweld heat treatment is required, (7) When a jacket is so closed as to be the tank must be treated as a unit gas-tight, a device must be provided to after completion of all the welds to the prevent any dangerous pressure from shell and heads. The method must be as developing in the insulation space. prescribed in the ASME Code. Welded (8) Materials which may react with attachments to pads may be made after oxygen or oxygen enriched postweld heat treatment is made. The atmospheres in a dangerous manner postweld heat treatment must be as may not be used in portable tanks inprescribed in Section VIII of the ASME tended for the transport of refrigerated Code, but in no event at less than 1,050 liquefied gases having a boiling point °F tank metal temperature. below minus 182 °C at atmospheric (3) Welding procedure and welder perpressure in locations with the thermal formance tests must be made annually insulation where there is a risk of conin accordance with Section IX of the tact with oxygen or with oxygen en- ASME Code (IBR, see § 171.7 of this subriched fluid. chapter). In addition to the essential variables named in the ASME Code, the (9) Insulating materials must not deteriorate to an extent that the effecfollowing must be considered as essentiveness of the insulation system, as tial variables: number of passes, thickness of plate. heat input per pass, and determined in accordance with parathe specified rod and flux. The number graph (b)(11) of this section, would be reduced in service. of passes, thickness of plate and heat input per pass may not vary more than (10) A reference holding time must be 25% from the procedure qualification. determined for each refrigerated lique- Records of the qualification must be fied gas intended for transport in a retained for at least 5 years by the portable tank. The reference holding portable tank manufacturer and made time must be determined by testing in available to the approval agency and accordance with the requirements of the owner of the portable tank as spec- § 178.338-9, considering the following ified in § 178.273. factors: (4) Shells and jackets must be made (i) The effectiveness of the insulation of metallic materials suitable for formsystem, determined in accordance with ing. Jackets must be made of steel. paragraph (b)(11) of this section; Non-metallic materials may be used (ii) The lowest set pressure of the for the attachments and supports bepressure limiting device; tween the shell and jacket, provided (iii) The initial filling conditions; their material properties at the min- (iv) An assumed ambient temperaimum design temperature are proven ture of 30 °C (86 °F); 941 § 178.277 49 CFR Ch. I (10-1-06 Edition) (v) The physical properties of the inclosest to the jacket must be a selfdividual refrigerated liquefied gas inclosing device, which is capable of tended to be transported. being closed from an accessible posi- (11) The effectiveness of the insulation on the portable tank that is retion system (heat influx in watts) may mote from the valve within 30 seconds be determined by type testing the portof actuation. This device must actuate able tank in accordance with a proceat a temperature of not more than 121 dure specified in 178.338-9(c) or by °C (250 °F). using the holding time test in § 178.338- (2) Each filling and discharge opening 9(b). This test must consist of either: in portable tanks used for the trans- (i) A constant pressure test (for export of non-flammable refrigerated liqample, at atmospheric pressure) when uefied gases must be fitted with at the loss of refrigerated liquefied gas is least two mutually independent shutmeasured over a period of time; or off devices in series: the first being a (ii) A closed system test when the stop-valve situated as close as reasonrise in pressure in the shell is measured ably practicable to the jacket and the over a period of time. (12) When performing the constant second a blank flange or equivalent device. pressure test, variations in atmospheric pressure must be taken into ac- (3) For sections of piping which can count. When performing either test, be closed at both ends and where liquid corrections must be made for any variproduct can be trapped, a method of ation of the ambient temperature from automatic pressure relief must be prothe assumed ambient temperature refvided to prevent excess pressure builderence value of 30 °C (86 °F). up within the piping. (13) The jacket of a vacuum-insulated (4) Each filling and discharge opening double-wall tank must have either an on a portable tank must be clearly external design pressure not less than marked to indicate its function. 100 kPa (1 bar) gauge pressure cal- (5) When pressure-building units are culated in accordance with Section used, the liquid and vapor connections VIII of the ASME Code or a calculated to that unit must be provided with a critical collapsing pressure of not less valve as close to the jacket as reasonthan 200 kPa (2 bar) gauge pressure. Inably practicable to prevent the loss of ternal and external reinforcements contents in case of damage to the presmay be included in calculating the sure-building unit. A check valve may ability of the jacket to resist the exterbe used for this purpose if it is located nal pressure. on the vapor side of the pressure build- NOTE TO PARAGRAPH (b): For the deterup coil. mination of the actual holding time, as indi- (6) The materials of construction of cated by paragraphs (b)(10), (11), (12), and valves and accessories must have satis- (13). before each journey. refer to $178.338- factory properties at the lowest oper- 9(b). ating temperature of the portable (c) Design criteria. For shells with tank. vacuum insulation, the test pressure (7) Vacuum insulated portable tanks must not be less than 1.3 times the sum are not required to have an inspection of the MAWP and 100 kPa (1 bar). In no opening. case may the test pressure be less than (e) Pressure relief devices. (1) Every 300 kPa (3 bar) gauge pressure. shell must be provided with not less (d) Service equipment. (1) Each filling than two independent reclosing presand discharge opening in portable sure relief devices. The pressure relief tanks used for the transport of flamdevices must open automatically at a mable refrigerated liquefied gases must pressure not less than the MAWP and be fitted with at least three mutually be fully open at a pressure equal to independent shut-off devices in series: 110% of the MAWP. These devices the first being a stop-valve situated as must, after discharge, close at a presclose as reasonably practicable to the sure not lower than 10% below the presjacket, the second being a stop-valve sure at which discharge starts and and the third being a blank flange or must remain closed at all lower presequivalent device. The shut-off device sures. The pressure relief devices must 942 Pipeline and Hazardous Materials Safety Admin., DOT § 178.318-2 be of the type that will resist dynamic § 178.318 Specification MC 201; conforces including surge. tainer for detonators and percus- (2) Except for portable tanks used for sion caps. oxygen, portable tanks for non-flam- § 178.318-1 Scope. mable refrigerated liquefied gases (except oxygen) and hydrogen may in ad- (a) This specification pertains to a dition have frangible discs in parallel container to be used for the transporwith the reclosing devices as specified tation of detonators and percussion in paragraphs (e)(4)(ii) and (e)(4)(iii) of caps in connection with the transporthis section. tation of liquid nitroglycerin, desen- (3) Pressure relief devices must be desitized liquid nitroglycerin or signed to prevent the entry of foreign diethylene glycol dinitrate, where any matter, the leakage of gas and the deor all of such types of caps may be used velopment of any dangerous excess for the detonation of liquid nitroglycerin, desentitized liquid nitroglycerin pressure. or diethylene glycol dinitrate in blast- (4) Capacity and setting of pressure relief devices. (i) In the case of the loss of ing operations. This specification is not intended to take the place of any vacuum in a vacuum-insulated tank or shipping or packing requirements of of loss of 20% of the insulation of a this Department where the caps in portable tank insulated with solid maquestion are themselves articles of terials, the combined capacity of all commerce. pressure relief devices installed must (b) [Reserved] be sufficient so that the pressure (including accumulation) inside the shell [29 FR 18975, Dec. 29, 1964. Redesignated at 32 does not exceed 120% of the MAWP. FR 5606, Apr. 5, 1967. and amended by Amdt. 178-60, 44 FR 70733, Dec. 10. 1979] (ii) For non-flammable refrigerated liquefied gases (except oxygen) and hy- § 178.318-2 Container. drogen, this capacity may be achieved by the use of frangible discs in parallel (a) Every container for detonators with the required safety-relief devices. and percussion caps coming within the Frangible discs must rupture at nomiscope of this specification shall be constructed entirely of hard rubber, nal pressure equal to the test pressure of the shell. phenolresinous or other resinous material, or other nonmetallic, nonsparking (iii) Under the circumstances dematerial, except that metal parts may scribed in paragraphs (e)(4)(i) and be used in such locations as not in any (e)(4)(ii) of this section, together with event to come in contact with any of complete fire engulfment, the comthe caps. Space shall be provided so bined capacity of all pressure relief dethat each detonator of whatever nature vices installed must be sufficient to may be inserted in an individual cell in limit the pressure in the shell to the the body of the container, into which test pressure. each such cap shall snugly fit. There (iv) The required capacity of the reshall be provided no more than twenty lief devices must be calculated in ac- (20) such cellular spaces. Space may be cordance with CGA Pamphlet S-1.2 provided into which a plurality of per- (IBR, see § 171.7 of this subchapter). cussion caps may be carried, provided [66 FR 33450, June 21, 2001, as amended at 68 that such space may be closed with a FR 75748, 75752, Dec. 31, 2003] screw cap, and further provided that each or any such space is entirely sepa- Subpart I [Reserved] rate from any space provided for any detonator. Each cellular space into which a detonator is to be inserted and Subpart J-Specifications for Concarried shall be capable of being covtainers for Motor Vehicle ered by a rotary cover so arranged as Transportation to expose not more than one cell at any time, and capable of rotation to such a SOURCE: 29 FR 18975, Dec. 29, 1964, unless place that all cells will be covered at otherwise noted. Redesignated at 32 FR 5606, the same time, at which place means Apr. 5, 1967. shall be provided to lock the cover in 943 § 178.318-2 49 CFR Ch. I (10-1-06 Edition) place. Means shall be provided to lock tion of moisture, such treatment shall in place the cover for the cells provided be applied as shall be necessary in for the carrying of detonators. The reorder to provide against the penetraquirement that not more than one cell tion of water by permeation. A suitable be exposed at one time need not apply carrying handle shall be provided, exin the case of detonators, although cept for which handle no part of the spaces for such caps and detonators container may project beyond the exteshall be separate. Sufficient annular rior of the body. space shall be provided inside the cover (b) Exhibited in plates I and II are for such detonators that, when the line drawings of a container for detocover is closed, there will be sufficient nators and percussion caps, illustrative space to accommodate the wires cusof the requirements set forth in tomarily attached to such caps. If the $178.318-2(a). These plates shall not be material is of such a nature as to reconstrued as a part of this specificaquire treatment to prevent the absorption. 944 Pipeline and Hazardous Materials Safety Admin., DOT § 178.320 Fuse cop container end Electric cop container end Section A-B-C BLASTING CAP CONTAINER PLATE 1 Spot for index button of close position "F" Spot for center holes at "G" C 2020 F Engrave and fill in white C E Percussion cap pocket 2 required Section E-E PLAN Handie removed PLATE Il [29 FR 18975, Dec. 29, 1964. Redesignated at 32 FR 5606, Apr. 5, 1967, and amended by Amdt. 178-60, 44 FR 70733, Dec. 10, 1979) § 178.318-3 Marking. tention or containment function and Each container must be marked as provides no structural support to the prescribed in $178.2(b). cargo tank. Baffle means a non-liquid-tight trans- [Amdt. 178-40, 41 FR 38181, Sept. 9, 1976. as verse partition device that deflects, amended at 66 FR 45185, Aug. 28, 2001] checks or regulates fluid motion in a tank. § 178.320 General requirements appli- Bulkhead means a liquid-tight transcable to all DOT specification cargo verse closure at the ends of or between tank motor vehicles. cargo tanks. (a) Definitions. For the purpose of this Cargo tank means a bulk packaging subchapter: that: Appurtenance means any attachment (1) Is a tank intended primarily for to a cargo tank that has no lading rethe carriage of liquids, gases, solids, or 945 § 178.320 49 CFR Ch. I (10-1-06 Edition) semi-solids and includes appurvariations in piping that do not affect tenances, reinforcements, fittings, and the lading retention capability of the closures (for tank, see SS 178.337-1, cargo tank; 178.338-1, or 178.345-1, as applicable); (4) Of the same materials of construc- (2) Is permanently attached to or tion; forms a part of a motor vehicle, or is (5) To the same cross-sectional dinot permanently attached to a motor mensions; vehicle but that, by reason of its size, (6) To a length varying by no more construction, or attachment to a than 5 percent; motor vehicle, is loaded or unloaded (7) With the volume varying by no without being removed from the motor more than 5 percent (due to a change in vehicle; and length only); and (3) Is not fabricated under a speci- (8) For the purposes of § 178.338 only, fication for cylinders, intermediate with the same insulation system. bulk containers, multi-unit tank car External self-closing stop valve means a tanks, portable tanks, or tank cars. self-closing stop valve designed so that Cargo tank motor vehicle means a the self-stored energy source is located motor vehicle with one or more cargo tanks permanently attached to or outside the cargo tank and the welded forming an integral part of the motor flange. vehicle. Extreme dynamic loading means the Cargo tank wall means those parts of maximum loading a cargo tank motor the cargo tank that make up the privehicle may experience during its exmary lading retention structure, inpected life, excluding accident loadings cluding shell, bulkheads, and fittings resulting from an accident, such as overturn or collision. and, when closed, yield the minimum volume of the cargo tank assembly. Flange means the structural ring for Charging line means a hose, tube, guiding or attachment of a pipe or fitpipe, or a similar device used to presting with another flange (companion surize a tank with material other than flange), pipe, fitting or other attachment. the lading. Companion flange means one of two Inspection pressure means the presmating flanges where the flange faces sure used to determine leak tightness are in contact or separated only by a of the cargo tank when testing with thin leak-sealing gasket and are sepneumatic pressure. cured to one another by bolts or Internal self-closing stop valve means a clamps. self-closing stop valve designed so that Connecting structure means the structhe self-stored energy source is located ture joining two cargo tanks. inside the cargo tank or cargo tank Constructed and certified in accordance sump, or within the welded flange, and with the ASME Code means a cargo the valve seat is located within the tank is constructed and stamped in accargo tank or within one inch of the cordance with Section VIII of the external face of the welded flange or ASME Code (IBR, see $171.7 of this subsump of the cargo tank. chapter), and is inspected and certified Lading means the hazardous material by an Authorized Inspector. contained in a cargo tank. Constructed in accordance with the Loading/unloading connection means ASME Code means a cargo tank is conthe fitting in the loading/unloading structed in accordance with Section line farthest from the loading/unload- VIII of the ASME Code with authorized ing outlet to which the loading/unloadexceptions (see $178.346 through ing hose, pipe, or device is attached. 178.348) and is inspected and certified Loading/unloading outlet means a by a Registered Inspector. cargo tank outlet used for normal load- Design type means one or more cargo ing/unloading operations. tanks that are made- Loading/unloading stop valve means (1) To the same specification: the stop valve farthest from the cargo (2) By the same manufacturer; tank loading/unloading outlet to which (3) To the same engineering drawings the loading/unloading connection is atand calculations, except for minor tached. 946 Pipeline and Hazardous Materials Safety Admin., DOT § 178.320 Manufacturer means any person enfabricated to more than one cargo tank gaged in the manufacture of a DOT specification. specification cargo tank, cargo tank Normal operating loading means the motor vehicle, or cargo tank equiploading a cargo tank motor vehicle ment that forms part of the cargo tank may be expected to experience rouwall. This term includes attaching a tinely in operation. cargo tank to a motor vehicle or to a Nozzle means a subassembly conmotor vehicle suspension component sisting of a pipe or tubular section with that involves welding on the cargo or without a welded or forged flange on tank wall. A manufacturer must regone end. ister with the Department in accord- Outlet means any opening in the shell ance with subpart F of part 107 in subor head of a cargo tank, (including the part A of this chapter. means for attaching a closure), except Maximum allowable working pressure that the following are not outlets: a or MAWP means the maximum presthreaded opening securely closed dursure allowed at the top of the tank in ing transportation with a threaded its normal operating position. The plug or a threaded cap. a flanged open- MAWP must be calculated as preing securely closed during transporscribed in Section VIII of the ASME tation with a bolted or welded blank Code. In use, the MAWP must be greatflange, a manhole, a gauging device, a er than or equal to the maximum ladthermometer well, or a pressure relief ing pressure conditions prescribed in device. $173.33 of this subchapter for each ma- Outlet stop valve means the stop valve terial transported. at a cargo tank loading or unloading Maximum lading pressure. See outlet. 173.33(c). Pipe coupling means a fitting with in- Minimum thickness means the minternal threads on both ends. imum required shell and head (and baf- Rear bumper means the structure defle and bulkhead when used as tank resigned to prevent a vehicle or object inforcement) thickness needed to meet from under-riding the rear of another the specification. The minimum thickmotor vehicle. See $393.86 of this title. ness is the greatest of the following val- Rear-end tank protection device means ues: (1)(i) For MC 330, MC 331, and MC the structure designed to protect a 338 cargo tanks, the specified minimum cargo tank and any lading retention thickness found the applicable specipiping or devices in case of a rear end fication(s): or collision. (ii) For DOT 406, DOT 407 and DOT Self-closing stop valve means a stop 412 cargo tanks, the specified minimum valve held in the closed position by thickness found in Tables I and II of means of self-stored energy, that opens the applicable specification(s); or only by application of an external force (iii) For MC 300, MC 301, MC 302, MC and that closes when the external force 303, MC 304, MC 305, MC 306, MC 307, MC is removed. 310, MC 311, and MC 312 cargo tanks, Shell means the circumferential porthe in-service minimum thickness pretion of a cargo tank defined by the scribed in Tables I and II of basic design radius or radii excluding $ 180.407(i)(5) of this subchapter, for the the bulkheads. minimum thickness specified by Tables Stop valve means a valve that stops I and Il of the applicable specificathe flow of lading. tion(s); or Sump means a protrusion from the (2) The thickness necessary to meet bottom of a cargo tank shell designed with the structural integrity and accito facilitate complete loading and undent damage requirements of the appliloading of lading. cable specification(s); or Tank means a container, consisting (3) The thickness as computed per of a shell and heads, that forms a presthe ASME Code requirements (if applisure tight vessel having openings decable). signed to accept pressure tight fittings Multi-specification cargo tank motor veor closures, but excludes any appurhicle means a cargo tank motor vehicle tenances, reinforcements. fittings, or equipped with two or more cargo tanks closures. 947 § 178.337 49 CFR Ch. I (10-1-06 Edition) Test pressure means the pressure to compliance with certain paragraphs of which a tank is subjected to determine the ASME Code, compliance with those structural integrity. paragraphs is not prohibited. Toughness of material means the capa- [Amdt. 178-89, 55 FR 37055, Sept. 7. 1990, as bility of a material to absorb energy amended by Amdt. 178-98, 58 FR 33306, June represented by the area under a stress 16, 1993; Amdt. 178-118, 61 FR 51339, Oct. 1. strain curve (indicating the energy ab- 1996: 68 FR 19277, Apr. 18, 2003; 68 FR 52370, sorbed per unit volume of the material) Sept. 3, 2003: 68 FR 75752, Dec. 31, 2003) up to the point of rupture. Vacuum cargo tank means a cargo § 178.337 Specification MC 331; cargo tank that is loaded by reducing the tank motor vehicle primarily for transportation of compressed gases pressure in the cargo tank to below atas defined in subpart G of part 173 mospheric pressure. of this subchapter. Variable specification cargo tank means a cargo tank that is constructed § 178.337-1 General requirements. in accordance with one specification, (a) ASME Code construction. Tanks but that may be altered to meet anmust beother specification by changing relief (1) Seamless or welded construction, device, closures, lading discharge deor a combination of both; vices, and other lading retention de- (2) Designed, constructed, certified, vices. and stamped in accordance with Sec- Void means the space between tank tion VIII of the ASME Code (IBR, see heads or bulkheads and a connecting $171.7 of this subchapter); structure. (3) Made of steel or aluminum; how- Welded flange means a flange atever, if aluminum is used, the cargo tached to the tank by a weld joining tank must be insulated and the hazthe tank shell to the cylindrical outer ardous material to be transported must surface of the flange, or by a fillet weld be compatible with the aluminum (see joining the tank shell to a flange §§ 178.337-1(e)(2), 173.315(a) table, and shaped to fit the shell contour. 178.337-2(a)(1) of this subchapter); and (b) Design certification. (1) Each cargo (4) Covered with a steel jacket if the tank or cargo tank motor vehicle decargo tank is insulated and used to sign type, including its required accitransport a flammable gas (see dent damage protection device, must $ 173.315(a) table Note 11 of this subbe certified to conform to the specificachapter). tion requirements by a Design Certi- (b) Design pressure. The design presfying Engineer who is registered in acsure of a cargo tank authorized under cordance with subpart F of part 107 of this specification shall be not less than this title. An accident damage protecthe vapor pressure of the commodity tion device is a rear-end protection, contained therein at 115 °F. or as preoverturn protection, or piping protecscribed for a particular commodity in tion device. $173.315(a) of this subchapter, except (2) The Design Certifying Engineer that in no case shall the design presshall furnish to the manufacturer a sure of any cargo tank be less than 100 certificate to indicate compliance with p.s.i.g. nor more than 500 p.s.i.g. the specification requirements. The certificate must include the sketches, NOTE 1: The term design pressure as used in drawings, and calculations used for certhis specification. is identical to the term MAWP as used in the ASME Code. tification. Each certificate, including sketches, drawings, and calculations, (c) Openings. (1) Excess pressure relief shall be signed by the Design Certivalves shall be located in the top of the fying Engineer. cargo tank or heads. (3) The manufacturer shall retain the (2) A chlorine cargo tank shall have design certificate at his principal place only one opening. That opening shall of business for as long as he manufacbe in the top of the cargo tank and tures DOT specification cargo tanks. shall be fitted with a nozzle that meets (c) Exceptions to the ASME Code. Unthe following requirements: less otherwise specified, when excep- (i) On a cargo tank manufactured on tions are provided in this subpart from or before December 31, 1974, the nozzle 948 Pipeline and Hazardous Materials Safety Admin., DOT § 178.337-1 shall be protected by a dome cover as a unit after completion of all the plate which conforms to either the welds in and/or to the shells and heads. standard of The Chlorine Institute, The method must be as prescribed in Inc., Dwg. 103-3, dated January 23, 1958, Section VIII of the ASME Code. Welded or to the standard specified in paraattachments to pads may be made after graph (c) (2) (ii) of this section. postweld heat treatment. A cargo tank (ii) On a cargo tank manufactured on used for anhydrous ammonia must be or after January 1, 1975. the nozzle postweld heat treated. The postweld shall be protected by a manway cover heat treatment must be as prescribed which conforms to the standard of The in Section VIII of the ASME Code, but Chlorine Institute, Inc., Dwg. 103-4, in no event at less than 1,050 SF cargo dated September 1, 1971. tank metal temperature. (d) Reflective design. Every (g) Definitions. The following definiuninsulated cargo tank permanently tions apply to §§ 178.337-1 through attached to a cargo tank motor vehicle 178.337-18: shall, unless covered with a jacket Emergency discharge control means the made of aluminum, stainless steel, or ability to stop a cargo tank unloading other bright nontarnishing metal, be operation in the event of an unintenpainted a white, aluminum or similar tional release. Emergency discharge reflecting color on the upper two-thirds control can utilize passive or off-truck of area of the cargo tank. remote means to stop the unloading (e) Insulation. (1) Each cargo tank reoperation. A passive means of emerquired to be insulated must conform gency discharge control automatically with the use and performance requireshuts off the flow of product without ments contained in 173.315(a) table the need for human intervention withand 178.337-1 (a)(3) and (e)(2) of this in 20 seconds of an unintentional resubchapter. lease caused by a complete separation (2) Each cargo tank intended for of the liquid delivery hose. An offchlorine; carbon dioxide, refrigerated truck remote means of emergency disliquid; or nitrous oxide, refrigerated charge control permits a qualified perliquid service must have suitable insuson attending the unloading operation lation of such thickness that the overto close the cargo tank's internal selfall thermal conductance is not more closing stop valve and shut off all mothan 0.08 Btu per square foot per °F diftive and auxiliary power equipment at ferential per hour. The conductance a distance from the cargo tank motor must be determined at 60 °F. Insulation vehicle. material used on cargo tanks for ni- Excess flow valve, integral excess flow trous oxide, refrigerated liquid must be valve, or excess flow feature means a noncombustible. Insulating material component that will close automatiused on cargo tanks for chlorine must cally if the flow rate of a gas or liquid be corkboard or polyurethane foam, through the component reaches or exwith a minimum thickness of 4 inches, ceeds the rated flow of gas or liquid or 2 inches minimum thickness of cespecified by the original valve manuramic fiber/fiberglass of 4 pounds per facturer when piping mounted directly cubic foot minimum density covered by on the valve is sheared off before the 2 inches minimum thickness of fiber. first valve, pump, or fitting down- (f) Postweld heat treatment. Postweld stream from the valve. heat treatment must be as prescribed Internal self-closing stop valve means a in the ASME Code except that each primary shut off valve installed in a cargo tank constructed in accordance product discharge outlet of a cargo with Part UHT of Section VIII of the tank and designed to be kept closed by ASME Code must be postweld heat self-stored energy. treated. Each chlorine cargo tank must Primary discharge control system be fully radiographed and postweld means a primary shut-off installed at a heat treated in accordance with the product discharge outlet of a cargo provisions in Section VIII of the ASME tank consisting of an Internal self-clos- Code under which it is constructed. ing stop valve that may include an in- Where postweld heat treatment is retegral excess flow valve or an excess quired, the cargo tank must be treated flow feature, together with linkages 949 § 178.337-2 49 CFR Ch. I (10-1-06 Edition) that must be installed between the ferential orientation of the cargo tank valve and remote actuator to provide shell. manual and thermal on-truck remote (b) For a chlorine cargo tank. Plates, means of closure. the manway nozzle, and anchorage [Order 59-B. 30 FR 579, Jan. 16, 1965. Redesigshall be made of carbon steel which nated at 32 FR 5606, Apr. 5. 1967] meets the following requirements: (1) For a cargo tank manufactured on EDITORIAL NOTE: For FEDERAL REGISTER cltations affecting 178.337-1, see the List of or before December 31, 1974- CFR Sections Affected which appears in the (i) Material shall conform to ASTM A Finding Aids section of the printed volume 300, "Steel Plates for Pressure Vessels and on GPO Access. for Service at Low Temperatures" (IBR, see § 171.7 of this subchapter); § 178.337-2 Material. (ii) Material shall be Class 1, Grade (a) General. (1) All material used for A, flange or firebox quality: construction of the cargo tank and ap- (iii) Plate impact test specimens, as purtenances must be suitable for use required under paragraph (a) of this with the commodities to be transsection, shall be of the Charpy keyhole ported therein and must conform to notch type; and the requirements in Section II of the (iv) Plate impact test specimens ASME Code (IBR, see $171.7 of this subshall meet the impact test requirechapter) and/or requirements of the ments in paragraph (a) of this section American Society for Testing and Main both the longitudinal and transverse terials in all respects. directions of rolling at a temperature (2) Impact tests are required on steel of minus 45.5 C. °F.). used in the fabrication of each cargo (2) For a cargo tank manufactured on tank constructed in accordance with or after January 1, 1975- part UHT in Section VIII of the ASME (i) Material shall conform to ASTM A Code. The tests must be made on a lot 612 (IBR, see $171.7 of this subchapter), basis. A lot is defined as 100 tons or less Grade B or A 516/A 516M (IBR, see 171.7 of the same heat treatment processing of this subchapter), Grade 65 or 70; lot having a thickness variation no (ii) Material shall meet the Charpy greater than plus or minus 25 percent. V-notch test requirements of ASTM A The minimum impact required for full 20/A 20M (IBR, see $171.7 of this subsize specimens must be 20 foot-pounds chapter); and in the longitudinal direction at -30 (iii) Plate impact test specimens °F., Charpy V-Notch and 15 foot-pounds shall meet the impact test requirein the transverse direction at -30 °F., ments in paragraph (a) of this section Charpy V-Notch. The required values in both the longitudinal and transverse for subsize specimens must be reduced directions of rolling at a temperature in direct proportion to the cross-secof minus 40 °C. (-40 °F.). tional area of the specimen beneath the (c) A cargo tank in anhydrous ammonotch. If a lot does not meet this renia service must be constructed of quirement, individual plates may be steel. The use of copper, silver, zinc or accepted if they individually meet this their alloys is prohibited. Baffles made requirement. from aluminum may be used only if (3) The fabricator shall record the joined to the cargo tank by a process heat, and slab numbers, and the ceΓ- not requiring postweld heat treatment tified Charpy impact values, where reof the cargo tank. quired, of each plate used in each cargo [Order 59-B, 30 FR 579, Jan. 16. 1965. Redesigtank on a sketch showing the location nated at 32 FR 5606, Apr. 5, 1967] of each plate in the shell and heads of EDITORIAL NOTE: For FEDERAL REGISTER cithe cargo tank. Copies of each sketch tations affecting $178.337-2, see the List of shall be provided to the owner and re- CFR Sections Affected which appears in the tained for at least five years by the Finding Aids section of the printed volume fabricator and made available to duly and on GPO Access. identified representatives of the Department of Transportation. $ 178.337-3 Structural integrity. (4) The direction of final rolling of (a) General requirements and acceptthe shell material shall be the circumance criteria. (1) Except as provided in 950 Pipeline and Hazardous Materials Safety Admin., DOT § 178.337-3 paragraph (d) of this section, the maxthroughout the cargo tank motor vehiimum calculated design stress at any cle. The vertical, longitudinal, and latpoint in the cargo tank may not exceed eral normal operating loadings can the maximum allowable stress value occur simultaneously and must be prescribed in Section VIII of the ASME combined. The vertical, longitudinal Code (IBR, see $171.7 of this suband lateral extreme dynamic loadings chapter), or 25 percent of the tensile occur separately and need not be comstrength of the material used. bined. (2) The relevant physical properties (1) Normal operating loadings. The folof the materials used in each cargo lowing procedure addresses stress in tank may be established either by a the tank shell resulting from normal certified test report from the material operating loadings. The effective stress manufacturer or by testing in conform- (the maximum principal stress at any ance with a recognized national standpoint) must be determined by the folard. In either case, the ultimate tensile lowing formula: strength of the material used in the de- S = 0.5(S, + Sx) ±[0.25(Sy - Sx)2 + S,2]0.5 sign may not exceed 120 percent of the ultimate tensile strength specified in Where: either the ASME Code or the ASTM (i) S = effective stress at any given standard to which the material is manpoint under the combination of static ufactured. and normal operating loadings that can (3) The maximum design stress at occur at the same time, in psi. any point in the cargo tank must be (ii) S, = circumferential stress gencalculated separately for the loading erated by the MAWP and external presconditions described in paragraphs (b). sure, when applicable, plus static head, (c), and (d) of this section. Alternate in psi. test or analytical methods, or a com- (iii) Sx = The following net longitubination thereof, may be used in place dinal stress generated by the following of the procedures described in parastatic and normal operating loading graphs (b), (c), and (d) of this section, if conditions, in psi: the methods are accurate and (A) The longitudinal stresses resultverifiable. ing from the MAWP and external pres- (4) Corrosion allowance material may sure, when applicable, plus static head, not be included to satisfy any of the in combination with the bending stress design calculation requirements of this generated by the static weight of the section. fully loaded cargo tank motor vehicle, (b) Static design and construction. (1) all structural elements, equipment and The static design and construction of appurtenances supported by the cargo each cargo tank must be in accordance tank wall; with Section VIII of the ASME Code. (B) The tensile or compressive stress The cargo tank design must include resulting from normal operating longicalculation of stresses generated by detudinal acceleration or deceleration. In sign pressure, the weight of lading, the each case, the forces applied must be weight of structure supported by the 0.35 times the vertical reaction at the cargo tank wall, and the effect of temsuspension assembly, applied at the perature gradients resulting from ladroad surface, and as transmitted to the ing and ambient temperature extremes. cargo tank wall through the suspension When dissimilar materials are used, assembly of a trailer during deceleratheir thermal coefficients must be used tion; or the horizontal pivot of the in calculation of thermal stresses. truck tractor or converter dolly fifth (2) Stress concentrations in tension, wheel, or the drawbar hinge on the bending and torsion which occur at fixed dolly during acceleration; or anpads, cradles, or other supports must choring and support members of a be considered in accordance with aptruck during acceleration and decelerapendix G in Section VIII of the ASME tion, as applicable. The vertical reac- Code. tion must be calculated based on the (c) Shell design. Shell stresses resultstatic weight of the fully loaded cargo ing from static or dynamic loadings, or tank motor vehicle, all structural elecombinations thereof, are not uniform ments, equipment and appurtenances 951 $ 178.337-3 49 CFR Ch. I (10-1-06 Edition) supported by the cargo tank wall. The sembly of a trailer, applied at the road following loadings must be included: surface, and as transmitted to the (1) The axial load generated by a cargo tank wall through the suspension decelerative force; assembly of a trailer, and the hori- (2) The bending moment generated by zontal pivot of the upper coupler (fifth a decelerative force; wheel) or turntable; or anchoring and (3) The axial load generated by an acsupport members of a truck, as applicacelerative force; and ble. The vertical reaction must be cal- (4) The bending moment generated by culated based on the static weight of an accelerative force; and the fully loaded cargo tank motor vehi- (C) The tensile or compressive stress cle, all structural elements, equipment generated by the bending moment reand appurtenances supported by the sulting from normal operating vertical cargo tank wall; and accelerative force equal to 0.35 times (D) The torsional shear stress genthe vertical reaction at the suspension erated by the same lateral forces as deassembly of a trailer; or the horizontal scribed in paragraph (c)(1)(iv)(C) of this pivot of the upper coupler (fifth wheel) section. or turntable; or anchoring and support (2) Extreme dynamic loadings. The folmembers of a truck, as applicable. The lowing procedure addresses stress in vertical reaction must be calculated the tank shell resulting from extreme based on the static weight of the fully dynamic loadings. The effective stress loaded cargo tank motor vehicle, all (the maximum principal stress at any structural elements, equipment and appoint) must be determined by the folpurtenances supported by the cargo lowing formula: tank wall. S = 0.5(Sy + Sx) ±[0.25(S, - Sx)2 + S,2]0.5 (iv) S, = The following shear stresses generated by the following static and Where: normal operating loading conditions, (i) S = effective stress at any given in psi: point under a combination of static (A) The static shear stress resulting and extreme dynamic loadings that can from the vertical reaction at the susoccur at the same time, in psi. pension assembly of a trailer, and the (ii) Sy = circumferential stress genhorizontal pivot of the upper coupler erated by MAWP and external pressure, (fifth wheel) or turntable; or anchoring when applicable, plus static head, in and support members of a truck, as appsi. plicable. The vertical reaction must be (iii) Sx = the following net longitucalculated based on the static weight dinal stress generated by the following of the fully loaded cargo tank motor static and extreme dynamic loading vehicle, all structural elements, equipconditions, in psi: ment and appurtenances supported by (A) The longitudinal stresses resultthe cargo tank wall; ing from the MAWP and external pres- (B) The vertical shear stress gensure, when applicable, plus static head, erated by a normal operating accelerain combination with the bending stress tive force equal to 0.35 times the generated by the static weight of the vertical reaction at the suspension asfully loaded cargo tank motor vehicle, sembly of a trailer; or the horizontal all structural elements, equipment and pivot of the upper coupler (fifth wheel) appurtenances supported by the tank or turntable; or anchoring and support wall; members of a truck, as applicable. The (B) The tensile or compressive stress vertical reaction must be calculated resulting from extreme longitudinal based on the static weight of the fully acceleration or deceleration. In each loaded cargo tank motor vehicle, all case the forces applied must be 0.7 structural elements, equipment and aptimes the vertical reaction at the suspurtenances supported by the cargo pension assembly, applied at the road tank wall; surface, and as transmitted to the (C) The lateral shear stress generated cargo tank wall through the suspension by a normal operating lateral acceleraassembly of a trailer during decelerative force equal to 0.2 times the tion; or the horizontal pivot of the vertical reaction at each suspension astruck tractor or converter dolly fifth 952 Pipeline and Hazardous Materials Safety Admin., DOT § 178.337-3 wheel, or the drawbar hinge on the loaded cargo tank motor vehicle, all fixed dolly during acceleration; or the structural elements, equipment and apanchoring and support members of a purtenances supported by the cargo truck during acceleration and deceleratank wall; tion, as applicable. The vertical reac- (C) The lateral shear stress generated tion must be calculated based on the by an extreme lateral accelerative static weight of the fully loaded cargo force equal to 0.4 times the vertical retank motor vehicle, all structural eleaction at the suspension assembly of a ments, equipment and appurtenances trailer, applied at the road surface, and supported by the cargo tank wall. The as transmitted to the cargo tank wall following loadings must be included: through the suspension assembly of a (1) The axial load generated by a trailer, and the horizontal pivot of the decelerative force; upper coupler (fifth wheel) or turn- (2) The bending moment generated by table; or anchoring and support mem- a decelerative force; bers of a truck, as applicable. The (3) The axial load generated by an acvertical reaction must be calculated celerative force; and based on the static weight of the fully (4) The bending moment generated by loaded cargo tank motor vehicle, all an accelerative force; and structural elements, equipment and ap- (C) The tensile or compressive stress purtenances supported by the cargo generated by the bending moment retank wall; and sulting from an extreme vertical accel- (D) The torsional shear stress generative force equal to 0.7 times the erated by the same lateral forces as devertical reaction at the suspension asscribed in paragraph (c)(2)(iv)(C) of this sembly of a trailer, and the horizontal section. pivot of the upper coupler (fifth wheel) (d) In order to account for stresses or turntable; or the anchoring and supdue to impact in an accident, the deport members of a truck, as applicable. sign calculations for the cargo tank The vertical reaction must be calshell and heads must include the load culated based on the static weight of resulting from the design pressure in the fully loaded cargo tank motor vehicombination with the dynamic prescle, all structural elements, equipment sure resulting from a longitudinal deand appurtenances supported by the celeration of "2g". For this loading cargo tank wall. condition the stress value used may (iv) Ss = The following shear stresses not exceed the lesser of the yield generated by static and extreme dystrength or 75 percent of the ultimate namic loading conditions, in psi: tensile strength of the material of con- (A) The static shear stress resulting struction. For cargo tanks constructed from the vertical reaction at the susof stainless steel the maximum design pension assembly of a trailer, and the stress may not exceed 75 percent of the horizontal pivot of the upper coupler ultimate tensile strength of the type (fifth wheel) or turntable: or anchoring steel used. and support members of a truck, as ap- (e) The minimum metal thickness for plicable. The vertical reaction must be the shell and heads on tanks with a decalculated based on the static weight sign pressure of 100 psig or more must of the fully loaded cargo tank motor be 4.75 mm (0.187 inch) for steel and 6.86 vehicle, all structural elements, equipmm (0.270 inch) for aluminum, except ment and appurtenances supported by for chlorine and sulfur dioxide tanks. the cargo tank wall; In all cases, the minimum thickness of (B) The vertical shear stress genthe tank shell and head shall be detererated by an extreme vertical acceleramined using structural design requiretive force equal to 0.7 times the ments in Section VIII of the ASME vertical reaction at the suspension as- Code or 25% of the tensile strength of sembly of a trailer, and the horizontal the material used. For a cargo tank pivot of the upper coupler (fifth wheel) used in chlorine or sulfur dioxide servor turntable; or anchoring and support ice, the cargo tank must be made of members of a truck, as applicable. The steel. A corrosion allowance of 20 pervertical reaction must be calculated cent or 2.54 mm (0.10 inch), whichever based on the static weight of the fully is less, must be added to the thickness 953 § 178.337-4 49 CFR Ch. I (10-1-06 Edition) otherwise required for sulfur dioxide thickness of the mounting pad may not and chlorine tank material. In chlorine be less than that of the shell wall or cargo tanks, the wall thickness must head wall to which it is attached, and be at least 1.59 cm (0.625 inch), includnot more than 1.5 times the shell or ing corrosion allowance. head thickness. However, a pad with a (f) Where a cargo tank support is atminimum thickness of 0.25 inch may be tached to any part of the cargo tank used when the shell or head thickness wall, the stresses imposed on the cargo is over 0.25 inch. If weep holes or telltank wall must meet the requirements tale holes are used, the pad must be in paragraph (a) of this section. drilled or punched at the lowest point (g) The design, construction, and inbefore it is welded to the tank. Each stallation of an attachment, appurpad musttenance to the cargo tank, structural (i) Be fabricated from material detersupport member between the cargo mined to be suitable for welding to tank and the vehicle or suspension both the cargo tank material and the component, or accident protection dematerial of the appurtenance or strucvice must conform to the following retural support member; a Design Certiquirements: fying Engineer must make this deter- (1) Structural members, the suspenmination considering chemical and sion sub-frame, accident protection physical properties of the materials structures, and external circumferenand must specify filler material contial reinforcement devices must be forming to the requirements in Section used as sites for attachment of appur- VIII of the ASME Code (IBR, see $ 171.7 tenances and other accessories to the of this subchapter). cargo tank, when practicable. (2) A lightweight attachment to the (ii) Be preformed to an inside radius cargo tank wall such as a conduit clip, no greater than the outside radius of brake line clip, skirting structure, the cargo tank at the attachment location. lamp mounting bracket, or placard holder must be of a construction hav- (iii) Extend at least 2 inches in each ing lesser strength than the cargo tank direction from any point of attachment wall materials and may not be more of an appurtenance or structural supthan 72 percent of the thickness of the port member. This dimension may be material to which it is attached. The measured from the center of the atlightweight attachment may be setached structural member. cured directly to the cargo tank wall if (iv) Have rounded corners, or otherthe device is designed and installed in wise be shaped in a manner to minisuch a manner that, if damaged, it will mize stress concentrations on the shell not affect the lading retention integor head. rity of the tank. A lightweight attach- (v) Be attached by continuous fillet ment must be secured to the cargo welding. Any fillet weld discontinuity tank shell or head by a continuous may only be for the purpose of preweld or in such a manner as to preclude venting an intersection between the filformation of pockets which may belet weld and a tank or jacket seam come sites for corrosion. Attachments weld. meeting the requirements of this para- (Amdt. 178-89, 55 FR 37056, Sept. 7, 1990, as graph are not authorized for cargo amended by Amdt. 178-104, 59 FR 49135, Sept. tanks constructed under part UHT in 26, 1994; Amdt. 178-105, 60 FR 17401. Apr. 5, Section VIII of the ASME Code. 1995; Amdt. 178-118, 61 FR 51340. Oct. 1. 1996; (3) Except as prescribed in para- 65 FR 58631, Sept. 29, 2000; 68 FR 19279, Apr. graphs (g) (1) and (g)(2) of this section, 18, 2003; 68 FR 52370, Sept. 3, 2003; 68 FR 75753, the welding of any appurtenance to the Dec. 31, 2003] cargo tank wall must be made by attachment of a mounting pad so that § 178.337-4 Joints. there will be no adverse effect upon the (a) Joints shall be as required in Seclading retention integrity of the cargo tion VIII of the ASME Code (IBR, see tank if any force less than that pre- $171.7 of this subchapter), with all unscribed in paragraph (b)(1) of this secdercutting in shell and head material tion is applied from any direction. The repaired as specified therein. 954 Pipeline and Hazardous Materials Safety Admin., DOT § 178.337-8 (b) Welding procedure and welder per- § 178.337-6 Closure for manhole. formance must be in accordance with Section IX of the ASME Code. In addi- (a) Each cargo tank marked or certion to the essential variables named tified after April 21, 1994, must be protherein, the following must be considvided with a manhole conforming to ered as essential variables: Number of paragraph UG-46(g) (1) and other applipasses; thickness of plate; heat input cable requirements in Section VIII of the ASME Code (IBR, see § 171.7 of this per pass; and manufacturer's identification of rod and flux. When fabricasubchapter), except that a cargo tank tion is done in accordance with part constructed of NQT steel having a ca- UHT in Section VIII of the ASME Code, pacity of 3,500 water gallons or less filler material containing more than may be provided with an inspection 0.08 percent vanadium must not be opening conforming to paragraph UGused. The number of passes, thickness 46 and other applicable requirements of the ASME Code instead of a manhole. of plate, and heat input per pass may not vary more than 25 percent from the (b) The manhole assembly of cargo tanks constructed after June 30, 1979, procedure or welder qualifications. Records of the qualifications must be may not be located on the front head of retained for at least 5 years by the the cargo tank. cargo tank manufacturer and must be [Amdt. 178-7. 34 FR 18250, Nov. 14, 1969, as made available to duly identified repamended by Amdt. 178-52, 43 FR 58820, Dec. resentatives of the Department and the 18, 1978; Amdt. 178-89. 54 FR 25017. June 12, owner of the cargo tank. 1989; 55 FR 21038, May 22, 1990; 56 FR 27876, (c) All longitudinal shell welds shall June 17, 1991; 58 FR 12905, March 8, 1993; Amdt. 178-118, 61 FR 51340, Oct. 1, 1996; 68 FR be located in the upper half of the 75753, Dec. 31, 2003] cargo tank. (d) Edge preparation of shell and § 178.337-7 Overturn protection. head components may be by machine (a) See § 178.337-10. heat processes, provided such surfaces (b) [Reserved] are remelted in the subsequent welding process. Where there will be no subse- [Order 59-B, 30 FR 580, Jan. 16, 1965. Redesigquent remelting of the prepared surface nated at 32 FR 5606, Apr. 5, 1967] as in a tapered section, the final 0.050 inch of material shall be removed by $ 178.337-8 Openings, inlets, and outlets. mechanical means. (e) The maximum tolerance for mis- (a) General. The requirements in this alignment and butting up shall be in paragraph (a) apply to MC 331 cargo accordance with the requirement in tanks except for those used to trans- Section VIII of the ASME Code. port chlorine. The requirements for in- (f) Substructures shall be properly lets and outlets on chlorine cargo fitted before attachment, and the weldtanks are in paragraph (b) of this secing sequence shall be such as to minition. mize stresses due to shrinkage of (1) An opening must be provided on welds. each cargo tank used for the transportation of liquefied materials to permit [Order 59-B. 30 FR 580, Jan. 16, 1965. Redesigcomplete drainage. nated at 32 FR 5606, Apr. 5, 1967] (2) Except for gauging devices, ther- EDITORIAL NOTE: For FEDERAL REGISTER cimometer wells, pressure relief valves, tations affecting $178.337-4, see the List of manhole openings, product inlet open- CFR Sections Affected which appears in the ings, and product discharge openings, Finding Aids section of the printed volume and on GPO Access. each opening in a cargo tank must be closed with a plug, cap, or bolted § 178.337-5 Bulkheads, baffles and ring flange. stiffeners. (3) Except as provided in paragraph (b) of this section, each product inlet (a) Not a specification requirement. opening, including vapor return lines, (b) [Reserved] must be fitted with a back flow check [Order 59-B, 30 FR 580, Jan. 16, 1965. Redesigvalve or an internal self-closing stop nated at 32 FR 5606, Apr. 5, 1967) valve located inside the cargo tank or 955 $ 178.337-8 49 CFR Ch. I (10-1-06 Edition) inside a welded nozzle that is an inteditions incident to discharge of prodgral part of the cargo tank. The valve uct. seat must be located inside the cargo (iii) All parts of a valve inside a tank or within 2.54 cm (one inch) of the cargo tank or within a welded flange external face of the welded flange. must be made of material that will not Damage to parts exterior to the cargo corrode or deteriorate in the presence tank or mating flange must not preof the lading. vent effective seating of the valve. All (iv) An excess flow valve, integral exparts of a valve inside a cargo tank or cess flow valve, or excess flow feature welded flange must be made of matemust close if the flow reaches the rated rial that will not corrode or deteriorate flow of a gas or liquid specified by the in the presence of the lading. original valve manufacturer when pip- (4) Except as provided in paragraphs ing mounted directly on the valve is (a)(5), (b), and (c) of this section, each sheared off before the first valve, liquid or vapor discharge outlet must pump, or fitting downstream from the be fitted with a primary discharge conexcess flow valve, integral excess flow trol system as defined in § 178.337-1(g). valve, or excess flow feature. Thermal remote operators must acti- (v) An integral excess flow valve or vate at a temperature of 121.11°C (250 the excess flow feature of an internal °F) or less. Linkages between closures self-closing stop valve may be designed and remote operators must be corrowith a bypass, not to exceed 0.1016 cm sion resistant and effective in all types (0.040 inch) diameter opening, to allow of environmental conditions incident equalization of pressure. to discharging of product. (vi) The internal self-closing stop (i) On a cargo tank over 13,247.5 L valve must be designed so that the self- (3,500 gallons) water capacity, thermal stored energy source and the valve seat and mechanical means of remote cloare located inside the cargo tank or sure must be installed at the ends of within 2.54 cm (one inch) of the exterthe cargo tank in at least two diagonal face of the welded flange. Damage nally opposite locations. If the loading/ to parts exterior to the cargo tank or unloading connection at the cargo tank mating flange must not prevent effecis not in the general vicinity of one of tive seating of the valve. the two locations specified in the first (5) A primary discharge control syssentence of this paragraph (a)(4)(i), adtem is not required on the following: ditional means of thermal remote clo- (i) A vapor or liquid discharge opensure must be installed so that heat ing of less than 1½ NPT equipped with from a fire in the loading/unloading an excess flow valve together with a connection area or the discharge pump manually operated external stop valve will activate the primary discharge in place of an internal self-closing stop control system. The loading/unloading valve. connection area is where hoses or hose (ii) An engine fuel line on a truckreels are connected to the permanent mounted cargo tank of not more than metal piping. 3/4 NPT equipped with a valve having an (ii) On a cargo tank of 13,247.5 L (3,500 Integral excess flow valve or excess gallons) water capacity or less, a therflow feature. mal means of remote closure must be (iii) A cargo tank motor vehicle used installed at or near the internal selfto transport refrigerated liquids such closing stop valve. A mechanical as argon, carbon dioxide, helium, krypmeans of remote closure must be inton, neon, nitrogen, and xenon, or mixstalled on the end of the cargo tank tures thereof. furthest away from the loading/unload- (6) In addition to the internal selfing connection area. The loading/unclosing stop valve, each filling and disloading connection area is where hoses charge line must be fitted with a stop or hose reels are connected to the pervalve located in the line between the manent metal piping. Linkages beinternal self-closing stop valve and the tween closures and remote operators hose connection. A back flow check must be corrosion resistant and effecvalve or excess flow valve may not be tive in all types of environmental conused to satisfy this requirement. 956 Pipeline and Hazardous Materials Safety Admin., DOT § 178.337-9 (7) An excess flow valve may be deservice, see paragraph (b)(7) of this secsigned with a bypass, not to exceed a tion. 0.1016 centimeter (0.040 inch) diameter (2) Pipe joints must be threaded, opening, to allow equalization of preswelded, or flanged. If threaded pipe is sure. used, the pipe and fittings must be (b) Inlets and discharge outlets on chlo- Schedule 80 weight or heavier, except rine tanks. The inlet and discharge outfor sacrificial devices. Malleable metal, lets on a cargo tank used to transport stainless steel, or ductile iron must be chlorine must meet the requirements used in the construction of primary of §178.337-1(c)(2) and must be fitted valve body parts and fittings used in with an internal excess flow valve. In liquid filling or vapor equalization. addition to the internal excess flow Stainless steel may be used for internal valve, the inlet and discharge outlets components such as shutoff discs and must be equipped with an external stop springs except where incompatible with valve (angle valve). Excess flow valves the lading to be transported. Where must conform to the standards of The copper tubing is permitted, joints must Chlorine Institute, Inc., as follows: be brazed or be of equally strong metal (1) A valve conforming to The Chlounion type. The melting point of the rine Institute, Inc., Dwg. 101-7 (IBR, brazing material may not be lower see $171.7 of this subchapter), must be than 538 °C (1,000 °F). The method of installed under each liquid angle valve. joining tubing may not reduce the (2) A valve conforming to The Chlostrength of the tubing. rine Institute, Inc., Dwg. 106-6 (IBR, (3) Each hose coupling must be desee $171.7 of this subchapter), must be signed for a pressure of at least 120 perinstalled under each gas angle valve. cent of the hose design pressure and so (c) Discharge outlets on carbon dioxide, that there will be no leakage when conrefrigerated liquid, cargo tanks. A disnected. charge outlet on a cargo tank used to (4) Piping must be protected from transport carbon dioxide, refrigerated damage due to thermal expansion and liquid is not required to be fitted with contraction, jarring, and vibration. an internal self-closing stop valve. Slip joints are not authorized for this purpose. [64 FR 28049, May 24, 1999, as amended at 66 (5) [Reserved] FR 45387, Aug. 28, 2001; 68 FR 19279, Apr. 18, (6) Cargo tank manufacturers and 2003; 68 FR 75753, Dec. 31, 2003] fabricators must demonstrate that all $ 178.337-9 Pressure relief devices, piping, valves, and fittings on a cargo piping, valves, hoses, and fittings. tank are free from leaks. To meet this requirement, the piping, valves, and (a) Pressure relief devices. (1) See fittings must be tested after installa- $ 1173.315(i) of this subchapter. tion at not less than 80 percent of the (2) On cargo tanks for carbon dioxide design pressure marked on the cargo or nitrous oxide see § 173.315 (i) (9) and tank. (10) of this subchapter. (7) A hose assembler must: (3) Each valve must be designed, con- (i) Permanently mark each hose asstructed, and marked for a rated pressembly with a unique identification sure not less than the cargo tank denumber. sign pressure at the temperature ex- (ii) Demonstrate that each hose aspected to be encountered. sembly is free from leaks by per- (b) Piping, valves, hose, and fittings. (1) forming the tests and inspections in The burst pressure of all piping, pipe § 180.416(f) of this subchapter. fittings, hose and other pressure parts, (iii) Mark each hose assembly with except for pump seals and pressure rethe month and year of its original preslief devices, must be at least 4 times sure test. the design pressure of the cargo tank. (8) Chlorine cargo tanks. Angle valves Additionally, the burst pressure may on cargo tanks intended for chlorine not be less than 4 times any higher service must conform to the standards pressure to which each pipe, pipe fitof The Chlorine Institute, Inc., Dwg. ting, hose or other pressure part may 104-8 (IBR, see $171.7 of this subbe subjected to in service. For chlorine chapter). Before installation, each 957 § 178.337-10 49 CFR Ch. I (10-1-06 Edition) angle valve must be tested for leakage hard surface, their opening will not be at not less than 225 psig using dry air prevented and their discharge will not or inert gas. be restricted. (c) Marking inlets and outlets. Except (b) The protective devices or housing for gauging devices, thermometer must be designed to withstand static wells, and pressure relief valves, each loading in any direction equal to twice cargo tank inlet and outlet must be the weight of the tank and attachmarked "liquid" or "vapor" to desments when filled with the lading, ignate whether it communicates with using a safety factor of not less than liquid or vapor when the cargo tank is four, based on the ultimate strength of filled to the maximum permitted fillthe material to be used, without daming density. A filling line that commuage to the fittings protected, and must nicates with vapor may be marked be made of metal at least 3/16-inch "spray-fill" instead of "vapor." thick. (d) Refrigeration and heating coils. (1) (c) Rear-end tank protection. Rear-end Refrigeration and heating coils must tank protection devices must: be securely anchored with provisions (1) Consist of at least one rear bumpfor thermal expansion. The coils must er designed to protect the cargo tank be pressure tested externally to at and all valves, piping and fittings loleast the cargo tank test pressure, and cated at the rear of the cargo tank internally to either the tank test presfrom damage that could result in loss sure or twice the working pressure of of lading in the event of a rear end colthe heating/refrigeration system, lision. The bumper design must transwhichever is higher. A cargo tank may mit the force of the collision directly not be placed in service If any leakage to the chassis of the vehicle. The rear occurs or other evidence of damage is bumper and its attachments to the found. The refrigerant or heating mechassis must be designed to withstand dium to be circulated through the coils a load equal to twice the weight of the must not be capable of causing any adloaded cargo tank motor vehicle and verse chemical reaction with the cargo attachments, using a safety factor of tank lading in the event of leakage. four based on the tensile strength of The unit furnishing refrigeration may the materials used, with such load be mounted on the motor vehicle. being applied horizontally and parallel (2) Where any liquid susceptible to to the major axis of the cargo tank. freezing, or the vapor of any such liq- The rear bumper dimensions must also uid, is used for heating or refrigerameet the requirements of $393.86 of this tion, the heating or refrigeration systitle: or tem shall be arranged to permit com- (2) Conform to the requirements of plete drainage. § 178.345-8(d). [Order 59-B, 30 FR 580, Jan. 16, 1965. Redesig- (d) Chlorine tanks. A chlorine tank nated at 32 FR 5606, Apr. 5. 1967) must be equipped with a protective EDITORIAL NOTE: For FEDERAL REGISTER cihousing and a manway cover to permit tations affecting $178.337-9, see the List of the use of standard emergency kits for CFR Sections Affected which appears in the controlling leaks in fittings on the Finding Aids section of the printed volume dome cover plate. The housing and and on GPO Access. manway cover must conform to the Chlorine Institute's standards as fol- § 178.337-10 Accident damage proteclows: tion. (1) Tanks manufactured on or before (a) All valves, fittings. pressure relief December 31, 1974: Dwg. 137-1 (IBR, see devices, and other accessories to the 171.7 of this subchapter), or Dwg. 137- tank proper shall be protected in ac- 2 (IBR, see $171.7 of this subchapter). cordance with paragraph (b) of this sec- (2) Tanks manufactured on or after tion against such damage as could be January 1, 1975: Dwg. 137-2, dated Sepcaused by collision with other vehicles tember 1, 1971. or objects, jack-knifing and over- (e) Piping and fittings. Piping and fitturning. In addition, pressure relief tings must be grouped in the smallest valves shall be so protected that in the practicable space and protected from event of overturn of the vehicle onto a damage as required in this section. 958 Pipeline and Hazardous Materials Safety Admin., DOT § 178.337-15 (f) Shear section. A shear section or use of restraining devices designed to sacrificial device is required for the prevent relative motion between the valves specified in the following locacargo tank and the vehicle chassis tions: when the vehicle is in operation. Such (1) A section that will break under restraining devices must be readily acstrain must be provided adjacent to or cessible for inspection and mainteoutboard of each valve specified in nance. § 178.337-8(a) (3) and (4). (b) On a cargo tank motor vehicle de- (2) Each internal self-closing stop signed and constructed so that the valve, excess flow valve, and check cargo tank constitutes in whole or in valve must be protected by a shear secpart the structural member used in tion or other sacrificial device. The place of a motor vehicle frame, the sacrificial device must be located in cargo tank must be supported by exterthe piping system outboard of the stop nal cradles. A cargo tank mounted on a valve and within the accident damage motor vehicle frame must be supported protection to prevent any accidental by external cradles or longitudinal loss of lading. The failure of the sacmembers. Where used, the cradles must rificial device must leave the protected subtend at least 120 degrees of the shell lading protection device and its attachcircumference. ment to the cargo tank wall intact and (c) The design calculations of the capable of retaining product. support elements must satisfy the re- [Order 59-B, 30 FR 581. Jan. 16, 1965. Redesigquirements of 178.337-3, (a), (b), (c), nated at 32 FR 5606, Apr. 5, 1967] and (d). EDITORIAL NOTE: For FEDERAL REGISTER ci- (d) Where any cargo tank support is tations affecting $178.337-10, see the List of attached to any part of a cargo tank CFR Sections Affected which appears in the head, the stresses imposed upon the Finding Aids section of the printed volume head must be provided for as required and on GPO Access. in paragraph (c) of this section. § 178.337-11 Emergency discharge con- [68 FR 19280, Apr. 18, 2003] trol. § 178.337-14 Gauging devices. (a) Emergency discharge control equipment. Emergency discharge control (a) Liquid level gauging devices. See equipment must be installed in a liquid § 173.315(h) of this subchapter. discharge line as specified by product (b) Pressure gauges. (1) See $173.315(h) and service in § 173.315(n) of this subof this subchapter. chapter. The performance and certifi- (2) Each cargo tank used in carbon cation requirements for emergency disdioxide, refrigerated liquid or nitrous charge control equipment are specified oxide, refrigerated liquid service must in § 173.315(n) of this subchapter and are be provided with a suitable pressure not a part of the cargo tank motor vegauge. A shut-off valve must be inhicle certification made under this stalled between the pressure gauge and specification. the cargo tank. (b) Engine fuel lines. On a truck- (c) Orifices. See § 173.315(h) (3) and (4) mounted cargo tank, emergency disof this subchapter. charge control equipment is not re- [Amdt. 178-29, 38 FR 27599, Oct. 5. 1973, as quired on an engine fuel line of not amended by Amdt. 178-89, 54 FR 25018, June more than 3/4 NPT equipped with a 12. 1989; Amdt. 178-118, 61 FR 51340, Oct. 1, valve having an integral excess flow 1996] valve or excess flow feature. § 178.337-15 Pumps and compressors. [64 FR 28050, May 24, 1999] (a) Liquid pumps or gas compressors, § 178.337-12 [Reserved] if used, must be of suitable design, adequately protected against breakage by $ 178.337-13 Supporting and anchorcollision, and kept in good condition. ing. They may be driven by motor vehicle (a) A cargo tank that is not permapower take-off or other mechanical, nently attached to or integral with a electrical, or hydraulic means. Unless vehicle chassis must be secured by the they are of the centrifugal type, they 959 § 178.337-16 49 CFR Ch. I (10-1-06 Edition) shall be equipped with suitable presformed, and the repaired areas shall sure actuated by-pass valves permitagain be tested. ting flow from discharge to suction or [Order 59-B, 30 FR 582, Jan. 16, 1965. Redesigto the cargo tank. nated at 32 FR 5606, Apr. 5, 1967, and amended (b) A liquid chlorine pump may not by Amdt. 178-7, 34 FR 18250, Nov. 14, 1969; be installed on a cargo tank intended Amdt. 178-99, 58 FR 51534, Oct. 1, 1993; Amdt. for the transportation of chlorine. 178-118, 61 FR 51340, Oct. 1, 1996; 68 FR 75753, Dec. 31, 2003] [Amdt. 178-89, 54 FR 25018, June 12, 1989, as amended by Amdt. 178-118, 61 FR 51340, Oct. § 178.337-17 Marking. 1, 1996] (a) General. Each cargo tank certified § 178.337-16 Testing. after October I, 2004 must have a corrosion-resistant metal name plate (a) Inspection and tests. Inspection of (ASME Plate) and specification plate materials of construction of the cargo permanently attached to the cargo tank and its appurtenances and origitank by brazing, welding, or other suitnal test and inspection of the finished able means on the left side near the cargo tank and its appurtenances must front, in a place accessible for inspecbe as required by Section VIII of the tion. If the specification plate is at- ASME Code (IBR, see § 171.7 of this subtached directly to the cargo tank wall chapter) and as further required by this by welding, it must be welded to the specification, except that for cargo tank before the cargo tank is postweld tanks constructed in accordance with heat treated. part UHT in Section VIII of the ASME (1) The plates must be legibly marked Code the original test pressure must be by stamping, embossing, or other at least twice the cargo tank design means of forming letters into the pressure. metal of the plate, with the informa- (b) Weld testing and inspection. (1) tion required in paragraphs (b) and (c) Each cargo tank constructed in accordof this section, in addition to that reance with part UHT in Section VIII of quired by the ASME Code, in charthe ASME Code must be subjected, acters at least 3/16 inch high (parafter postweld heat treatment and hyenthetical abbreviations may be used). drostatic tests, to a wet fluorescent All plates must be maintained in a legmagnetic particle inspection to be ible condition. made on all welds in or on the cargo (2) Each insulated cargo tank must tank shell and heads both inside and have additional plates, as described, atout. The method of inspection must tached to the jacket in the location conform to appendix 6 in Section VIII specified unless the specification plate of the ASME Code except that permais attached to the chassis and has the nent magnets shall not be used. information required in paragraphs (b) (2) On cargo tanks of over 3,500 galand (c) of this section. lons water capacity other than those (3) The information required for both described in paragraph (b)(1) of this the name and specification plate may section unless fully radiographed, a be displayed on a single plate. If the intest must be made of all welds in or on formation required by this section is the shell and heads both inside and displayed on a plate required by the outside by either the wet fluorescent ASME, the information need not be remagnetic particle method conforming peated on the name and specification to appendix U in Section VIII of the plates. ASME Code, liquid dye penetrant (4) The specification plate may be atmethod, or ultrasonic testing in actached to the cargo tank motor vehicle cordance with appendix 12 in Section chassis rail by brazing, welding, or VIII of the ASME Code. Permanent other suitable means on the left side magnets must not be used to perform near the front head, in a place accesthe magnetic particle inspection. sible for inspection. If the specification (c) All defects found shall be replate is attached to the chassis rail, paired, the cargo tanks shall then then the cargo tank serial number asagain be postweld heat treated, if such signed by the cargo tank manufacturer heat treatment was previously permust be included on the plate. 960 Pipeline and Hazardous Materials Safety Admin., DOT $ 178.337-18 (b) Name plate. The following infor- (6) Lining materials (Lining), if apmation must be marked on the name plicable. plate in accordance with this section: (7) Heating system design pressure (1) DOT-specification number MC 331 (Heating sys. press.), in psig, If applica- (DOT MC 331). ble. (2) Original test date (Orig. Test (8) Heating system design tempera- Date). ture (Heating sys. temp.), in °F, if ap- (3) MAWP in psig. plicable. (4) Cargo tank design temperature (9) Cargo tank serial number, as- (Design Temp. Range) °F to signed by cargo tank manufacturer (CT °F. serial), if applicable. (5) Nominal capacity (Water Cap.), in NOTE 1 TO PARAGRAPH (c): See $173.315(a) of pounds. this chapter regarding water capacity. (6) Maximum design density of lading NOTE 2 TO PARAGRAPH (c): When the shell (Max. Lading density), in pounds per and head materials are the same thickness, gallon. they may be combined (Shell & head matl, yyy***). (7) Material specification number- (d) The design weight of lading used shell (Shell matl, yyy***). where "yyy" in determining the loading in $ § 178.337- is replaced by the alloy designation 3(b), 178.337-10(b) and (c), and 178.337- and ****** is replaced by the alloy type. 13(a) and (b), must be shown as the (8) Material specification numbermaximum weight of lading marking reheads (Head matl. yyy***), where quired by paragraph (c) of this section. "yyy" is replaced by the alloy designation and by the alloy type. [68 FR 19280, Apr. 18, 2003; 68 FR 52370, Sept. (9) Minimum Thickness-shell (Min. 3. 2003, as amended at 68 FR 57633, Oct. 6, Shell-thick), in inches. When minimum 2003] shell thicknesses are not the same for § 178.337-18 Certification. different areas, show (top side , , bottom in inches). (a) At or before the time of delivery, (10) Minimum thickness-heads (Min. the cargo tank motor vehicle manufacheads thick.), in inches. turer must supply and the owner must (11) Manufactured thickness-shell obtain, a cargo tank motor vehicle (Mfd. Shell thick.), top , side manufacturer's data report as required . bottom , in inches. (Required when by Section VIII of the ASME Code additional thickness is provided for (IBR, see $171.7 of this subchapter). and corrosion allowance.) a certificate stating that the com- (12) Manufactured thickness-heads pleted cargo tank motor vehicle con- (Mfd. Heads thick.), in inches. (Reforms in all respects to Specification quired when additional thickness is MC 331 and the ASME Code. The regprovided for corrosion allowance.) istration numbers of the manufacturer, (13) Exposed surface area, in square the Design Certifying Engineer, and feet. the Registered Inspector, as appro- NOTE TO PARAGRAPH (b): When the shell and priate, must appear on the certificates head materials are the same thickness, they (see subpart F. part 107 in subchapter A may be combined, (Shell&head matl, of this chapter). yyy***). (1) For each design type, the certifi- (c) Specification plate. The following cate must be signed by a responsible ofinformation must be marked on the ficial of the manufacturer and a Design specification plate in accordance with Certifying Engineer; and this section: (2) For each cargo tank motor vehi- (1) Cargo tank motor vehicle manucle, the certificate must be signed by a facturer (CTMV mfr.). responsible official of the manufac- (2) Cargo tank motor vehicle certifiturer and a Registered Inspector. cation date (CTMV cert. date). (3) When a cargo tank motor vehicle (3) Cargo tank manufacturer (CT is manufactured in two or more stages, mfr.). each manufacturer who performs a (4) Cargo tank date of manufacture manufacturing function or portion (CT date of mfr.), month and year. thereof on the incomplete cargo tank (5) Maximum weight of lading (Max. motor vehicle must provide to the suc- Payload). in pounds ceeding manufacturer, at or before the 961 § 178.338 49 CFR Ch. I (10-1-06 Edition) time of delivery, a certificate that hicle and for at least one year therestates the function performed by the after; and in the event of change in manufacturer, including any certifiownership, retention by the prior cates received from previous manufacowner of nonfading photographically turers, Registered Inspectors, and Dereproduced copies will be deemed to sign Certifying Engineers. satisfy this requirement. Each motor (4) Specification shortages. When a carrier using the cargo tank motor vecargo tank motor vehicle is manufachicle, if not the owner thereof, shall tured in two or more stages, the manuobtain a copy of the data report and facturer of the cargo tank must attach certificate and retain them in his files the name plate and specification plate during the time he uses the cargo tank as required by § 178.337-17(a) and (b) motor vehicle and for at least one year without the original date of certifithereafter. cation stamped on the specification plate. Prior manufacturers must list [Order 59-B, 30 FR 583, Jan. 16, 1965. Redesigthe specification requirements that are nated at 32 FR 5606, Apr. 5, 1967] not completed on the Certificate of EDITORIAL NOTE: For FEDERAL REGISTER cì- Compliance. When the cargo tank tations affecting 178.337-18. see the List of motor vehicle is brought into full com- CFR Sections Affected which appears in the pliance with the applicable specifica- Finding Aids section of the printed volume and on GPO Access. tion, the cargo tank motor vehicle manufacturer must have a Registered $ 178.338 Specification MC-338; insu- Inspector stamp the date of certifilated cargo tank motor vehicle. cation on the specification plate and issue a Certificate of Compliance to the § 178.338-1 General requirements. owner of the cargo tank motor vehicle. The Certificate of Compliance must (a) For the purposes of this sectionlist the actions taken to bring the (1) Design pressure means the cargo tank motor vehicle into full "MAWP" as used in Section VIII of the compliance. In addition, the certificate ASME Code (IBR, see § 171.7 of this submust include the date of certification chapter), and is the gauge pressure at and the person (manufacturer, carrier the top of the tank. or repair organization) accomplishing (2) Design service temperature means compliance. the coldest temperature for which the (5) The certificate must state whethtank is suitable (see §§ 173.318 (a) and er or not it includes certification that (f) of this subchapter). all valves, piping, and protective de- (b) Each cargo tank must consist of a vices conform to the requirements of suitably supported welded inner vessel the specification. If it does not so cerenclosed within an outer shell or jacktify, the installer of any such valve, et, with insulation between the inner piping, or device shall supply and the vessel and outer shell or jacket, and owner shall obtain a certificate asserthaving piping, valves, supports and ing complete compliance with these other appurtenances as specified in this specifications for such devices. The subchapter. For the purpose of this certificate, or certificates, will include specification, tank means inner vessel sufficient sketches, drawings, and and jacket means either the outer shell other information to indicate the locaor insulation cover. tion, make, model, and size of each (c) Each tank must be designed, convalve and the arrangement of all piping structed, certified, and stamped in acassociated with the cargo tank. cordance with Section VIII of the (6) The certificate must contain a ASME Code. statement indicating whether or not (d) The exterior surface of the tank the cargo tank was postweld heat must be insulated with a material comtreated for anhydrous ammonia as patible with the lading. specified in 178.337-1(f) (1) Each cargo tank must have an in- (b) The owner shall retain the copy of sulation system that will prevent the the data report and certificates and retank pressure from exceeding the preslated papers in his files throughout his sure relief valve set pressure within the ownership of the cargo tank motor vespecified holding time when the tank is 962 Pipeline and Hazardous Materials Safety Admin., DOT 178.338-2 loaded with the specific cryogenic liqto be transported. All material used for uid at the design conditions oftank pressure parts must conform to (i) The specified temperature and the requirements in Section II of the pressure of the cryogenic liquid, and ASME Code (IBR, see $171.7 of this sub- (ii) The exposure of the filled cargo chapter). All material used for evacutank to an average ambient temperaated jacket pressure parts must conture of 85 °F. form to the chemistry and steelmaking (2) For a cargo tank used to transport practices of one of the material specioxygen, the insulation may not sustain fications of Section II of the ASME combustion in a 99.5 percent oxygen at- Code or the following ASTM Specificamosphere at atmospheric pressure tions (IBR, see $171.7 of this subwhen contacted with a continuously chapter): A 242, A 441, A 514, A 572, A heated glowing platinum wire. The 588, A 606, A 633, A 715, A 1008/A 1008M, cargo tank must be marked in accord- A 1011/A 1011M. ance with § 178.338-18(b)(7). (b) All tie-rods, mountings, and other (3) Each vacuum-insulated cargo tank must be provided with a connecappurtenances within the jacket and tion for a vacuum gauge to indicate the all piping, fittings and valves must be of material suitable for use at the lowabsolute pressure within the insulation est temperature to be encountered. space. (e) The insulation must be com- (c) Impact tests are required on all pletely covered by a metal jacket. The tank materials, except materials that jacket or the insulation must be so are excepted from impact testing by constructed and sealed as to prevent the ASME Code, and must be permoisture from coming into contact formed using the procedure prescribed with the insulation (see § 173.318(a)(3) of in Section VIII of the ASME Code. this subchapter). Minimum metal (d) The direction of final rolling of thicknesses are as follows: the shell material must be the circumferential orientation of the tank shell. Jacket evacu- Jacket not (e) Each tank constructed in accord- Type metal ated evacuated ance with part UHT in Section VIII of Gauge Inches Gauge Inches the ASME Code must be postweld heat Stainless steel 18 0.0428 22 0.0269 treated as a unit after completion of Low carbon mild steel 12 0.0946 14 0.0677 all welds to the shell and heads. Other Aluminum 0.125 0.1000 tanks must be postweld heat treated as required in Section VIII of the ASME (f) An evacuated jacket must be in Code. For all tanks the method must compliance with the following requirebe as prescribed in the ASME Code. ments: (1) The jacket must be designed to Welded attachments to pads may be sustain a minimum critical collapsing made after postweld heat treatment. pressure of 30 psig. (f) The fabricator shall record the (2) If the jacket also supports addiheat and slab numbers and the certified tional loads, such as the weight of the Charpy impact values of each plate tank and lading, the combined stress, used in the tank on a sketch showing computed according to the formula in the location of each plate in the shell § 178.338-3(b). may not exceed 25 percent and heads of the tank. A copy of the of the minimum specified tensile sketch must be provided to the owner strength. of the cargo tank and a copy must be retained by the fabricator for at least [Amdt. 178-77, 48 FR 27703, June 16, 1983. as five years and made available, upon reamended at 49 FR 24316, June 12, 1984; Amdt. 178-104, 59 FR 49135, Sept. 26, 1994: 66 FR quest, to any duly identified represent- 45387, Aug. 28, 2001; 68 FR 75754, Dec. 31, 2003] ative of the Department. § 178.338-2 Material. (Approved by the Office of Management and Budget under control number 2137-0017) (a) All material used in the construc- [Amdt. 178-77, 48 FR 27703 and 27713, June 16, tion of a tank and its appurtenances 1983, as amended at 49 FR 24316, June 12, 1984: that may come in contact with the lad- 68 FR 19281, Apr. 18, 2003; 68 FR 75754. Dec. 31, ing must be compatible with the lading 2003; 70 FR 34076, June 13. 2005) 963 § 178.338-3 49 CFR Ch. I (10-1-06 Edition) § 178.338-3 Structural integrity. (c) Stresses resulting from static and dynamic loadings, or a combination (a) General requirements and acceptthereof, are not uniform throughout ance criteria. (1) Except as permitted in the cargo tank motor vehicle. The folparagraph (d) of this section, the maxlowing is a simplified procedure for calimum calculated design stress at any culating the effective stress in the point in the tank may not exceed the tank resulting from static and dynamic lesser of the maximum allowable stress loadings. The effective stress (the maxvalue prescribed in section VIII of the imum principal stress at any point) ASME Code, or 25 percent of the tensile must be determined by the following strength of the material used. formula: (2) The relevant physical properties of the materials used in each tank may S = 0.5 (Sy + Sx) ±(0.25(S, - Sx)2 + S,2) 0.5 be established either by a certified test Where: report from the material manufacturer or by testing in conformance with a (1) S = effective stress at any given recognized national standard. In either point under the most severe combinacase, the ultimate tensile strength of tion of static and dynamic loadings the material used in the design may that can occur at the same time, in psi. not exceed 120 percent of the minimum (2) Sy = circumferential stress genultimate tensile strength specified in erated by internal and external preseither the ASME Code or the ASTM sure when applicable, in psi. standard to which the material is man- (3) Sx = the net longitudinal stress, in ufactured. psi, generated by the following loading conditions: (3) The maximum design stress at (i) The longitudinal tensile stress any point in the tank must be calgenerated by internal pressure; culated separately for the loading con- (ii) The tensile or compressive stress ditions described in paragraphs (b), (c), generated by the axial load resulting and (d) of this section. Alternate test from a decelerative force applied indeor analytical methods, or a combinapendently to each suspension assembly tion thereof, may be used in lieu of the at the road surface using applicable procedures described in paragraphs (b), static loadings specified in § 178.338-13 (c), and (d) of this section, if the meth- (b); ods are accurate and verifiable. (iii) The tensile or compressive stress (4) Corrosion allowance material may generated by the bending moment Γe- not be included to satisfy any of the sulting from a decelerative force apdesign calculation requirements of this plied independently to each suspension section. assembly at the road surface using ap- (b) Static design and construction. (1) plicable static loadings specified in The static design and construction of § 178.338-13 (b): each tank must be in accordance with (iv) The tensile or compressive stress appendix G in Section VIII of the generated by the axial load resulting ASME Code (IBR, see $171.7 of this subfrom an accelerative force applied to chapter). The tank design must include the horizontal pivot of the fifth wheel calculation of stress due to the design supporting the vehicle using applicable pressure, the weight of lading, the static loadings specified in § 178.338-13 weight of structures supported by the (b); tank wall, and the effect of tempera- (v) The tensile or compressive stress ture gradients resulting from lading generated by the bending moment reand ambient temperature extremes. sulting from an accelerative force ap- When dissimilar materials are used, plied to the horizontal pivot of the their thermal coefficients must be used fifth wheel supporting the vehicle in calculation of the thermal stresses. using applicable static loadings speci- (2) Stress concentrations in tension, fied in § 178.338-13 (b); and bending, and torsion which occur at (vi) The tensile or compressive stress pads, cradles, or other supports must generated by a bending moment probe considered in accordance with apduced by a vertical force using applicapendix G in Section VIII of the ASME ble static loadings specified in $178.338- Code. 13 (b). 964 Pipeline and Hazardous Materials Safety Admin., DOT § 178.338-3 (4) Ss = The following shear stresses brakeline clip, skirting structure, lamp that apply, in psi.: The vectorial sum mounting bracket, or placard holder of the applicable shear stresses in the must be of a construction having lesser plane under consideration, including strength than the cargo tank wall madirect shear generated by the static terials and may not be more than 72 vertical loading; direct lateral and torpercent of the thickness of the matesional shear generated by a lateral acrial to which it is attached. The lightcelerative force applied at the road surweight attachment may be secured diface, using applicable static loads specrectly to the cargo tank wall if the deified in $178.338-13 (b) vice is designed and installed in such a (d) In order to account for stresses manner that, if damaged, it will not afdue to impact in an accident, the defect the lading retention integrity of sign calculations for the tank shell and the tank. A lightweight attachment heads must include the load resulting must be secured to the cargo tank shell from the design pressure in combinaor head by a continuous weld or in such tion with the dynamic pressure result- a manner as to preclude formation of ing from a longitudinal deceleration of pockets that may become sites for cor- "2g". For this loading condition the rosion. Attachments meeting the restress value used may not exceed the quirements of this paragraph are not lesser of the yield strength or 75 perauthorized for cargo tanks constructed cent of the ultimate tensile strength of under part UHT in Section VIII of the the material of construction. For a ASME Code. cargo tank constructed of stainless (3) Except as prescribed in parasteel, the maximum design stress may not exceed 75 percent of the ultimate graphs (g) (1) and (g)(2) of this section, tensile strength of the type steel used. the welding of any appurtenance the (e) The minimum thickness of the cargo tank wall must be made by atshell or heads of the tank must be 0.187 tachment of a mounting pad so that inch for steel and 0.270 inch for aluthere will be no adverse effect upon the minum. However, the minimum thicklading retention integrity of the cargo ness for steel may be 0.110 inches protank if any force less than that previded the cargo tank is: scribed in paragraph (b)(1) of this sec- (1) Vacuum insulated, or tion is applied from any direction. The (2) Double walled with a load bearing thickness of the mounting pad may not be less than that of the shell or head to jacket designed to carry a proportionate amount of structural loads prewhich it is attached, and not more scribed in this section. than 1.5 times the shell or head thick- (f) Where a tank support is attached ness. However, a pad with a minimum to any part of the tank wall, the thickness of 0.187 inch may be used stresses imposed on the tank wall must when the shell or head thickness is meet the requirements in paragraph (a) over 0.187 inch. If weep holes or tellof this section. tale holes are used, the pad must be (g) The design, construction and indrilled or punched at the lowest point stallation of an attachment, appurbefore it is welded to the tank. Each tenance to the cargo tank or structural pad must: support member between the cargo (i) Be fabricated from material detertank and the vehicle or suspension mined to be suitable for welding to component or accident protection deboth the cargo tank material and the vice must conform to the following rematerial of the appurtenance or strucquirements: tural support member; a Design Certi- (1) Structural members. the suspenfying Engineer must make this detersion subframe, accident protection mination considering chemical and structures and external circumferenphysical properties of the materials tial reinforcement devices must be and must specify filler material conused as sites for attachment of appurforming to the requirements in Section tenances and other accessories to the IX of the ASME Code (IBR, see $171.7 of cargo tank, when practicable. this subchapter). (2) A lightweight attachment to the (ii) Be preformed to an inside radius cargo tank wall such as a conduit clip, no greater than the outside radius of 965 $ 178.338-4 49 CFR Ch. I (10-1-06 Edition) the cargo tank at the attachment loca- (f) All tank nozzle-to-shell and noztion. zle-to-head welds must be full penetra- (iii) Extend at least 2 inches in each tion welds. direction from any point of attachment of an appurtenance or structural sup- (Approved by the Office of Management and Budget under control number 2137-0017) port member. This dimension may be measured from the center of the at- [Amdt. 178-77, 48 FR 27704 and 27713, June 16, tached structural member. 1983. as amended at 49 FR 24316, June 12, 1984; (iv) Have rounded corners, or other- 68 FR 75754, Dec. 31, 2003] wise be shaped in a manner to mini- § 178.338-5 Stiffening rings. mize stress concentrations on the shell or head. (a) A tank is not required to be pro- (v) Be attached by continuous fillet vided with stiffening rings, except as welding. Any fillet weld discontinuity prescribed in Section VIII of the ASME may only be for the purpose of pre- Code (IBR, see § 171.7 of this subventing an intersection between the filchapter). let weld and a tank or jacket seam (b) If a jacket is evacuated, it must weld. be constructed in compliance with § 178.338-1(f). Stiffening rings may be [Amdt. 178-89. 55 FR 37057, Sept. 7, 1990, as used to meet these requirements. amended by Amdt. 178-89, 56 FR 27876, June 17. 1991: 56 FR 46354, Sept. 11, 1991; 68 FR [Amdt. 178-77, 48 FR 27704, June 16, 1983, as 19281, Apr. 18, 2003; 68 FR 57633, Oct. 6, 2003; 68 amended at 68 FR 75754, Dec. 31, 2003] FR 75754, Dec. 31, 2003] § 178.338-6 Manholes. § 178.338-4 Joints. (a) Each tank in oxygen service must (a) All joints in the tank, and in the be provided with a manhole as prejacket If evacuated, must be as prescribed in Section VIII of the ASME scribed in Section VIII of the ASME Code (IBR, see $171.7 of this sub- Code (IBR, see $171.7 of this subchapter). chapter), except that a butt weld with (b) Each tank having a manhole must one plate edge offset is not authorized. be provided with a means of entrance (b) Welding procedure and welder perand exit through the jacket, or the formance tests must be made in acjacket must be marked to Indicate the cordance with Section IX of the ASME manway location on the tank. Code. Records of the qualification must (c) A manhole with a bolted closure be retained by the tank manufacturer may not be located on the front head of for at least five years and must be the tank. made available, upon request, to any [Amdt. 178-77, 48 FR 27704, June 16, 1983, as duly identified representative of the amended at 49 FR 24316, June 12, 1984; 68 FR Department, or the owner of the cargo 75754, Dec. 31, 2003] tank. (c) All longitudinal welds in tanks § 178.338-7 Openings. and load bearing jackets must be lo- (a) The inlet to the liquid product cated so as not to intersect nozzles or discharge opening of each tank insupports other than load rings and tended for flammable ladings must be stiffening rings. at the bottom centerline of the tank. (d) Substructures must be properly (b) If the leakage of a single valve, fitted before attachment and the weldexcept a pressure relief valve, pressure ing sequence must minimize stresses control valve, full trycock or gas phase due to shrinkage of welds. manual vent valve, would permit loss (e) Filler material containing more of flammable material, an additional than 0.05 percent vanadium may not be closure that is leak tight at the tank used with quenched and tempered steel. design pressure must be provided outboard of such valve. [Amdt. 178-77, 48 FR 27704, June 16, 1983) 966 Pipeline and Hazardous Materials Safety Admin., DOT § 178.338-9 § 178.338-8 Pressure relief devices, they will be subjected in actual servpiping, valves, and fittings. ice. (a) Pressure relief devices. Each tank (8) All piping, valves, and fittings pressure relief device must be designed, must be grouped in the smallest pracconstructed, and marked in accordance ticable space and protected from damwith $173.318(b) of this subchapter. age as required by $178.338-10. (b) Piping, valves, and fittings. (1) The (9) When a pressure-building coil is burst pressure of all piping, pipe fitused on a tank designed to handle oxytings, hoses and other pressure parts, gen or flammable ladings, the vapor except for pump seals and pressure reconnection to that coil must be prolief devices, must be at least 4 times vided with a valve or check valve as the design pressure of the tank. Addiclose to the tank shell as practicable to tionally, the burst pressure may not be prevent the loss of vapor from the tank less than 4 times any higher pressure in case of damage to the coil. The liquid connection to that coil must also to which each pipe, pipe fitting, hose or be provided with a valve. other pressure part may be subjected to in service. [Amdt. 178-77, 48 FR 27704, June 16, 1983, as (2) Pipe joints must be threaded, amended by Amdt. 178-89, 54 FR 25019, June welded or flanged. If threaded pipe is 12, 1989] used, the pipe and fittings must be § 178.338-9 Holding time. Schedule 80 weight or heavier. Malleable metals must be used in the con- (a) "Holding time" is the time, as destruction of valves and fittings. Where termined by testing, that will elapse copper tubing is permitted, joints shall from loading until the pressure of the be brazed or be of equally strong metal contents, under equilibrium conditions, union type. The melting point of the reaches the level of the lowest pressure brazing materials may not be lower control valve or pressure relief valve than 1000 °F. The method of joining setting. tubing may not reduce the strength of (b) Holding time test. (1) The test to the tubing, such as by the cutting of determine holding time must be perthreads. formed by charging the tank with a (3) Each hose coupling must be decryogenic liquid having a boiling point, signed for a pressure of at least 120 perat a pressure of one atmosphere, absocent of the hose design pressure and so lute, no lower than the design service that there will be no leakage when contemperature of the tank. The tank nected. must be charged to its maximum per- (4) Piping must be protected from mitted filling density with that liquid damage due to thermal expansion and and stabilized to the lowest practical pressure, which must be equal to or contraction, jarring, and vibration. Slip joints are not authorized for this less than the pressure to be used for loading. The cargo tank together with purpose. its contents must then be exposed to (5) All piping, valves and fittings on a ambient temperature. cargo tank must be proved free from (2) The tank pressure and ambient leaks. This requirement is met when temperature must be recorded at 3- such piping, valves, and fittings have hour intervals until the pressure level been tested after installation with gas of the contents reaches the set-to-disor air and proved leak tight at not less charge pressure of the pressure control than the design pressure marked on the valve or pressure relief valve with the cargo tank. This requirement is applilowest setting. This total time lapse in cable to all hoses used in a cargo tank, hours represents the measured holding except that hose may be tested before time at the actual average ambient or after installation on the tank. temperature. This measured holding (6) Each valve must be suitable for time for the test cryogenic liquid must the tank design pressure at the tank be adjusted to an equivalent holding design service temperature. time for each cryogenic liquid that is (7) All fittings must be rated for the to be identified on or adjacent to the maximum tank pressure and suitable specification plate, at an average ambifor the coldest temperature to which ent temperature of 85 °F. This is the 967 § 178.338-10 49 CFR Ch. I (10-1-06 Edition) rated holding time (RHT). The marked RHT = [(U₂ - U1) W] / q rated holding time (MRHT) displayed Where: on or adjacent to the specification RHT = rated holding time, in hours plate (see § 178.338-18(c)(10)) may not ex- U1 and U₂ = internal energy for the combined ceed this RHT. liquid and vapor lading at the pressure of- (c) Optional test regimen. (1) If more fered for transportation, and the set presthan one cargo tank is made to the sure of the applicable pressure control same design, only one cargo tank must valve or pressure relief valve, respectively, be subjected to the full holding time Btu/lb. test at the time of manufacture. How- W = total weight of the combined liquid and ever, each subsequent cargo tank made vapor lading in the cargo tank, pounds. q = calculated heat transfer rate to cargo to the same design must be performtank with lading, Btu/hr. ance tested during its first trip. The holding time determined in this test (iii) The MRHT (see § 178.338-18(b) may not be less than 90 percent of the of this subchapter) may not exceed the marked rated holding time. This test RHT. must be performed in accordance with [Amdt. 178-77, 48 FR 27704. June 16, 1983; 48 §§ 173.318(g)(3) and 177.840(h) of this sub- FR 50442, Nov. 1, 1983, as amended at 49 FR chapter, regardless of the classification 24316, June 12, 1984; 49 FR 43965, Nov. 1, 1984; of the cryogenic liquid. 59 FR 55173, Nov. 3, 1994: Amdt. 178-118, 61 FR 51340, Oct. 1. 1996; 68 FR 57634, Oct. 6. 2003; 71 (2) Same design. The term "same de- FR 54397, Sept. 14, 2006] sign" as used in this section means cargo tanks made to the same design § 178.338-10 Accident damage protectype. See $178.320(a) for definition of tion. "design type". (a) All valves, fittings, pressure relief (3) For a cargo tank used in nonflamdevices and other accessories to the mable cryogenic liquid service, in place tank proper, which are not isolated of the holding time tests prescribed in from the tank by closed intervening paragraph (b) of this section, the shut-off valves or check valves, must marked rated holding time (MRHT) be installed within the motor vehicle may be determined as follows: framework or within a suitable colli- (i) While the cargo tank is stasion resistant guard or housing, and tionary, the heat transfer rate must be appropriate ventilation must be prodetermined by measuring the normal vided. Each pressure relief device must evaporation rate (NER) of the test be protected so that in the event of the cryogenic liquid (preferably the lading, upset of the vehicle onto a hard surwhere feasible) maintained at approxiface, the device's opening will not be mately one atmosphere. The calculated prevented and its discharge will not be heat transfer rate must be determined restricted. from: (b) Each protective device or housing, q = [n(A / [tₛ - ti] and its attachment to the vehicle structure, must be designed to with- Where: stand static loading in any direction q = calculated heat transfer rate to cargo that it may be loaded as a result of tank with lading. Btu/hr. front, rear, side, or sideswipe collision, n = normal evaporation rate (NER). which is or the overturn of the vehicle. The the rate of evaporation, determined by the static loading shall equal twice the test of a test cryogenic liquid in a cargo tank maintained at a pressure of approxiloaded weight of the tank and attachmately one atmosphere, absolute, lb/hr. ments. A safety factor of four, based on A h - latent heat of vaporization of test fluid the tensile strength of the material, at test pressure, Btu/lb. shall be used. The protective device or t. = average temperature of outer shell durthe housing must be made of steel at ing test, °F. least 3/16-inch thick, or other material t, - equilibrium temperature of lading at of equivalent strength. maximum loading pressure, °F. (c) Rear-end tank protection. Rear-end tr = equilibrium temperature of test fluid at tank protections devices must: one atmosphere, °F. (1) Consist of at least one rear bump- (ii) The rated holding time (RHT) er designed to protect the cargo tank must be calculated as follows: and piping in the event of a rear-end 968 Pipeline and Hazardous Materials Safety Admin., DOT § 178.338-12 collision. The rear-end tank protection the opening nozzle or flange, or in a device design must transmit the force companion flange bolted to the nozzle. of the collision directly to the chassis If the jacket is evacuated, the reof the vehicle. The rear-end tank promotely controlled valve must be lotection device and its attachments to cated as close to the tank as practhe chassis must be designed to withticable. stand a load equal to twice the weight (2) Each remotely controlled shut off of the loaded cargo tank and attachvalve must be provided with on-vehicle ments, using a safety factor of four remote means of automatic closure, based on the tensile strength of the both mechanical and thermal. One materials used, with such load being means may be used to close more than applied horizontally and parallel to the one remotely controlled valve. Cable major axis of the cargo tank. The rearlinkage between closures and remote end tank protection device dimensions operators must be corrosion resistant must meet the requirements of § 393.86 and effective in all types of environof this title and extend vertically to a ment and weather. The thermal means height adequate to protect all valves must consist of fusible elements actuand fittings located at the rear of the ated at a temperature not exceeding cargo tank from damage that could re- 121 °C (250 °F). or equivalent devices. sult in loss of lading; or The loading/unloading connection area (2) Conform to the requirements of is where hoses are connected to the § 178.345-8(b). permanent metal piping. The number (d) Every part of the loaded cargo and location of remote operators and tank, and any associated valve, pipe, thermal devices shall be as follows: enclosure, or protective device or (i) On a cargo tank motor vehicle structure (exclusive of wheel assemover 3,500 gallons water capacity, reblies), must be at least 14 inches above mote means of automatic closure must level ground. be installed at the ends of the cargo [Amdt. 178-77, 48 FR 27705, June 16, 1983, as tank in at least two diagonally oppoamended at 49 FR 24316, June 12, 1984; Amdt. site locations. If the loading/unloading 178-99, 58 FR 51534, Oct. 1, 1993; 68 FR 19282, connection at the cargo tank is not in Apr. 18, 2003; 68 FR 52371, Sept. 3, 2003] the general vicinity of one of these locations, at least one additional ther- § 178.338-11 Discharge control devices. mal device must be installed so that (a) Excess-flow valves are not reheat from a fire in the loading/unloadquired. ing connection area will activate the (b) Each liquid filling and liquid disemergency control system. charge line must be provided with a (ii) On a cargo tank motor vehicle of shut-off valve located as close to the 3,500 gallons water capacity or less, at tank as practicable. Unless this valve least one remote means of automatic is manually operable at the valve, the closure must be installed on the end of line must also have a manual shut-off the cargo tank farthest away from the valve. loading/unloading connection area. At (c) Except for a cargo tank that is least one thermal device must be inused to transport argon, carbon dioxstalled so that heat from a fire in the ide, helium, krypton, neon, nitrogen, loading/unloading connection area will xenon, or mixtures thereof, each liquid activate the emergency control sysfilling and liquid discharge line must tem. be provided with an on-vehicle re- [Amdt. 178-77. 48 FR 27705, June 16, 1983, as motely controlled self-closing shutoff amended by Amdt. 178-105, 59 FR 55173, Nov. valve. 3, 1994; 60 FR 17402, Apr. 5, 1995; 68 FR 19282, (1) If pressure from a reservoir or Apr. 18, 2003] from an engine-driven pump or compressor is used to open this valve, the § 178.338-12 Shear section. control must be of fail-safe design and Unless the valve is located in a rear spring-biased to stop the admission of cabinet forward of and protected by the such pressure into the cargo tank. If bumper (see § 178.338-10(c)). the design the jacket is not evacuated, the seat of and installation of each valve, damage the valve must be inside the tank, in to which could result in loss of liquid 969 § 178.338-13 49 CFR Ch. I (10-1-06 Edition) or vapor, must incorporate a shear sectural members, the design calculations tion or breakage groove adjacent to, for the tank and its structural memand outboard of, the valve. The shear bers must be based on a safety factor of section or breakage groove must yield four and the tensile strength of the maor break under strain without damage terial at ambient temperature. The ento the valve that would allow the loss hanced tensile strength of the material of liquid or vapor. The protection specat actual operating temperature may ified in $178.338-10 is not a substitute be substituted for the tensile strength for a shear section or breakage groove. at ambient temperature to the extent [Amdt. 178-77, 49 FR 24316, June 12. 1984] recognized in the ASME Code for static loadings. Static loadings must take § 178.338-13 Supporting and anchorinto consideration the weight of the ing. tank and the structural members when (a) On a cargo tank motor vehicle dethe tank is filled to the design weight signed and constructed so that the of lading (see Appendix G of Section VIII, Division 1 of the ASME Code), cargo tank constitutes in whole or in part the structural member used in multiplied by the following factors. place of a motor vehicle frame, the Static loadings must take into considcargo tank or the jacket must be superation the weight of the tank and the structural members when the tank is ported by external cradles or by load rings. For a cargo tank mounted on a filled to the design weight of lading motor vehicle frame, the tank or jack- (see appendix G in Section VIII of the et must be supported by external cra- ASME Code). multiplied by the foldles, load rings, or longitudinal memlowing factors. When load rings in the bers. If cradles are used, they must jacket are used for supporting the tank, they must be designed to carry subtend at least 120 degrees of the the fully loaded tank at the specified cargo tank circumference. The design static loadings, plus external pressure. calculations for the supports and load- Minimum static loadings must be as bearing tank or jacket, and the support follows: attachments must include beam stress, (1) Vertically downward of 2; shear stress, torsion stress, bending (2) Vertically upward of 1½; moment, and acceleration stress for (3) Longitudinally of 11/2; and, (4) Latthe loaded vehicle as a unit, using a erally of 11/2. safety factor of four, based on the tensile strength of the material, and static [68 FR 19282, Apr. 18. 2003, as amended at 68 loading that uses the weight of the FR 75754, Dec. 31, 2003] cargo tank and its attachments when § 178.338-14 Gauging devices. filled to the design weight of the lading (see appendix G in Section VIII of the (a) Liquid level gauging devices. (1) Un- ASME Code) (IBR, see $171.7 of this less a cargo tank is intended to be subchapter), multiplied by the folfilled by weight, it must be equipped lowing factors. The effects of fatigue with one or more gauging devices, must also be considered in the calculawhich accurately indicate the maxtions. Minimum static loadings must imum permitted liquid level at the be as follows: loading pressure, in order to provide a (1) For a vacuum-insulated cargo minimum of two percent outage below tankthe inlet of the pressure control valve (1) Vertically downward of 2; or pressure relief valve at the condition (ii) Vertically upward of 2; of incipient opening of that valve. A (iii) Longitudinally of 2; and fixed-length dip tube, a fixed trycock (iv) Laterally of 2. line, or a differential pressure liquid (2) For any other insulated cargo level gauge must be used as the pritank- mary control for filling. Other gauging (i) Vertically downward of 3; devices, except gauge glasses, may be (ii) Vertically upward of 2; used, but not as the primary control (iii) Longitudinally of 2; and for filling. (iv) Laterally of 2. (2) The design pressure of each liquid (b) When a loaded tank is supported level gauging device must be at least within the vacuum jacket by structhat of the tank. 970 Pipeline and Hazardous Materials Safety Admin., DOT § 178.338-16 (3) If a fixed length dip tube or must be inspected for conformance to trycock line gauging device is used, it Section VIII of the ASME Code (IBR, must consist of a pipe or tube of small see $171.7 of this subchapter). The tank diameter equipped with a valve at or must be subjected to either a hydronear the jacket and extending into the static or pneumatic test. The test prescargo tank to a specified filling height. sure must be one and one-half times The fixed height at which the tube ends the sum of the design pressure, plus in the cargo tank must be such that static head of lading, plus 101.3 kPa the device will function when the liq- (14.7 psi) if subjected to external vacuuid reaches the maximum level perum, except that for tanks constructed mitted in loading. in accordance with Part UHT in Sec- (4) The liquid level gauging device tion VIII of the ASME Code the test used as a primary control for filling pressure must be twice the design presmust be designed and installed to accusure. rately indicate the maximum filling (b) Additional requirements for pneulevel at the point midway of the tank matic test. A pneumatic test may be both longitudinally and laterally. used in place of the hydrostatic test. (b) Pressure gauges. Each cargo tank Due regard for protection of all permust be provided with a suitable pressonnel should be taken because of the sure gauge indicating the lading pressure and located on the front of the potential hazard involved in a pneujacket so it can be read by the driver in matic test. The pneumatic test presthe rear view mirror. Each gauge must sure in the tank must be reached by have a reference mark at the cargo gradually increasing the pressure to tank design pressure or the set presone-half of the test pressure. Theresure of the pressure relief valve or presafter, the test pressure must be insure control valve, whichever is lowest. creased in steps of approximately one- (c) Orifices. All openings for dip tube tenth of the test pressure until the regauging devices and pressure gauges in quired test pressure has been reached. flammable cryogenic liquid service Then the pressure must be reduced to a must be restricted at or inside the value equal to four-fifths of the test jacket by orifices no larger than 0.060- pressure and held for a sufficient time inch diameter. Trycock lines, if proto permit inspection of the cargo tank vided, may not be greater than 1/2-inch for leaks. nominal pipe size. (c) Weld inspection. All tank shell or head welds subject to pressure shall be [Amdt. 178-77, 48 FR 27706, June 16, 1983, as radiographed in accordance with Secamended at 49 FR 24317, June 12, 1984] tion VIII of the ASME Code. A tank § 178.338-15 Cleanliness. which has been subjected to inspection by the magnetic particle method, the A cargo tank constructed for oxygen liquid penetrant method, or any methservice must be thoroughly cleaned to od involving a material deposit on the remove all foreign material in accordinterior tank surface, must be cleaned ance with CGA G-4.1 (IBR, see $171.7 of to remove any such residue by scrubthis subchapter). All loose particles bing or equally effective means, and all from fabrication, such as weld beads, such residue and cleaning solution dirt, grinding wheel debris, and other must be removed from the tank prior loose materials, must be removed prior to final closure of the tank. to the final closure of the manhole of the tank. Chemical or solvent cleaning (d) Defect repair. All cracks and other with a material compatible with the defects must be repaired as prescribed in Section VIII of the ASME Code. The intending lading must be performed to remove any contaminants likely to welder and the welding procedure must react with the lading. be qualified in accordance with Section IX of the ASME Code (IBR, see § 171.7 of [68 FR 75755, Dec. 31, 2003] this subchapter). After repair, the tank must again be postweld heat-treated, if § 178.338-16 Inspection and testing. such heat treatment was previously (a) General. The material of construcperformed, and the repaired areas must tion of a tank and its appurtenances be retested. 971 $ 178.338-17 49 CFR Ch. I (10-1-06 Edition) (e) Verification must be made of the chapter), in characters at least 3/16 interior cleanliness of a tank coninch high (parenthetical abbreviations structed for oxygen service by means may be used). All plates must be mainthat assure that all contaminants that tained in a legible condition. are likely to react with the lading have (2) Each insulated cargo tank must been removed as required by $178.338- have additional plates, as described, at- 15. tached to the jacket in the location specified unless the specification plate [Amdt. 178-77, 48 FR 27706, June 16, 1983, as is attached to the chassis and has the amended at 49 FR 24317, June 12. 1984; 49 FR 42736, Oct. 24, 1984; 68 FR 75755, Dec. 31, 2003] information required in paragraphs (b) and (c) of this section. $ 178.338-17 Pumps and compressors. (3) The information required for both (a) Liquid pumps and gas compressors, the name and specification plate may if used, must be of suitable design. adebe displayed on a single plate. If the inquately protected against breakage by formation required by this section is collision, and kept in good condition. displayed on a plate required by Sec- They may be driven by motor vehicle tion VIII of the ASME Code, the inforpower take-off or other mechanical, mation need not be repeated on the electrical, or hydraulic means. Unless name and specification plates. they are of the centrifugal type, they (4) The specification plate may be atshall be equipped with suitable prestached to the cargo tank motor vehicle sure actuated by-pass valves permitchassis rail by brazing, welding, or other suitable means on the left side ting flow from discharge to suction to the tank. near the front head, in a place acces- (b) A valve or fitting made of alusible for inspection. If the specification minum with internal rubbing or abradplate is attached to the chassis rail, ing aluminum parts that may come in then the cargo tank serial number ascontact with oxygen (cryogenic liquid) signed by the cargo tank manufacturer may not be installed on any cargo tank must be included on the plate. used to transport oxygen (cryogenic (b) Name plate. The following information must be marked on the name liquid) unless the parts are anodized in accordance with ASTM B 580 (IBR, see plate in accordance with this section: $171.7 of this subchapter). (1) DOT-specification number MC 338 (DOT MC 338). [Amdt. 178-89, 54 FR 25020. June 12, 1989, as (2) Original test date (Orig, Test amended at 55 FR 37058, Sept. 7, 1990; 67 FR Date). 61016, Sept. 27, 2002; 68 FR 75755, Dec. 31, 2003] (3) MAWP in psig. § 178.338-18 Marking. (4) Cargo tank test pressure (Test P), in psig. (a) General. Each cargo tank certified (5) Cargo tank design temperature after October 1, 2004 must have a corro- (Design Temp. Range) °F to sion-resistant metal name plate °F. (ASME Plate) and specification plate (6) Nominal capacity (Water Cap.), in permanently attached to the cargo pounds. tank by brazing, welding, or other suit- (7) Maximum design density of lading able means on the left side near the (Max. Lading density), in pounds per front, in a place accessible for inspecgallon. tion. If the specification plate is at- (8) Material specification numbertached directly to the cargo tank wall shell (Shell matl, yyy *), where by welding, it must be welded to the "yyy" is replaced by the alloy designatank before the cargo tank is postweld tion and is replaced by the heat treated. alloy type. (1) The plates must be legibly marked (9) Material specification numberby stamping, embossing, or other heads (Head matl. yyy *), where means of forming letters into the "yyy" is replaced by the alloy designametal of the plate, with the information and by the alloy type. tion required in paragraphs (b) and (c) NOTE: When the shell and heads materials of this section, in addition to that reare the same thickness, they may be comquired by Section VIII of the ASME bined, (Shell & head matl, yyy *). Code (IBR, see $171.7 of this sub- (10) Weld material (Weld matl.). 972 Pipeline and Hazardous Materials Safety Admin., DOT § 178.338-19 (11) Minimum Thickness-shell (Min. (d) The design weight of lading used Shell-thick), in inches. When minimum in determining the loading in §§ 178.338- shell thicknesses are not the same for 3 (b), 178.338-10 (b) and (c), and 178.338- different areas, show (top side , 13 (b), must be shown as the maximum , bottom 1 in inches). weight of lading marking required by (12) Minimum thickness-heads (Min paragraph (c) of this section. heads thick.), in inches. [68 FR 19283, Apr. 18, 2003, as amended at 68 (13) Manufactured thickness-shell FR 57634, Oct. 6, 2003; 68 FR 75755, Dec. 31, (Mfd. Shell thick.), top , side , 2003] bottom , in inches. (Required when additional thickness is provided for § 178.338-19 Certification. corrosion allowance.) (a) At or before the time of delivery, (14) Manufactured thickness-heads the manufacturer of a cargo tank (Mfd. Heads thick.), in inches. (Remotor vehicle shall furnish to the quired when additional thickness is owner of the completed vehicle the folprovided for corrosion allowance.) lowing: (15) Exposed surface area, in square (1) The tank manufacturer's data refeet. port as required by the ASME Code (c) Specification plate. The following (IBR, see $171.7 of this subchapter), and information must be marked on the a certificate bearing the manufacturspecification plate in accordance with er's vehicle serial number stating that this section: the completed cargo tank motor vehi- (1) Cargo tank motor vehicle manucle conforms to all applicable requirefacturer (CTMV mfr.). ments of Specification MC 338, includ- (2) Cargo tank motor vehicle certifiing Section VIII of the ASME Code cation date (CTMV cert. date). (IBR, see $171.7 of this subchapter) in (3) Cargo tank manufacturer (CT effect on the date (month, year) of ceΓ- mfr.). tification. The registration numbers of the manufacturer, the Design Certi- (4) Cargo tank date of manufacture fying Engineer, and the Registered In- (CT date of mfr.), month and year. spector, as appropriate, must appear on (5) Maximum weight of lading (Max. the certificates (see subpart F. part 107 Payload), in pounds. in subchapter B of this chapter). (6) Maximum loading rate in gallons (2) A photograph, pencil rub, or other per minute (Max. Load rate, GPM). facsimile of the plates required by (7) Maximum unloading rate in galparagraphs (a) and (b) of 178.338-18. lons per minute (Max Unload rate). (b) In the case of a cargo tank vehicle (8) Lining materials (Lining). if apmanufactured in two or more stages, plicable. each manufacturer who performs a (9) "Insulated for oxygen service" or manufacturing operation on the incom- "Not insulated for oxygen service" as plete vehicle or portion thereof shall appropriate. furnish to the succeeding manufac- (10) Marked rated holding time for at turer, at or before the time of delivery, least one cryogenic liquid, in hours, a certificate covering the particular and the name of that cryogenic liquid operation performed by that manufac- (MRHT hrs, name of cryogenic liqturer, and any certificates received uid). Marked rated holding marking for from previous manufacturers, Regadditional cryogenic liquids may be istered Inspectors, and Design Certidisplayed on or adjacent to the specifying Engineers. The certificates must fication plate. include sufficient sketches. drawings, (11) Cargo tank serial number (CT seand other information to indicate the rial), as assigned by cargo tank manulocation, make, model and size of each facturer, if applicable. valve and the arrangement of all piping associated with the tank. Each certifi- NOTE 1 TO PARAGRAPH (c): See $173.315(a) of this chapter regarding water capacity. cate must be signed by an official of NOTE 2 TO PARAGRAPH (c): When the shell the manufacturing firm responsible for and head materials are the same thickness, the portion of the complete cargo tank they may be combined (Shell & head matl, vehicle represented thereby, such as yyy***). basic tank fabrication, insulation, 973 §§ 178.340-178.343 49 CFR Ch. I (10-1-06 Edition) jacket, or piping. The final manufac- Bulkhead means a liquid-tight transturer shall furnish the owner with all verse closure at the ends of or between certificates, as well as the documents cargo tanks. required by paragraph (a) of this sec- Charging line means a hose, tube, tion. pipe, or similar device used to pres- (c) The owner shall retain the data surize a tank with material other than report, certificates, and related papers the lading. throughout his ownership of the cargo Companion flange means one of two tank. In the event of change of ownermating flanges where the flange faces ship, the prior owner shall retain nonare in contact or separated only by a fading photographically reproduced thin leak sealing gasket and are secopies of these documents for at least cured to one another by bolts or one year. Each operator using the clamps. cargo tank vehicle, if not the owner thereof, shall obtain a copy of the data Connecting structure means the strucreport and the certificate or certifiture joining two cargo tanks. Constructed and certified in conformcates and retain them during the time he uses the cargo tank and for at least ance with the ASME Code means the one year thereafter. cargo tank is constructed and stamped in accordance with the ASME Code, (Approved by the Office of Management and and is inspected and certified by an Au- Budget under control number 2137-0017) thorized Inspector. [Amdt. 178-77, 48 FR 27707 and 27713, June 16, Constructed in accordance with the 1983, as amended by Amdt. 178-89, 55 FR ASME Code means the cargo tank is 37058, Sept. 7. 1990; Amdt. 178-99, 58 FR 51534, constructed in accordance with the Oct. 1, 1993; 62 FR 51561, Oct. 1, 1997; 68 FR 75755, Dec. 31, 2003] ASME Code with the authorized exceptions (see §§ 178.346, 178.347, and 178.348) §§ 178.340-178.343 [Reserved] and is inspected and certified by a Registered Inspector. § 178.345 General design and construc- External self-closing stop-valve means tion requirements applicable to a self-closing stop-valve designed so Specification DOT 406 178.346), that the self-stored energy source is lo- DOT 407 (§ 178.347), and DOT 412 ($178.348) cargo tank motor vehicated outside the cargo tank and the cles. welded flange. Extreme dynamic loading means the § 178.345-1 General requirements. maximum single-acting loading a cargo (a) Specification DOT 406, DOT 407 tank motor vehicle may experience and DOT 412 cargo tank motor vehicles during its expected life, excluding accimust conform to the requirements of dent loadings. this section in addition to the require- Flange means the structural ring for ments of the applicable specification guiding or attachment of a pipe or fltcontained in §§ 178.346, 178.347 or 178.348. ting with another flange (companion (b) All specification requirements are flange), pipe, fitting or other attachminimum requirements. ment. (c) Definitions. See $178.320(a) for the Inspection pressure means the presdefinition of certain terms used in sure used to determine leak tightness 178.345, 178.346, 178.347, and 178.348. In of the cargo tank when testing with addition, the following definitions pneumatic pressure. apply to $178.345. 178.346, 178.347, and Internal self-closing stop-valve means a 178.348: self-closing stop-valve designed so that Appurtenance means any cargo tank the self-stored energy source is located accessory attachment that has no ladinside the cargo tank or cargo tank ing retention or containment function sump, or within the welded flange, and and provides no structural support to the valve seat is located within the the cargo tank. cargo tank or within one inch of the Baffle means a non-liquid-tight transexternal face of the welded flange or verse partition device that deflects, sump of the cargo tank. checks or regulates fluid motion in a Lading means the hazardous material tank. contained in a cargo tank. 974 Pipeline and Hazardous Materials Safety Admin., DOT § 178.345-1 Loading/unloading connection means the strength of the weakest piping elethe fitting in the loading/unloading ment between the cargo tank and the line farthest from the loading/unloadsacrificial device. Operation of the sacing outlet to which the loading/unloadrificial device must leave the remaining ing hose or device is attached. piping and its attachment to the cargo Loading/unloading outlet means the tank intact and capable of retaining cargo tank outlet used for normal loadlading. ing/unloading operations. Self-closing stop-valve means a stop- Loading/unloading stop-valve means valve held in the closed position by the stop valve farthest from the cargo means of self-stored energy, which tank loading/unloading outlet to which opens only by application of an exterthe loading/unloading connection is atnal force and which closes when the extached. ternal force is removed. MAWP. See § 178.320(a). Shear section means a sacrificial de- Multi-specification cargo tank motor vevice fabricated in such a manner as to hicle means a cargo tank motor vehicle abruptly reduce the wall thickness of equipped with two or more cargo tanks the adjacent piping or valve material fabricated to more than one cargo tank by at least 30 percent. specification. Shell means the circumferential por- Normal operating loading means the tion of a cargo tank defined by the loading a cargo tank motor vehicle basic design radius or radil excluding may be expected to experience routhe closing heads. tinely in operation. Stop-valve means a valve that stops Nozzle means the subassembly conthe flow of lading. sisting of a pipe or tubular section with Sump means a protrusion from the or without a welded or forged flange on bottom of a cargo tank shell designed one end. to facilitate complete loading and un- Outlet means any opening in the shell loading of lading. or head of a cargo tank, (including the Tank means a container, consisting means for attaching a closure), except of a shell and heads, that forms a presthat the following are not outlets: A sure tight vessel having openings dethreaded opening securely closed dursigned to accept pressure tight fittings ing transportation with a threaded or closures, but excludes any appurplug or a threaded cap, a flanged opentenances, reinforcements, fittings, or ing securely closed during transporclosures. tation with a bolted or welded blank Test pressure means the pressure to flange, a manhole, or gauging devices, which a tank is subjected to determine thermometer wells, and safety relief pressure integrity. devices. Toughness of material means the capa- Outlet stop-valve means the stop-valve bility of a material to absorb the enat the cargo tank loading/unloading ergy represented by the area under the outlet. stress strain curve (indicating the en- Pipe coupling means a fitting with inergy absorbed per unit volume of the ternal threads on both ends. material) up to the point of rupture. Rear bumper means the structure de- Vacuum cargo tank means a cargo signed to prevent a vehicle or object tank that is loaded by reducing the from under-riding the rear of a motor pressure in the cargo tank to below atvehicle. See $393.86 of this title. mospheric pressure. Rear-end tank protection device means Variable specification cargo tank the structure designed to protect a means a cargo tank that is constructed cargo tank and any lading retention in accordance with one specification, piping or devices in case of a rear end but which may be altered to meet ancollision. other specification by changing relief Sacrificial device means an element, device, closures, lading discharge desuch as a shear section, designed to fail vices, and other lading retention deunder a load in order to prevent damvices. age to any lading retention part or de- Void means the space between tank vice. The device must break under heads or bulkheads and a connecting strain at no more than 70 percent of structure. 975 § 178.345-2 49 CFR Ch. I (10-1-06 Edition) Welded flange means a flange ated to the atmosphere and have a drain tached to the tank by a weld joining located on the bottom centerline. Each the tank shell to the cylindrical outer drain must be accessible and must be surface of the flange, or by a fillet weld kept open at all times. The drain in joining the tank shell to a flange any void within the connecting strucshaped to fit the shell contour. ture of a carbon steel. self-supporting (d) A manufacturer of a cargo tank cargo tank may be either a single drain must hold a current ASME certificate of at least 1.0 inch diameter, or two or of authorization and must be registered more drains of at least 0.5 inch diamewith the Department in accordance ter, 6.0 inches apart, one of which is lowith part 107, subpart F of this chapter. cated on the bottom centerline. (e) All construction must be certified (j) Variable specification cargo tank. A by an Authorized Inspector or by a cargo tank that may be physically al- Registered Inspector as applicable to tered to conform to another cargo tank the cargo tank. specification must have the required (f) Each cargo tank must be designed physical alterations to convert from and constructed in conformance with one specification to another clearly inthe requirements of the applicable dicated on the variable specification cargo tank specification. Each DOT 412 plate. cargo tank with a "MAWP" greater [Amdt. 178-89, 54 FR 25020, June 12, 1989, as than 15 psig, and each DOT 407 cargo amended at 55 FR 37058, Sept. 7. 1990; Amdt. tank with a maximum allowable work- 178-105, 59 FR 55173, Nov. 3, 1994; Amdt. 178- ing pressure greater than 35 psig must 118, 61 FR 51340, Oct. I. 1996; 66 FR 45387, be "constructed and certified in con- 45389, Aug. 28, 2001; 68 FR 19283, Apr. 18, 2003; formance with Section VIII of the 68 FR 52371, Sept. 3, 2003; 68 FR 75755, Dec. 31, ASME Code" (IBR, see $171.7 of this 2003; 70 FR 56099, Sept. 23, 2005) subchapter) except as limited or modi- § 178.345-2 Material and material fied by the applicable cargo tank specithickness. fication. Other cargo tanks must be "constructed in accordance with Sec- (a) All material for shell. heads, tion VIII of the ASME Code," except as bulkheads, and baffles must conform to limited or modified by the applicable Section II of the ASME Code (IBR, see cargo tank specification. $171.7 of this subchapter) except as fol- (g) Requirements relating to parts lows: and accessories on motor vehicles, (1) The following steels are also auwhich are contained in part 393 of the thorized for cargo tanks "constructed Federal Motor Carrier Safety Regulain accordance with the ASME Code", tions of this title, are incorporated Section VIII. into these specifications. ASTM A 569 (h) Any additional requirements pre- ASTM A 570 scribed in part 173 of this subchapter ASTM A 572 that pertain to the transportation of a ASTM A 622 ASTM A 656 specific lading are incorporated into ASTM A 715 these specifications. ASTM A 1008/ A 1008M. ASTM A 1011/A 1011M (i) Cargo tank motor vehicle composed of multiple cargo tanks. (1) A cargo tank (2) Aluminum alloys suitable for fumotor vehicle composed of more than sion welding and conforming with the one cargo tank may be constructed 0, H32 or H34 tempers of one of the folwith the cargo tanks made to the same lowing ASTM specifications may be specification or to different specificaused for cargo tanks "constructed in tions. Each cargo tank must conform accordance with the ASME Code": in all respects with the specification ASTM B-209 Alloy 5052 for which it is certified. ASTM B-209 Alloy 5086 (2) The strength of the connecting ASTM B-209 Alloy 5154 structure joining multiple cargo tanks ASTM B-209 Alloy 5254 in a cargo tank motor vehicle must ASTM B-209 Alloy 5454 ASTM B-209 Alloy 5652 meet the structural design requirements in $178.345-3. Any void within All heads, bulkheads and baffles must the connecting structure must be ventbe of 0 temper (annealed) or stronger 976 Pipeline and Hazardous Materials Safety Admin., DOT § 178.345-3 tempers. All shell materials shall be of strength of the material used at design H 32 or H 34 tempers except that the conditions. lower ultimate strength tempers may (2) The relevant physical properties be used if the minimum shell of the materials used in each cargo thicknesses in the tables are increased tank may be established either by a in inverse proportion to the lesser ulticertified test report from the material mate strength. manufacturer or by testing in conform- (b) Minimum thickness. The minimum ance with a recognized national standthickness for the shell and heads (or ard. In either case, the ultimate tensile baffles and bulkheads when used as strength of the material used in the detank reinforcement) must be no less sign may not exceed 120 percent of the than that determined under criteria for minimum ultimate tensile strength minimum thickness specified in specified in either the ASME Code or § 178.320(a). the ASTM standard to which the mate- (c) Corrosion or abrasion protection. rial is manufactured. When required by 49 CFR part 173 for a (3) The maximum design stress at particular lading, a cargo tank or a any point in the cargo tank must be part thereof, subject to thinning by calculated separately for the loading corrosion or mechanical abrasion due conditions described in paragraphs (b) to the lading, must be protected by and (c) of this section. Alternate test providing the tank or part of the tank or analytical methods, or a combinawith a suitable increase in thickness of tion thereof, may be used in place of material, a lining or some other sultthe procedures described in paragraphs able method of protection. (b) and (c) of this section, if the meth- (1) Corrosion allowance. Material ods are accurate and verifiable. added for corrosion allowance need not (4) Corrosion allowance material may be of uniform thickness if different not be included to satisfy any of the rates of attack can reasonably be expected for various areas of the cargo design calculation requirements of this section. tank. (2) Lining. Lining material must con- (b) ASME Code design and construcsist of a nonporous, homogeneous mation. The static design and constructerial not less elastic than the parent tion of each cargo tank must be in accordance with Section VIII of the metal and substantially immune to attack by the lading. The lining material ASME Code. The cargo tank design must be bonded or attached by other must include calculation of stresses appropriate means to the cargo tank generated by the MAWP, the weight of wall and must be imperforate when apthe lading, the weight of structures plied. Any joint or seam in the lining supported by the cargo tank wall and must be made by fusing the materials the effect of temperature gradients retogether, or by other satisfactory sulting from lading and ambient temmeans. perature extremes. When dissimilar materials are used, their thermal coef- (Amdt. 178-89, 54 FR 25021, June 12. 1989, as ficients must be used in the calculation amended at 55 FR 37059, Sept. 7. 1990; 56 FR of thermal stresses. 27876, June 17, 1991; Amdt. 178-97, 57 FR 45465, Oct. 1. 1992; Amdt. 178-118, 61 FR 51341, Oct. (1) Stress concentrations in tension, 1. 1996; 68 FR 19283, Apr. 18, 2003; 68 FR 75755, bending and torsion which occur at Dec. 31, 2003; 70 FR 34076, June 13, 2005] pads, cradles, or other supports must be considered in accordance with ap- § 178.345-3 Structural integrity. pendix G in Section VIII of the ASME (a) General requirements and accept- Code. ance criteria. (1) The maximum cal- (2) Longitudinal compressive buckculated design stress at any point in ling stress for ASME certified vessels the cargo tank wall may not exceed the must be calculated using paragraph maximum allowable stress value pre- UG-23(b) in Section VIII of the ASME scribed in Section VIII of the ASME Code. For cargo tanks not required to Code (IBR, see $171.7 of this subbe certified in accordance with the chapter), or 25 percent of the tensile ASME Code, compressive buckling 977 $ 178.345-3 49 CFR Ch. I (10-1-06 Edition) stress may be calculated using altertudinal acceleration or deceleration. In native analysis methods which are aceach case, the forces applied must be curate and verifiable. When alternative 0.35 times the vertical reaction at the methods are used, calculations must suspension assembly, applied at the include both the static loads described road surface, and as transmitted to the in this paragraph and the dynamic cargo tank wall through the suspension loads described in paragraph (c) of this assembly of a trailer during decelerasection. tion; or the horizontal pivot of the (3) Cargo tank designers and manutruck tractor or converter dolly fifth facturers must consider all of the conwheel, or the drawbar hinge on the ditions specified in $173.33(c) of this fixed dolly during acceleration; or ansubchapter when matching a cargo choring and support members of a tank's performance characteristic to truck during acceleration and decelerathe characteristic of each lading transtion, as applicable. The vertical reacported. tion must be calculated based on the (c) Shell design. Shell stresses resultstatic weight of the fully loaded cargo ing from static or dynamic loadings, or tank motor vehicle, all structural elecombinations thereof, are not uniform ments, equipment and appurtenances throughout the cargo tank motor vehisupported by the cargo tank wall. The cle. The vertical, longitudinal, and latfollowing loadings must be included: eral normal operating loadings can (1) The axial load generated by a occur simultaneously and must be decelerative force; combined. The vertical, longitudinal (2) The bending moment generated by and lateral extreme dynamic loadings a decelerative force; occur separately and need not be com- (3) The axial load generated by an acbined. celerative force; and (1) Normal operating loadings. The fol- (4) The bending moment generated by lowing procedure addresses stress in an accelerative force; and the cargo tank shell resulting from (C) The tensile or compressive stress normal operating loadings. The effecgenerated by the bending moment retive stress (the maximum principal sulting from normal operating vertical stress at any point) must be deteraccelerative force equal to 0.35 times mined by the following formula: the vertical reaction at the suspension S = 0.5(Sy + Sx) ±[0.25(Sy-Sx)² + Ss2]0.5 assembly of a trailer; or the horizontal pivot of the upper coupler (fifth wheel) Where: or turntable; or anchoring and support (i) S = effective stress at any given members of a truck, as applicable. The point under the combination of static vertical reaction must be calculated and normal operating loadings that can based on the static weight of the fully occur at the same time, in psi. loaded cargo tank motor vehicle, all (ii) Sy = circumferential stress genstructural elements, equipment and aperated by the MAWP and external prespurtenances supported by the cargo sure, when applicable, plus static head, tank wall. in psi. (iv) Ss = The following shear stresses (iii) Sx = The following net longitugenerated by the following static and dinal stress generated by the following normal operating loading conditions, static and normal operating loading in psi: conditions, in psi: (A) The static shear stress resulting (A) The longitudinal stresses resultfrom the vertical reaction at the susing from the MAWP and external prespension assembly of a trailer, and the sure, when applicable, plus static head, horizontal pivot of the upper coupler in combination with the bending stress (fifth wheel) or turntable; or anchoring generated by the static weight of the and support members of a truck, as apfully loaded cargo tank motor vehicle, plicable. The vertical reaction must be all structural elements, equipment and calculated based on the static weight appurtenances supported by the cargo of the fully loaded cargo tank motor tank wall; vehicle, all structural elements, equip- (B) The tensile or compressive stress ment and appurtenances supported by resulting from normal operating longithe cargo tank wall; 978 Pipeline and Hazardous Materials Safety Admin., DOT § 178.345-3 (B) The vertical shear stress gensure, when applicable, plus static head, erated by a normal operating accelerain combination with the bending stress tive force equal to 0.35 times the generated by the static weight of the vertical reaction at the suspension asfully loaded cargo tank motor vehicle, sembly of a trailer: or the horizontal all structural elements, equipment and pivot of the upper coupler (fifth wheel) appurtenances supported by the tank or turntable; or anchoring and support wall; members of a truck, as applicable. The (B) The tensile or compressive stress vertical reaction must be calculated resulting from extreme longitudinal based on the static weight of the fully acceleration or deceleration. In each loaded cargo tank motor vehicle, all case the forces applied must be 0.7 structural elements, equipment and aptimes the vertical reaction at the suspurtenances supported by the cargo pension assembly, applied at the road tank wall; surface, and as transmitted to the (C) The lateral shear stress generated cargo tank wall through the suspension by a normal operating lateral acceleraassembly of a trailer during decelerative force equal to 0.2 times the tion; or the horizontal pivot of the vertical reaction at each suspension astruck tractor or converter dolly fifth sembly of a trailer, applied at the road wheel, or the drawbar hinge on the surface, and as transmitted to the fixed dolly during acceleration; or the cargo tank wall through the suspension anchoring and support members of a assembly of a trailer, and the horitruck during acceleration and decelerazontal pivot of the upper coupler (fifth tion, as applicable. The vertical reacwheel) or turntable; or anchoring and tion must be calculated based on the support members of a truck, as applicastatic weight of the fully loaded cargo ble. The vertical reaction must be caltank motor vehicle, all structural eleculated based on the static weight of ments, equipment and appurtenances the fully loaded cargo tank motor vehisupported by the cargo tank wall. The cle, all structural elements, equipment following loadings must be included: and appurtenances supported by the (1) The axial load generated by a cargo tank wall; and decelerative force; (D) The torsional shear stress gen- (2) The bending moment generated by erated by the same lateral forces as de- a decelerative force; scribed in paragraph (c)(1)(iv)(C) of this (3) The axial load generated by an acsection. celerative force; and (2) Extreme dynamic loadings. The fol- (4) The bending moment generated by lowing procedure addresses stress in an accelerative force; and the cargo tank shell resulting from ex- (C) The tensile or compressive stress treme dynamic loadings. The effective generated by the bending moment restress (the maximum principal stress sulting from an extreme vertical accelat any point) must be determined by erative force equal to 0.7 times the the following formula: vertical reaction at the suspension as- S = 0.5(Sy + Sx) ±[0.25(S, - Sx)2 + Sₛ²]0.5 sembly of a trailer, and the horizontal pivot of the upper coupler (fifth wheel) Where: or turntable; or the anchoring and sup- (i) S = effective stress at any given port members of a truck, as applicable. point under a combination of static The vertical reaction must be caland extreme dynamic loadings that can culated based on the static weight of occur at the same time, in psi. the fully loaded cargo tank motor vehi- (ii) Sy = circumferential stress gencle, all structural elements, equipment erated by MAWP and external pressure, and appurtenances supported by the when applicable, plus static head, in cargo tank wall. psi. (iv) Ss = The following shear stresses (iii) Sx = the following net longitugenerated by static and extreme dydinal stress generated by the following namic loading conditions, in psi: static and extreme dynamic loading (A) The static shear stress resulting conditions, in psi: from the vertical reaction at the sus- (A) The longitudinal stresses resultpension assembly of a trailer, and the ing from the MAWP and external preshorizontal pivot of the upper coupler 979 § 178.345-3 49 CFR Ch. I (10-1-06 Edition) (fifth wheel) or turntable; or anchoring support member between the cargo and support members of a truck, as aptank and the vehicle or suspension plicable. The vertical reaction must be component must conform to the folcalculated based on the static weight lowing requirements: of the fully loaded cargo tank motor (1) Structural members, the suspenvehicle, all structural elements, equipsion sub-frame, accident protection ment and appurtenances supported by structures and external circumferenthe cargo tank wall; tial reinforcement devices must be (B) The vertical shear stress genused as sites for attachment of appurerated by an extreme vertical acceleratenances and other accessories to the tive force equal to 0.7 times the cargo tank, when practicable. vertical reaction at the suspension assembly of a trailer, and the horizontal (2) A lightweight attachment to a pivot of the upper coupler (fifth wheel) cargo tank wall such as a conduit clip, or turntable; or anchoring and support brake line clip, skirting structure, members of a truck, as applicable. The lamp mounting bracket, or placard vertical reaction must be calculated holder must be of a construction havbased on the static weight of the fully ing lesser strength than the cargo tank loaded cargo tank motor vehicle, all wall materials and may not be more structural elements, equipment and apthan 72 percent of the thickness of the purtenances supported by the cargo material to which it is attached. The tank wall; lightweight attachment may be se- (C) The lateral shear stress generated cured directly to the cargo tank wall if by an extreme lateral accelerative the device is designed and installed in force equal to 0.4 times the vertical resuch a manner that, if damaged, it will action at the suspension assembly of a not affect the lading retention integtrailer, applied at the road surface, and rity of the tank. A lightweight attachas transmitted to the cargo tank wall ment must be secured to the cargo through the suspension assembly of a tank shell or head by continuous weld trailer, and the horizontal pivot of the or in such a manner as to preclude forupper coupler (fifth wheel) or turnmation of pockets which may become table: or anchoring and support memsites for corrosion. bers of a truck, as applicable. The vertical reaction must be calculated (3) Except as prescribed in parabased on the static weight of the fully graphs (f)(1) and (f)(2) of this section, loaded cargo tank motor vehicle, all the welding of any appurtenance to the structural elements, equipment and apcargo tank wall must be made by atpurtenances supported by the cargo tachment of a mounting pad so that tank wall; and there will be no adverse effect upon the (D) The torsional shear stress genlading retention integrity of the cargo erated by the same lateral forces as detank if any force less than that prescribed in paragraph (c)(2)(iv)(C) of this scribed in paragraph (b)(1) of this secsection. tion is applied from any direction. The (d) In no case may the minimum thickness of the mounting pad may not thickness of the cargo tank shells and be less than that of the shell or head to heads be less than that prescribed in which it is attached, and not more $178.346-2, 178.347-2, or $178.348-2, as than 1.5 times the shell or head thickapplicable. ness. However, a pad with a minimum (e) For a cargo tank mounted on a thickness of 0.187 inch may be used frame or built with integral structural when the shell or head thickness is supports, the calculation of effective over 0.187 inch. If weep holes or tellstresses for the loading conditions in tale holes are used, the pad must be paragraph (c) of this section may indrilled or punched at the lowest point clude the structural contribution of before it is welded to the tank. Each the frame or the integral structural pad must: supports. (i) Be fabricated from material deter- (f) The design, construction, and inmined to be suitable for welding to stallation of an attachment, appurtenance to a cargo tank, structural both the cargo tank material and the 980 Pipeline and Hazardous Materials Safety Admin., DOT § 178.345-5 material of the appurtenance or strucage or permanent deformation that tural support member; a Design Certiwould affect its structural integrity, a fying Engineer must make this deterstatic internal fluid pressure of at least mination considering chemical and 36 psig, or cargo tank test pressure, physical properties of the materials whichever is greater. The manhole asand must specify filler material consembly manufacturer shall verify comforming to the requirements of the pliance with this requirement by ASME Code (incorporated by reference; hydrostatically testing at least one see § 171.7 of this subchapter). percent (or one manhole closure, (ii) Be preformed to an inside radius whichever is greater) of all manhole no greater than the outside radius of closures of each type produced each 3 the cargo tank at the attachment locamonths, as follows: tion. (1) The manhole, fill opening, or (iii) Extend at least 2 inches in each washout assembly must be tested with direction from any point of attachment the venting devices blocked. Any leakof an appurtenance or structural supage or deformation that would affect port member. This dimension may be the product retention capability of the measured from the center of the strucassembly shall constitute a failure. tural member attached. (2) If the manhole, fill opening, or (iv) Have rounded corners, or otherwashout assembly tested fails, then wise be shaped in a manner to minifive more covers from the same lot mize stress concentrations on the shell must be tested. If one of these five COVor head. ers fails, then all covers in the lot from (v) Be attached by continuous fillet which the tested covers were selected welding. Any fillet weld discontinuity are to be 100% tested or rejected for may only be for the purpose of preservice. venting an intersection between the fil- (c) Each manhole, filler and washout let weld and the tank or jacket seam cover must be fitted with a safety deweld. vice that prevents the cover from open- [Amdt. 178-89, 55 FR 37059, Sept. 7. 1990, as ing fully when internal pressure is amended by Amdt. 178-89, 56 FR 27876, June present. 17, 1991; Amdt. 178-104, 59 FR 49135, Sept. 26, (d) Each manhole and fill cover must 1994; Amdt. 178-105, 59 FR 55173, 55174 and be secured with fastenings that will 55175, Nov. 3, 1994; 60 FR 17402, Apr. 5. 1995; prevent opening of the covers as a re- Amdt. 178-118, 61 FR 51341, Oct. 1, 1996; 65 FR sult of vibration under normal trans- 58631, Sept. 29, 2000; 68 FR 19283, Apr. 18, 2003: portation conditions or shock impact 68 FR 75755, Dec. 31, 2003] due to a rollover accident on the road- $ 178.345-4 Joints. way or shoulder where the fill cover is not struck by a substantial obstacle. (a) All joints between the cargo tank (e) On cargo tank motor vehicles shell, heads, baffles, baffle attaching manufactured after October 1, 2004, rings, and bulkheads must be welded in each manhole assembly must be perconformance with Section VIII of the manently marked on the outside by ASME Code (IBR, see § 171.7 of this substamping or other means in a location chapter). visible without opening the manhole (b) Where practical all welds must be assembly or fill opening, with: easily accessible for inspection. (1) Manufacturer's name; [Amdt. 178-89, 54 FR 25022, June 12, 1989, as (2) Test pressure psig: amended by Amdt. 178-118, 61 FR 51341, Oct. (3) A statement certifying that the 1, 1996; 68 FR 75756, Dec. 31, 2003] manhole cover meets the requirements in § 178.345-5. § 178.345-5 Manhole assemblies. (f) All fittings and devices mounted (a) Each cargo tank with capacity on a manhole cover, coming in contact greater than 400 gallons must be acceswith the lading. must withstand the sible through a manhole at least 15 same static internal fluid pressure and inches in diameter. contain the same permanent compli- (b) Each manhole, fill opening and ance markings as that required for the washout assembly must be structurally manhole cover. The fitting or device capable of withstanding, without leakmanufacturer shall verify compliance 981 § 178.345-6 49 CFR Ch. I (10-1-06 Edition) using the same test procedure and freloaded by vacuum, spacing of circumquency of testing as specified in ferential reinforcement may exceed 60 $178.345-5(b). inches provided the maximum [Amdt. 178-89, 54 FR 25022, June 12, 1989, as unreinforced portion of the shell conamended by Amdt. 178-105, 59 FR 55175, Nov. forms with the requirements in Section 3, 1994; 68 FR 19284, Apr. 18, 2003) VIII of the ASME Code (IBR, see 171.7 of this subchapter). $ 178.345-6 Supports and anchoring. (2) Where circumferential joints are (a) A cargo tank with a frame not inmade between conical shell sections, or tegral to the cargo tank must have the between conical and cylindrical shell tank secured by restraining devices to sections, and the angle between adjaeliminate any motion between the cent sections is less than 160 degrees, tank and frame that may abrade the circumferential reinforcement must be tank shell due to the stopping, startlocated within one inch of the shell ing, or turning of the cargo tank motor joint, unless otherwise reinforced with vehicle. The design calculations of the structural members capable of mainsupport elements must include the taining shell stress levels authorized in stresses indicated in § 178.345-3(b) and 178.345-3. When the joint is formed by as generated by the loads described in the large ends of adjacent conical shell $178.345-3(c). Such restraining devices sections, or by the large end of a conmust be readily accessible for inspecical shell and a cylindrical shell section and maintenance, except that intion, this angle is measured inside the sulation and jacketing are permitted to shell; when the joint is formed by the cover the restraining devices. small end of a conical shell section and (b) A cargo tank designed and con- a cylindrical shell section, it is measstructed so that it constitutes, in ured outside the shell. whole or in part, the structural mem- (b) Except for doubler plates and ber used in lieu of a frame must be supknuckle pads, no reinforcement may ported in such a manner that the recover any circumferential joint. sulting stress levels in the cargo tank (c) When a baffle or baffle attachdo not exceed those specified in ment ring is used as a circumferential $178.345-3(a). The design calculations of reinforcement member, it must the support elements must include the produce structural integrity at least stresses indicated in $178.345-3(b) and equal to that prescribed in $178.345-3 as generated by the loads described in and must be circumferentially welded §178.345-3(c). to the cargo tank shell. The welded [Amdt. 178-89, 54 FR 25023, June 12, 1989, as portion may not be less than 50 percent amended by Amdt. 178-105, 59 FR 55175, Nov. of the total circumference of the cargo 3, 1994; Amdt. 178-118, 61 FR 51341. Oct. 1, tank and the length of any unwelded 1996] space on the joint may not exceed 40 times the shell thickness unless rein- § 178.345-7 Circumferential reinforceforced external to the cargo tank. ments. (d) When a ring stiffener is used as a (a) A cargo tank with a shell thickcircumferential reinforcement memness of less than 3/8 inch must be cirber, whether internal or external, reincumferentially reinforced with bulkforcement must be continuous around heads, baffles, ring stiffeners, or any the circumference of the cargo tank combination thereof, in addition to the shell and must be in accordance with cargo tank heads. the following: (1) Circumferential reinforcement (1) The section modulus about the must be located so that the thickness neutral axis of the ring section parallel and tensile strength of the shell mateto the shell must be at least equal to rial in combination with the frame and that derived from the applicable forreinforcement produces structural inmula: tegrity at least equal to that pre- I/C = 0.00027WL, for MS. HSLA and SS; scribed in § 178.345-3 and in such a manner that the maximum unreinforced or portion of the shell does not exceed 60 I/C = 0.000467WL, for aluminum alloys; inches. For cargo tanks designed to be Where: 982 Pipeline and Hazardous Materials Safety Admin., DOT § 178.345-8 I/C - Section modulus in Inches 3 minimize the potential for the loss of W = Tank width, or diameter, inches lading due to an accident. L - Spacing of ring stiffener, inches; i.e., the (1) Any dome, sump, or washout maximum longitudinal distance from the midpoint of the unsupported shell on one cover plate projecting from the cargo side of the ring stiffener to the midpoint of tank wall that retains lading in any the unsupported shell on the opposite side tank orientation, must be as strong of the ring stiffener. and tough as the cargo tank wall and have a thickness at least equal to that (2) If a ring stiffener is welded to the specified by the appropriate cargo tank cargo tank shell, a portion of the shell may be considered as part of the ring specification. Any such projection located in the lower 1/3 of the tank cirsection for purposes of computing the cumference (or cross section perimeter ring section modulus. This portion of for non-circular cargo tanks) that exthe shell may be used provided at least tends more than half its diameter at 50 percent of the total circumference of the point of attachment to the tank or the cargo tank is welded and the length more than 4 inches from the cargo tank of any unwelded space on the joint does wall, or located in the upper 2/3 of the not exceed 40 times the shell thickness. tank circumference (or cross section The maximum portion of the shell to be used in these calculations is as folperimeter for non-circular cargo tanks) that extends more than 1/4 its diameter lows: or more than 2 inches from the point of Number of circumattachment to the tank must have ac- J1 Shell secferential ring stiffenertion cident damage protection devices that to-shell welds are: 1 20t (i) As specified in this section; 2 Less than 20t 201+J 2 201 or more 40t (ii) 125 percent as strong as the otherwise required accident damage protec- ¹where: t=Shell thickness, inches; tion device; or J=Longitudinal distance between parallel circumferential (iii) Attached to the cargo tank in ring stiffener-to-shell welds. accordance with the requirements of (3) When used to meet the vacuum reparagraph (a)(3) of this section. quirements of this section, ring stiff- (2) Outlets, valves, closures, piping, eners must be as prescribed in Section or any devices that if damaged in an VIII of the ASME Code. accident could result in a loss of lading (4) If configuration of internal or exfrom the cargo tank must be protected ternal ring stiffener encloses an air by accident damage protection devices space, this air space must be arranged as specified in this section. for venting and be equipped with drain- (3) Accident damage protection deage facilities which must be kept opervices attached to the wall of a cargo ative at all times. tank must be able to withstand or de- (5) Hat shaped or open channel ring flect away from the cargo tank the stiffeners which prevent visual inspecloads specified in this section. They tion of the cargo tank shell are prohibmust be designed, constructed and inited on cargo tank motor vehicles constalled so as to maximize the distribustructed of carbon steel. tion of loads to the cargo tank wall and to minimize the possibility of ad- [Amdt. 178-89, 55 FR 37060, Sept. 7. 1990, as amended by Amdt. 178-89, 56 FR 27876, June versely affecting the lading retention 17, 1991; 56 FR 46354, Sept. 11, 1991; Amdt. 178- integrity of the cargo tank. Accident 104, 59 FR 49135, Sept. 26. 1994; Amdt. 178-118, induced stresses resulting from the ap- 61 FR 51341, Oct. 1, 1996; 68 FR 75756, Dec. 31, propriate accident damage protection 2003] device requirements in combination with the stresses from the cargo tank § 178.345-8 Accident damage protecoperating at the MAWP may not result tion. in a cargo tank wall stress greater (a) General. Each cargo tank motor than the ultimate strength of the mavehicle must be designed and conterial of construction using a safety structed in accordance with the refactor of 1.3. Deformation of the proquirements of this section and the aptection device is acceptable provided plicable individual specification to the devices being protected are not 983 § 178.345-8 49 CFR Ch. I (10-1-06 Edition) damaged when loads specified in this structural mounting members may be section are applied. used to provide all, or part, of this pro- (4) Any piping that extends beyond tection. The device must extend no less an accident damage protection device than 6 inches beyond any component must be equipped with a stop-valve and that may contain lading in transit. a sacrificial device such as a shear sec- (2) A lading discharge opening tion. The sacrificial device must be loequipped with an internal self-closing cated in the piping system outboard of stop-valve need not conform to parathe stop-valve and within the accident graph (b)(1) of this section provided it damage protection device to prevent is protected 50 as to reasonably assure any accidental loss of lading. The deagainst the accidental loss of lading. vice must break at no more than 70 This protection must be provided by a percent of the load that would be resacrificial device located outboard of quired to cause the failure of the proeach internal self-closing stop-valve tected lading retention device, part or and within 4 inches of the major radius cargo tank wall. The failure of the sacof the cargo tank shell or within 4 rificial device must leave the protected inches of a sump, but in no case more lading retention device and its attachthan 8 inches from the major radius of ment to the cargo tank wall intact and the tank shell. The device must break capable of retaining product. at no more than 70 percent of the load (5) Minimum road clearance. The minthat would be required to cause the imum road clearance of any cargo tank failure of the protected lading retenmotor vehicle component or protection tion device, part or cargo tank wall. device located between any two adja- The failure of the sacrificial device cent axles on a vehicle or vehicle commust leave the protected lading retenbination must be at least one-half inch tion device or part and its attachment for each foot separating the component to the cargo tank wall intact and capaor device from the nearest axle of the ble of retaining product. adjacent pair, but in no case less than (c) Each closure for openings, includtwelve (12) inches, except that the mining but not limited to the manhole, imum road clearance for landing gear filling or inspection openings, and each or other attachments within ten (10) valve, fitting, pressure relief device. feet of an axle must be no less than ten vapor recovery stop valve or lading re- (10) inches. These measurements must taining fitting located in the upper 2/3 be calculated at the gross vehicle of a cargo tank circumference (or cross weight rating of the cargo tank motor section perimeter for non-circular vehicle. tanks) must be protected by being lo- (b) Each outlet, projection or piping cated within or between adjacent rolllocated in the lower 1/3 of the cargo over damage protection devices, or by tank circumference (or cross section being 125 percent of the strength that perimeter for non-circular cargo tanks) would be provided by the otherwise rethat could be damaged in an accident quired damage protection device. that may result in the loss of lading (1) A rollover damage protection demust be protected by a bottom damage vice on a cargo tank motor vehicle protection device, except as provided must be designed and installed to withby paragraph (a)(1) of this section and stand loads equal to twice the weight $173.33(e) of this subchapter. Outlets, of the loaded cargo tank motor vehicle projections and piping may be grouped applied as follows: normal to the cargo or clustered together and protected by tank shell (perpendicular to the cargo a single protection device. tank surface); and tangential (perpen- (1) Any bottom damage protection dicular to the normal load) from any device must be able to withstand a direction. The stresses shall not exceed force of 155,000 pounds (based on the ulthe ultimate strength of the material timate strength of the material) from of construction. These design loads the front, side, or rear, uniformly dismay be considered to be uniformly distributed over each surface of the detributed and independently applied. If vice, over an area not to exceed 6 more than one rollover protection desquare feet, and a width not to exceed vice is used, each device must be capa- 6 feet. Suspension components and ble of carrying its proportionate share 984 Pipeline and Hazardous Materials Safety Admin., DOT $ 178.345-9 of the required loads and in each case (iii) The widest part of the motor veat least one-fourth the total tangential hicle at the rear may not extend more load. The design must be proven capathan 18 inches beyond the outermost ble of carrying the required loads by ends of the device or (if separated) decalculations, tests or a combination of vices on either side of the vehicle. tests and calculations. (3) The structure of the rear-end pro- (2) A rollover damage protection detection device and its attachment to vice that would otherwise allow the acthe vehicle must be designed to satisfy cumulation of liquid on the top of the the conditions specified in paragraph cargo tank, must be provided with a (d)(1) of this section when subjected to drain that directs the liquid to a safe an impact of the cargo tank motor vepoint of discharge away from any hicle at rated payload, at a decelerastructural component of the cargo tion of 2 "g". Such impact must be tank motor vehicle. considered as being uniformly applied (d) Rear-end tank protection. Each in the horizontal plane at an angle of cargo tank motor vehicle must be pro- 10 degrees or less to the longitudinal vided with a rear-end tank protection axis of the vehicle. device to protect the cargo tank and (e) Longitudinal deceleration protecpiping in the event of a rear-end collition. In order to account for stresses sion and reduce the likelihood of damdue to longitudinal impact in an acciage that could result in the loss of laddent, the cargo tank shell and heads must be able to withstand the load reing. Nothing in this paragraph relieves the manufacturer of responsibility for sulting from the design pressure in complying with the requirements of combination with the dynamic pres- $393.86 of this title and, if applicable, sure resulting from a longitudinal deparagraph (b) of this section. The rearceleration of 2 "g". For this loading end tank protection device must concondition, the allowable stress value form to the following requirements: used may not exceed the ultimate strength of the material of construc- (1) The rear-end cargo tank protection using a safety factor of 1.3. Pertion device must be designed so that it formance testing, analytical methods, can deflect at least 6 inches horior a combination thereof, may be used zontally forward with no contact beto prove this capability provided the tween any part of the cargo tank methods are accurate and verifiable. motor vehicle which contains lading For cargo tanks with internal baffles, during transit and with any part of the the decelerative force may be reduced rear-end protection device, or with a by 0.25 "g" for each baffle assembly, vertical plane passing through the outbut in no case may the total reduction board surface of the protection device. in decelerative force exceed 1.0 "g". (2) The dimensions of the rear-end cargo tank protection device shall con- [Amdt. 178-89. 54 FR 25023, June 12, 1989. as form to the following: amended at 55 FR 37061, Sept. 7, 1990; Amdt. 178-105, 59 FR 55175, Nov. 3, 1994; Amdt. 178- (i) The bottom surface of the rear-end 118, 61 FR 51341, Oct. I, 1996; 68 FR 19284, Apr. protection device must be at least 4 18, 2003] inches below the lower surface of any part at the rear of the cargo tank § 178.345-9 Pumps, piping, hoses and motor vehicle which contains lading connections. during transit and not more than 60 (a) Suitable means must be provided inches from the ground when the vehiduring loading or unloading operations cle is empty. to ensure that pressure within a cargo (ii) The maximum width of a notch, tank does not exceed test pressure. indentation, or separation between sec- (b) Each hose, piping, stop-valve, ladtions of a rear-end cargo tank protecing retention fitting and closure must tion device may not exceed 24 inches. A be designed for a bursting pressure of notched, indented, or separated rearthe greater of 100 psig or four times the end protection device may be used only MAWP. when the piping at the rear of the (c) Each hose coupling must be decargo tank is equipped with a sacrifisigned for a bursting pressure of the cial device outboard of a shut-off valve. greater of 120 psig or 4.8 times the 985 § 178.345-10 49 CFR Ch. I (10-1-06 Edition) MAWP of the cargo tank, and must be sisting of another pressure relief valve designed so that there will be no leakin parallel with the primary pressure age when connected. relief system may be used to augment (d) Suitable provision must be made the total venting capacity of the cargo to allow for and prevent damage due to tank. Non-reclosing pressure relief deexpansion, contraction, jarring, and vivices are not authorized in any cargo bration. Slip joints may not be used for tank except when in series with a rethis purpose in the lading retention closing pressure relief device. Gravity system. actuated reclosing valves are not au- (e) Any heating device, when inthorized on any cargo tank. stalled, must be so constructed that the breaking of its external connec- (2) When provided by $ 173.33(c)(1)(iii) tions will not cause leakage of the of this subchapter, cargo tanks may be cargo tank lading. equipped with a normal vent. Such (f) Any gauging, loading or charging vents must be set to open at not less device, including associated valves, than 1 psig and must be designed to must be provided with an adequate prevent loss of lading through the demeans of secure closure to prevent vice in case of vehicle overturn. leakage. (3) Each pressure relief system must (g) The attachment and construction be designed to withstand dynamic presof each loading/unloading or charging sure surges in excess of the design set line must be of sufficient strength, or pressure as specified in paragraphs be protected by a sacrificial device, (b) (i) and (ii) of this section. Set such that any load applied by loading/ pressure is a function of MAWP as set unloading or charging lines connected forth in paragraph (d) of this section. to the cargo tank cannot cause damage (i) Each pressure relief device must resulting in loss of lading from the be able to withstand dynamic pressure cargo tank. surge reaching 30 psig above the design (h) Use of a nonmetallic pipe, valve set pressure and sustained above the or connection that is not as strong and set pressure for at least 60 milliseconds heat resistant as the cargo tank matewith a total volume of liquid released rial is authorized only if such attachnot exceeding one gallon before the rement is located outboard of the lading lief device recloses to a leak-tight conretention system. dition. This requirement must be met [Amdt. 178-89, 54 FR 25025, June 12, 1989, as regardless of vehicle orientation. This amended at 55 FR 37061, Sept. 7. 1990, Amdt. capability must be demonstrated by 178-89, 56 FR 27877, June 17, 1991; Amdt. 178- testing. An acceptable method is out- 118, 61 FR 51341, Oct. 1, 1996] lined in TTMA RP No. 81-97 "Perform- § 178.345-10 Pressure relief. ance of Spring Loaded Pressure Relief Valves on MC 306, MC 307, MC 312, DOT (a) Each cargo tank must be equipped 406, DOT 407, and DOT 412 Tanks" (into relieve pressure and vacuum conditions in conformance with this section corporated by reference; see $171.7 of and the applicable individual specificathis subchapter). tion. The pressure and vacuum relief (ii) After August 31, 1995, each pressystem must be designed to operate sure relief device must be able to withand have sufficient capacity to prevent stand a dynamic pressure surge reachcargo tank rupture or collapse due to ing 30 psig above the design set presover-pressurization or vacuum resultsure and sustained above the design set ing from loading, unloading, or from pressure for at least 60 milliseconds heating and cooling of lading. Pressure with a total volume of liquid released relief systems are not required to connot exceeding 1 L before the relief form to the ASME Code. valve recloses to a leak-tight condi- (b) Type and construction of relief systion. This requirement must be met retems and devices. (1) Each cargo tank gardless of vehicle orientation. This must be provided with a primary prescapability must be demonstrated by sure relief system consisting of one or testing. TTMA RP No. 81, cited in paramore reclosing pressure relief valves. A graph (b)(3)(i) of this section, is an acsecondary pressure relief system conceptable test procedure. 986 Pipeline and Hazardous Materials Safety Admin., DOT § 178.345-10 (4) Each reclosing pressure relief that specified in table I, except as provalve must be constructed and invided in § 178.348-4. stalled in such a manner as to prevent unauthorized adjustment of the relief TABLE I-MINIMUM EMERGENCY VENT CAPACITY valve setting. [In cubic feel free air/hour at 60 °F and 1 atm.] (5) No shut-off valve or other device Cubic feet that could prevent venting through the Exposed area in square feet free air per hour pressure relief system may be installed in a pressure relief system. 20 15,800 (6) The pressure relief system must 30 23,700 40 31,600 be mounted, shielded and drainable so 50 39,500 as to minimize the accumulation of 60 47,400 material that could impair the oper- 70 55,300 ation or discharge capability of the 80 63,300 90 71,200 system by freezing. corrosion or block- 100 79,100 age. 120 94,900 (c) Location of relief devices. Each 140 110,700 160 126,500 pressure relief device must commu- 180 142,300 nicate with the vapor space above the 200 158,100 lading as near as practicable to the 225 191,300 250 203,100 center of the vapor space. For example, 275 214,300 on a cargo tank designed to operate in 300 225,100 a level attitude, the device should be 350 245,700 400 265,000 positioned at the horizontal and trans- 450 283,200 verse center of the cargo tank; on 500 300,600 cargo tanks sloped to the rear, the de- 550 317,300 600 333,300 vice should be located in the forward 650 348,800 half of the cargo tank. The discharge 700 363,700 from any device must be unrestricted. 750 378,200 800 392,200 Protective devices which deflect the 850 405,900 flow of vapor are permissible provided 900 419,300 the required vent capacity is main- 950 432,300 1,000 445,000 tained. (d) Settings of pressure relief system. NOTE 1: Interpolate for intermediate sizes. The set pressure of the pressure relief (1) Primary pressure relief system. Unsystem is the pressure at which it less otherwise specified in the applicastarts to open, allowing discharge. ble individual specification, the pri- (1) Primary pressure relief system. The mary relief system must have a minset pressure of each primary relief imum venting capacity of 12,000 SCFH valve must be no less than 120 percent per 350 square feet of exposed cargo of the MAWP, and no more than 132 tank area, but in any case at least one percent of the MAWP. The valve must fourth the required total venting careclose at not less than 108 percent of pacity for the cargo tank. the MAWP and remain closed at lower (2) Secondary pressure relief system. If pressures. the primary pressure relief system does (2) Secondary pressure relief system. not provide the required total venting The set pressure of each pressure relief capacity, additional capacity must be valve used as a secondary relief device provided by a secondary pressure relief must be not less than 120 percent of the system. MAWP. (f) Certification of pressure relief de- (e) Venting capacity of pressure relief vices. The manufacturer of any pressure systems. The pressure relief system (prirelief device, including valves, franmary and secondary, including piping) gible (rupture) disks, vacuum vents and must have sufficient venting capacity combination devices must certify that to limit the cargo tank internal presthe device model was designed and sure to not more than the cargo tank tested in accordance with this section test pressure. The total venting capacand the appropriate cargo tank speciity, rated at not more than the cargo fication. The certificate must contain tank test pressure, must be at least sufficient information to describe the 987 § 178.345-11 49 CFR Ch. I (10-1-06 Edition) device and its performance. The certifiternal self-closing stop-valve, or altercate must be signed by a responsible ofnatively, with an external stop-valve ficial of the manufacturer who aplocated as close as practicable to the proved the flow capacity certification. cargo tank wall. Each cargo tank load- (g) Rated flow capacity certification ing/unloading outlet must be in accordtest. Each pressure relief device model ance with the following provisions: must be successfully flow capacity cer- (1) Each loading/unloading outlet tification tested prior to first use. Demust be fitted with a self-closing sysvices having one design, size and set tem capable of closing all such outlets pressure are considered to be one in an emergency within 30 seconds of model. The testing requirements are as actuation. During normal operations follows: the outlets may be closed manually. (1) At least 3 devices of each specific The self-closing system must be demodel must be tested for flow capacity signed according to the following: at a pressure not greater than the test (i) Each self-closing system must inpressure of the cargo tank. For a declude a remotely actuated means of vice model to be certified, the capacclosure located more than 10 feet from ities of the devices tested must fall the loading/unloading outlet where vewithin a range of plus or minus 5 perhicle length allows, or on the end of cent of the average for the devices testthe cargo tank farthest away from the ed. loading/unloading outlet. The actu- (2) The rated flow capacity of a deating mechanism must be corrosion-revice model may not be greater than 90 sistant and effective in all types of enpercent of the average value for the devironment and weather. vices tested. (ii) If the actuating system is acci- (3) The rated flow capacity derived dentally damaged or sheared off during for each device model must be certified transportation. each loading/unloading by a responsible official of the device outlet must remain securely closed and manufacturer. capable of retaining lading. (h) Marking of pressure relief devices. (iii) When required by part 173 of this Each pressure relief device must be subchapter for materials which are permanently marked with the folflammable, pyrophoric, oxidizing, or lowing: Division 6.1 (poisonous liquid) mate- (1) Manufacturer's name; rials, the remote means of closure (2) Model number; must be capable of thermal activation. (3) Set pressure, in psig; and The means by which the self-closing (4) Rated flow capacity, in SCFH at system is thermally activated must be the rating pressure, in psig. located as close as practicable to the primary loading/unloading connection [Amdt. 178-89, 54 FR 25025, June 12. 1989, as amended at 55 FR 21038, May 22, 1990; 55 FR and must actuate the system at a tem- 37062, Sept. 7, 1990; Amdt. 178-89, 56 FR 27877, perature not over 250 °F. In addition, June 17, 1991; Amdt. 178-105, 59 FR 55175, Nov. outlets on these cargo tanks must be 3. 1994; Amdt. 178-118, 61 FR 51341, Oct. 1, capable of being remotely closed manu- 1996; 65 FR 58631, Sept. 29, 2000; 66 FR 45389, ally or mechanically. Aug. 28, 2001; 68 FR 19284, Apr. 18, 2003] (2) Bottom loading outlets which discharge lading into the cargo tank $ 178.345-11 Tank outlets. through fixed internal piping above the (a) General. As used in this section, maximum liquid level of the cargo "loading/unloading outlet" means any tank need not be equipped with a selfopening in the cargo tank wall used for closing system. loading or unloading of lading, as dis- (c) Any loading/unloading outlet extinguished from outlets such as mantending beyond an internal self-closing hole covers, vents, vapor recovery destop-valve, or beyond the innermost exvices, and similar closures. Cargo tank ternal stop-valve which is part of a outlets, closures and associated piping self-closing system, must be fitted with must be protected in accordance with another stop-valve or other leak-tight $178.345-8. closure at the end of such connection. (b) Each cargo tank loading/unload- (d) Each cargo tank outlet that is not ing outlet must be equipped with an in- a loading/unloading outlet must be 988 Pipeline and Hazardous Materials Safety Admin., DOT § 178.345-14 equipped with a stop-valve or other least 10 minutes during which time the leak-tight closure located as close as cargo tank must be inspected for leakpracticable to the cargo tank outlet. age, bulging, or other defect. Any connection extending beyond this (2) Pneumatic method. A pneumatic closure must be fitted with another test may be used in place of the hydrostop-valve or other leak-tight closure static test. However, pneumatic presat the end of such connection. sure testing may involve higher risk [Amdt. 178-89, 56 FR 27877. June 17, 1991, as than hydrostatic testing. Therefore, amended by Amdt. 178-97, 57 FR 45465, Oct. 1, suitable safeguards must be provided to 1992; Amdt. 178-118. 61 FR 51341, Oct. 1. 1996] protect personnel and facilities should failure occur during the test. The cargo § 178.345-12 Gauging devices. tank must be pressurized with air or an Each cargo tank, except a cargo tank inert gas. Test pressure must be intended to be filled by weight, must be reached gradually by increasing the equipped with a gauging device that inpressure to one half of test pressure. dicates the maximum permitted liquid Thereafter, the pressure must be inlevel to within 0.5 percent of the nomicreased in steps of approximately one nal capacity as measured by volume or tenth of the test pressure until test liquid level. Gauge glasses are not perpressure is reached. Test pressure must mitted. be held for at least 5 minutes. The pressure must then be reduced to the in- [Amdt. 178-89, 55 FR 37062, Sept. 7, 1990, as amended by Amdt. 178-118, 61 FR 51342, Oct. spection pressure which must be main- 1, 1996] tained while the entire cargo tank surface is inspected for leakage and other § 178.345-13 Pressure and leakage sign of defects. The inspection method tests. must consist of coating all joints and (a) Each cargo tank must be pressure fittings with a solution of soap and and leakage tested in accordance with water or other equally sensitive meththis section and §§ 178.346-5, 178.347-5. or od. 178.348-5. (c) Leakage test. The cargo tank with (b) Pressure test. Each cargo tank or all its accessories in place and operable cargo tank compartment must be testmust be leak tested at not less than 80 ed hydrostatically or pneumatically. percent of tank's MAWP with the pres- Each cargo tank of a multi-cargo tank sure maintained for at least 5 minutes. motor vehicle must be tested with the (d) Any cargo tank that leaks, bulges adjacent cargo tanks empty and at ator shows any other sign of defect must mospheric pressure. Each closure, exbe rejected. Rejected cargo tanks must cept pressure relief devices and loadbe suitably repaired and retested sucing/unloading venting devices rated at cessfully prior to being returned to less than the prescribed test pressure, service. The retest after any repair must be in place during the test. If the must use the same method of test venting device is not removed during under which the cargo tank was origithe test, such device must be rendered nally rejected. inoperative by a clamp, plug or other [Amdt. 178-89, 54 FR 25026, June 12, 1989, as equally effective restraining device, amended at 55 FR 37063, Sept. 7, 1990; Amdt. which may not prevent the detection of 178-105, 59 FR 55176. Nov. 3, 1994; Amdt. 178- leaks, or damage the device. Restrain- 118, 61 FR 51342, Oct. 1, 1996: 65 FR 58631. ing devices must be removed imme- Sept. 29, 2000; 68 FR 19284, Apr. 18, 2003) diately after the test is completed. (1) Hydrostatic method. Each cargo § 178.345-14 Marking. tank, including its domes, must be (a) General. The manufacturer shall filled with water or other liquid having certify that each cargo tank motor vesimilar viscosity, the temperature of hicle has been designed, constructed which may not exceed 100 °F. The cargo and tested in accordance with the aptank must then be pressurized as preplicable Specification DOT 406, DOT 407 scribed in the applicable specification. or DOT 412 (§§ 178.345, 178.346, 178.347, The pressure must be gauged at the top 178.348) cargo tank requirements and, of the cargo tank. The prescribed test when applicable, with Section VIII of pressure must be maintained for at the ASME Code (IBR, see §171.7 of this 989 § 178.345-14 49 CFR Ch. I (10-1-06 Edition) subchapter). The certification shall be "yyy" is replaced by the alloy designaaccomplished by marking the cargo tion and by the alloy type. tank as prescribed in paragraphs (b) NOTE: When the shell and heads materials and (c) of this section, and by preare the same thickness. they may be comparing the certificate prescribed in bined, (Shell&head matl, yyy***). $178.345-15. Metal plates prescribed by paragraphs (b), (c), (d) and (e) of this (10) Weld material (Weld matl.). (11) Minimum thickness-shell (Min. section, must be permanently attached shell-thick), in inches. When minimum to the cargo tank or its integral supshell thicknesses are not the same for porting structure, by brazing, welding different areas, show (top side or other suitable means. These plates bottom in inches). must be affixed on the left side of the (12) Minimum thickness-heads (Min. vehicle near the front of the cargo tank heads thick.). in inches. (or the frontmost cargo tank of a (13) Manufactured thickness-shell multi-cargo tank motor vehicle), in a (Mfd. shell thick.). top side botplace readily accessible for inspection. tom in inches. (Required when addi- The plates must be permanently and tional thickness is provided for corroplainly marked in English by stampsion allowance.) ing, embossing or other means in char- (14) Manufactured thickness-heads acters at least 3/16 inch high. The infor- (Mfd. heads thick.), in inches. (Remation required by paragraphs (b) and quired when additional thickness is (c) of this section may be combined on provided for corrosion allowance.) one specification plate. (15) Exposed surface area, in square (b) Nameplate. Each cargo tank must feet. have a corrosion resistant nameplate (c) Specification plate. Each cargo permanently attached to it. The foltank motor vehicle must have an addilowing information, in addition to any tional corrosion resistant metal speciapplicable information required by the fication plate attached to it. The speci- ASME Code, must be marked on the fication plate must contain the foltank nameplate (parenthetical abbrelowing information (parenthetical abviations may be used): breviations may be used): (1) DOT-specification number DOT (1) Cargo tank motor vehicle manu- XXX (DOT XXX) where "XXX" is refacturer (CTMV mfr.). placed with the applicable specification (2) Cargo tank motor vehicle certifinumber. For cargo tanks having a varication date (CTMV cert. date), if difable specification plate, the DOT-speciferent from the cargo tank certifification number is replaced with the cation date. words "See variable specification (3) Cargo tank manufacturer (CT plate." mfr.). (2) Original test date, month and (4) Cargo tank date of manufacture year (Orig. Test Date). (CT date of mfr.), month and year. (3) Tank MAWP in psig. (5) Maximum weight of lading (Max. (4) Cargo tank test pressure (Test P), Payload), in pounds. in psig. (6) Maximum loading rate in gallons (5) Cargo tank design temperature per minute (Max. Load rate, GPM). range (Design temp. range), °F to (7) Maximum unloading rate in gal- °F. lons per minute (Max. Unload rate). (8) Lining material (Lining), if appli- (6) Nominal capacity (Water cap.), in cable. gallons. (9) Heating system design pressure (7) Maximum design density of lading (Heating sys. press.), in psig, if applica- (Max. lading density), in pounds per ble. gallon. (10) Heating system design tempera- (8) Material specification numberture (Heating sys. temp.). in °F, if apshell (Shell matl, yyy***). where "yyy" plicable. is replaced by the alloy designation (d) Multi-cargo tank motor vehicle. For and by the alloy type, a multi-cargo tank motor vehicle hav- (9) Material specification numbering all its cargo tanks not separated by heads (Head matl, yyy***). where any void, the information required by 990 Pipeline and Hazardous Materials Safety Admin., DOT § 178.345-15 paragraphs (b) and (c) of this section priate MC or DOT Specification markmay be combined on one specification ings. plate. When separated by a void, each (4) The alterations that must be cargo tank must have an individual made in order for the tank to be modinameplate as required in paragraph (b) fied from one specification to another of this section, unless all cargo tanks must be clearly indicated on the manuare made by the same manufacturer facturer's certificate and on the variwith the same materials, manufactured able specification plate. thickness, minimum thickness and to [Amdt. 178-89, 54 FR 25027, June 12. 1989, as the same specification. The cargo tank amended at 55 FR 37063, Sept. 7. 1990; Amdt. motor vehicle may have a combined 178-99, 58 FR 51534, Oct. I, 1993: Amdt. 178-104, nameplate and specification plate. 59 FR 49135, Sept. 26, 1994; Amdt. 178-105, 59 When only one plate is used, the plate FR 55176, Nov. 3, 1994; 60 FR 17402, Apr. 5, must be visible and not covered by in- 1995; Amdt. 178-118, 61 FR 51342, Oct. 1. 1996; sulation. The required information 66 FR 45389, Aug. 28, 2001; 68 FR 19284, Apr. 18, must be listed on the plate from front 2003; 68 FR 52371, Sept. 3, 2003; 68 FR 75756, Dec. 31, 2003] to rear in the order of the corresponding cargo tank location. § 178.345-15 Certification. (e) Variable specification cargo tank. Each variable specification cargo tank (a) At or before the time of delivery, must have a corrosion resistant metal the manufacturer of a cargo tank variable specification plate attached to motor vehicle must provide certification documents to the owner of the it. The mounting of this variable specification plate must be such that only cargo tank motor vehicle. The registration numbers of the manufacturer, the the plate identifying the applicable specification under which the tank is Design Certifying Engineer, and the being operated is legible. Registered Inspector, as appropriate. (1) The following information must must appear on the certificates (see be included (parenthetical abbreviasubpart F. part 107 in subchapter A of this chapter). tions are authorized): (b) The manufacturer of a cargo tank Specification DOT XXX (DOT XXX), where motor vehicle made to any of these "XXX" is replaced with the applicable specispecifications must provide: fication number. (1) For each design type, a certificate signed by a responsible official of the Equipment required Required rating¹ manufacturer and a Design Certifying Engineer certifying that the cargo Pressure relief devices: tank motor vehicle design meets the Pressure actuated applicable specification; and type. (2) For each ASME cargo tank, a Frangible type cargo tank manufacturer's data report Lading discharge deas required by Section VIII of the vices. ASME Code (IBR, see $171.7 of this sub- Top Bottom chapter). For each cargo tank motor Pressure unloading vehicle, a certificate signed by a refitting. sponsible official of the manufacturer Closures: and a Registered Inspector certifying Manhole that the cargo tank motor vehicle is Fill openings constructed, tested and completed in Discharge openings conformance with the applicable speci- 1 Required rating-to meet the applicable fication. specification. (c) The manufacturer of a variable (2) If no change of information in the specification cargo tank motor vehicle specification plate is required, the letmust provide: ters "NC" must follow the rating re- (1) For each design type, a certificate quired. If the cargo tank is not so signed by a responsible official of the equipped, the word "None" must be inmanufacturer and a Design Certifying serted. Engineer certifying that the cargo (3) Those parts to be changed or tank motor vehicle design meets the added must be stamped with the approapplicable specifications; and 991 § 178.346 49 CFR Ch. I (10-1-06 Edition) (2) For each variable specification or repair organization) accomplishing cargo tank motor vehicle, a certificate the compliance. signed by a responsible official of the [Amdt. 178-89. 55 FR 37063, Sept. 7, 1990, as manufacturer and a Registered Inspecamended by Amdt. 178-98. 58 FR 33306, June tor certifying that the cargo tank 16, 1993; Amdt. 178-105, 59 FR 55176, Nov. 3, motor vehicle is constructed, tested 1994; Amdt. 178-118, 61 FR 51342, Oct. 1, 1996; and completed in conformance with the 68 FR 75756, Dec. 31. 2003) applicable specifications. The certificate must include all the information § 178.346 Specification DOT 406; cargo tank motor vehicle. required and marked on the variable specification plate. § 178.346-1 General requirements. (d) In the case of a cargo tank motor (a) Each Specification DOT 406 cargo vehicle manufactured in two or more tank motor vehicle must meet the genstages, each manufacturer who pereral design and construction requireforms a manufacturing operation on ments in § 178.345, in addition to the the incomplete vehicle or portion specific requirements contained in this thereof shall provide to the succeeding section. manufacturer, at or before the time of (b) MAWP: The MAWP of each cargo delivery, a certificate covering the partank must be no lower than 2.65 psig ticular operation performed by that and no higher than 4 psig. manufacturer, including any certifi- (c) Vacuum loaded cargo tanks must cates received from previous manufacnot be constructed to this specificaturers, Registered Inspectors, and Detion. sign Certifying Engineers. Each certifi- (d) Each cargo tank must be "concate must indicate the portion of the structed in accordance with Section complete cargo tank motor vehicle rep- VIII of the ASME Code" (IBR, see resented thereby, such as basic cargo $171.7 of this subchapter) except as tank fabrication, insulation, jacket, modified herein: lining, or piping. The final manufac- (1) The record-keeping requirements turer shall provide all applicable cercontained in the ASME Code Section tificates to the owner. VIII do not apply. Parts UG-90 through (e) Specification shortages. If a cargo 94 in Section VIII do not apply. Inspectank is manufactured which does not tion and certification must be made by an inspector registered in accordance meet all applicable specification rewith subpart F of part 107. quirements, thereby requiring subse- (2) Loadings must be as prescribed in quent manufacturing involving the in- § 178.345-3. stallation of additional components, (3) The knuckle radius of flanged parts, appurtenances or accessories, heads must be at least three times the the cargo tank manufacturer may affix material thickness, and in no case less the name plate and specification plate, than 0.5 inch. Stuffed (inserted) heads as required by $178.345-14 (b) and (c), may be attached to the shell by a fillet without the original date of certifiweld. The knuckle radius and dish racation stamped on the specification dius versus diameter limitations of plate. The manufacturer shall state the UG-32 do not apply. Shell sections of specification requirements not comcargo tanks designed with a non-cirplied with on the manufacturer's Cercular cross section need not be given a tificate of Compliance. When the cargo preliminary curvature, as prescribed in tank is brought into full compliance UG-79(b). with the applicable specification, the (4) Marking, certification, data re- Registered Inspector shall stamp the ports, and nameplates must be as predate of compliance on the specification scribed in §§ 178.345-14 and 178.345-15. plate. The Registered Inspector shall (5) Manhole closure assemblies must issue a Certificate of Compliance statconform to §§ 178.345-5 and 178.346-5. ing details of the particular operations (6) Pressure relief devices must be as performed on the cargo tank, and the prescribed in § 178.346-3. date and person (manufacturer, carrier, (7) The hydrostatic or pneumatic test must be as prescribed in § 178.346-5. 992 Pipeline and Hazardous Materials Safety Admin., DOT $ 178.346-2 (8) The following paragraphs in parts tests are completed. Before welding, UG and UW in Section VIII of the the fit-up of the joints on the test ASME Code do not apply: UG-11, UGspecimens must represent production 12, UG-22(g). UG-32(e), UG-34, UG-35, conditions that would result in the UG-44, UG-76, UG-77, UG-80, UG-81, least joint strength. Evidence of joint UG-96, UG-97, UW-13(b)(2), UW-13.1(f) fit-up and test results must be retained and the dimensional requirements at the manufacturers' facility. found in Figure UW-13.1. (iv) Weld joint efficiency. The lower (9) Single full fillet lap joints withvalue of stress at failure attained in out plug welds may be used for arc or the two tensile test specimens shall be gas welded longitudinal seams without used to compute the efficiency of the radiographic examination under the joint as follows: Determine the failure following conditions: (i) For a truck-mounted cargo tank, ratio by dividing the stress at failure no more than two such joints may be by the mechanical properties of the adused on the top half of the tank and no Jacent metal; this value, when multimore than two joints may be used on plied by 0.75, is the design weld joint efthe bottom half. They may not be loficiency. cated farther from the top and bottom (10) The requirements of paragraph centerline than 16 percent of the shell's UW-9(d) in Section VIII of the ASME circumference. Code do not apply. (ii) For a self-supporting cargo tank, [Amdt. 178-89. 54 FR 25028, June 12, 1989, as no more than two such joints may be amended at 55 FR 37063, Sept. 7, 1990; Amdt. used on the top of the tank. They may 178-89, 56 FR 27877. June 17. 1991; Amdt. 178- not be located farther from the top 105, 59 FR 55176, Nov. 3, 1994: 65 FR 58631, centerline than 12.5 percent of the Sept. 29. 2000; 66 FR 45387, Aug. 28, 2001; 68 FR shell's circumference. 19285, Apr. 18, 2003; 68 FR 75756, Dec. 31, 2003] (iii) Compliance test. Two test specimens of the material to be used in the $ 178.346-2 Material and thickness of material. manufacture of a cargo tank must be tested to failure in tension. The test The type and thickness of material specimens must be of the same for DOT 406 specification cargo tanks thicknesses and joint configuration as must conform to § 178.345-2, but in no the cargo tank, and joined by the same case may the thickness be less than welding procedures. The test specimens that determined by the minimum may represent all the tanks that are thickness requirements in $178.320(a). made of the same materials and weld- The following Tables I and II identify ing procedures, have the same joint the specified minimum thickness valconfiguration, and are made in the ues to be employed in that determinasame facility within 6 months after the tion. TABLE I-SPECIFIED MINIMUM THICKNESS OF HEADS (OR BULKHEADS AND BAFFLES WHEN USED AS TANK REINFORCEMENT) USING MILD STEEL (MS), HIGH STRENGTH Low ALLOY STEEL (HSLA), AUSTENITIC STAINLESS STEEL (SS), OR ALUMINUM (AL)-EXPRESSED IN DECIMALS OF AN INCH AFTER FORMING Volume capacity in gallons per inch of length Material 14 or less Over 14 to 23 Over 23 MS HSLA AL HSLA MS HSLA SS SS AL MS AL SS Thickness .100 .100 .160 .115 .115 .173 .129 .129 .187 TABLE II-SPECIFIED MINIMUM THICKNESS OF SHELL USING MILD STEEL (MS), HIGH STRENGTH Low ALLOY STEEL (HSLA), AUSTENITIC STAINLESS STEEL (SS), OR ALUMINUM (AL)-EXPRESSED IN DECIMALS OF AN INCH AFTER FORMING 1 Cargo tank motor vehicle rated capacity (gallons) MS SS/HSLA AL More than 0 to at least 4,500 0.100 0.100 0.151 More than 4,500 to at least 8,000 0.115 0.100 0.160 993 § 178.346-3 49 CFR Ch. I (10-1-06 Edition) TABLE II-SPECIFIED MINIMUM THICKNESS OF SHELL USING MILD STEEL (MS), HIGH STRENGTH Low ALLOY STEEL (HSLA), AUSTENITIC STAINLESS STEEL (SS), OR ALUMINUM (AL)-EXPRESSED IN DECIMALS OF AN INCH AFTER FORMING 1-Continued Cargo tank motor vehicle rated capacity (gallons) MS SS/HSLA AL More than 8,000 to at least 14,000 0.129 0.129 0.173 More than 14,000 0.143 0.143 0.187 , Maximum distance between bulkheads, baffles, or ring stiffeners shall not exceed 60 inches. [Amdt. 178-89, 54 FR 25028, June 12, 1989, as amended at 55 FR 37064, Sept. 7, 1990; Amdt. 178- 105, 59 FR 55176, Nov. 3. 1994; 68 FR 19285, Apr. 18, 2003] § 178.346-3 Pressure relief. (2) Each vacuum relief device must (a) Each cargo tank must be equipped be set to open at no more than 6 ounces with a pressure relief system in accordvacuum. ance with $178.345-10 and this section. (d) Venting capacities. (1) Notwith- (b) Type and construction. In addition standing the requirements in § 178.345- to the pressure relief devices required 10 (e) and (g), the primary pressure rein $ 178.345-10: lief valve must have a venting capacity (1) Each cargo tank must be equipped of at least 6,000 SCFH, rated at not with one or more vacuum relief degreater than 125 percent of the tank vices; test pressure and not greater than 3 (2) When intended for use only for psig above the MAWP. The venting calading meeting the requirements of pacity required in $178.345-10(e) may be §173.33(c)(1)(iii) of this subchapter, the rated at these same pressures. cargo tank may be equipped with a (2) Each vacuum relief system must normal vent. Such vents must be set to have sufficient capacity to limit the open at not less than 1 psig and must vacuum to 1 psig. be designed to prevent loss of lading (3) If pressure loading or unloading through the device in case of vehicle devices are provided, the relief system upset; and (3) Notwithstanding the requirements must have adequate vapor and liquid in § 178.345-10(b), after August 31, 1996, capacity to limit the tank pressure to each pressure relief valve must be able the cargo tank test pressure at maxto withstand a dynamic pressure surge imum loading or unloading rate. The reaching 30 psig above the design set maximum loading and unloading rates pressure and sustained above the set must be included on the metal specipressure for at least 60 milliseconds fication plate. with a total volume of liquid released (Amdt. 178-89. 54 FR 25029, June 12, 1989, as not exceeding 1 L before the relief amended at 55 FR 37064, Sept. 7. 1990; Amdt. valve recloses to a leak-tight condi- 178-105, 59 FR 55176, Nov. 3, 1994. Redesigtion. This requirement must be met renated by Amdt. 178-112, 61 FR 18934, Apr. 29, gardless of vehicle orientation. This 1996; 66 FR 45389, Aug. 28, 2001: 68 FR 75756, capability must be demonstrated by Dec. 31, 2003] testing. TTMA RP No. 81 (IBR, see $171.7 of this subchapter). cited at § 178.346-4 Outlets. § 178.345-10(b) is an acceptable test (a) All outlets on each tank must procedure. conform to $178.345-11 and this section. (c) Pressure settings of relief valves. (1) (b) External self-closing stop-valves Notwithstanding the requirements in are not authorized as an alternative to § 178.345-10(d), the set pressure of each primary relief valve must be not less internal self-closing stop-valves on than 110 percent of the MAWP or 3.3 loading/unloading outlets. psig, whichever is greater, and not [Amdt. 178-89, 54 FR 25029, June 12, 1989. Remore than 138 percent of the MAWP. designated by Amdt. 178-112, 61 FR 18934, The valve must close at not less than Apr. 29, 1996] the MAWP and remain closed at lower pressures. 994 Pipeline and Hazardous Materials Safety Admin., DOT § 178.347-1 $178.346-5 Pressure and leakage tests. of this subchapter). The external de- (a) Each cargo tank must be tested in sign pressure for a cargo tank loaded accordance with § 178.345-13 and this by vacuum must be at least 15 psi. section. (d) Each cargo tank built to this (b) Pressure test. Test pressure must specification with MAWP of 35 psig or be as follows: less must be "constructed in accord- (1) Using the hydrostatic test methance with Section VIII of the ASME od, the test pressure must be the great- Code" except as modified. er of 5.0 psig or 1.5 times the cargo (1) The record-keeping requirements tank MAWP. contained in Section VIII of the ASME (2) Using the pneumatic test method, Code do not apply. The inspection rethe test pressure must be the greater of quirements of parts UG-90 through 94 5.0 psig or 1.5 times the cargo tank do not apply. Inspection and certifi- MAWP, and the inspection pressure cation must be made by an inspector must be the cargo tank MAWP. registered in accordance with subpart (c) Leakage test. A cargo tank used to F of part 107. transport a petroleum distillate fuel (2) Loadings must be as prescribed in that is equipped with vapor recovery $178.345-3. equipment may be leakage tested in (3) The knuckle radius of flanged accordance with 40 CFR 63.425(e). To heads must be at least three times the satisfy the leakage test requirements material thickness, and in no case less of this paragraph, the test specified in than 0.5 inch. Stuffed (inserted) heads 40 CFR 63.425(e)(1) must be conducted may be attached to the shell by a fillet using air. The hydrostatic test alterweld. The knuckle radius and dish ranative permitted under Appendix A to dius versus diameter limitations of 40 CFR Part 60 ("Method 27-Deter- UG-32 do not apply for cargo tank mination of Vapor Tightness of Gasomotor vehicles with a MAWP of 35 psig line Delivery Tank Using Pressureor less. Vacuum Test") may not be used to sat- (4) Marking, certification, data reisfy the leakage test requirements of ports and nameplates must be as prethis paragraph. A cargo tank tested in scribed in 178.345-14 and 178.345-15. accordance with 40 CFR 63.425(e) may (5) Manhole closure assemblies must be marked as specified in $180.415 of conform to 178.347-3. this subchapter. (6) Pressure relief devices must be as prescribed in $178.347-4. [Amdt. 178-89, 54 FR 25029, June 12, 1989, as (7) The hydrostatic or pneumatic test amended at 55 FR 37064, Sept. 7, 1990; Amdt. 178-105, 59 FR 55176, Nov. 3, 1994. Redesigmust be as prescribed in § 178.347-5. nated by Amdt. 178-112, 61 FR 18934, Apr. 29, (8) The following paragraphs in parts 1996; 68 FR 19285, Apr. 18, 2003) UG and UW in Section VIII the ASME Code do not apply: UG-11, UG-12, UG- $178.347 Specification DOT 407; cargo 22(g). UG-32(e), UG-34, UG-35, UG-44, tank motor vehicle. UG-76, UG-77, UG-80, UG-81, UG-96, UG-97, UW-12, UW-13(b)(2), UW-13.1(f). 178.347-1 General requirements. and the dimensional requirements (a) Each specification DOT 407 cargo found in Figure UW-13.1. tank motor vehicle must conform to (9) The strength of a weld seam in a the general design and construction rebulkhead that has not been radioquirements in $178.345 in addition to graphically examined shall be 0.85 of the specific requirements contained in the strength of the bulkhead under the this section. following conditions: (b) Each tank must be of a circular (i) The welded seam must be a full cross-section and have an MAWP of at penetration butt weld. least 25 psig. (ii) No more than one seam may be (c) Any cargo tank built to this specused per bulkhead. ification with a MAWP greater than 35 (iii) The welded seam must be compsig and each tank designed to be loadpleted before forming the dish radius ed by vacuum must be constructed and and knuckle radius. certified in conformance with Section (iv) Compliance test: Two test speci- VIII of the ASME Code (IBR, see $171.7 mens of materials representative of 995 § 178.347-2 49 CFR Ch. I (10-1-06 Edition) those to be used in the manufacture of cent material of all samples of a test a cargo tank bulkhead must be tested lot must be greater than 0.85. to failure in tension. The test specimen must be of the same thickness and (Amdt. 178-89, 54 FR 25029, June 12, 1989. as amended at 55 FR 37064, Sept. 7, 1990; Amdt. joined by the same welding procedure. 178-89, 56 FR 27877, June 17. 1991; 65 FR 58632, The test specimens may represent all Sept. 29, 2000; 66 FR 45387, Aug. 28, 2001; 68 FR the tanks that are made in the same 19285, Apr. 18, 2003; 68 FR 75756. Dec. 31, 2003] facility within 6 months after the tests are completed. Before welding, the fit- § 178.347-2 Material and thickness of up of the joints on the test specimens material. must represent production conditions (a) The type and thickness of matethat would result in the least joint rial for DOT 407 specification cargo strength. Evidence of joint fit-up and tanks must conform to § 178.345-2, but test results must be retained at the in no case may the thickness be less manufacturers' facility for at least 5 than that determined by the minimum years. thickness requirements in $178.320(a). (v) Acceptance criteria: The ratio of Tables I and II identify the specified the actual tensile stress at failure to minimum thickness values to be emthe actual tensile strength of the adjaployed in that the determination: TABLE I-SPECIFIED MINIMUM THICKNESS OF HEADS (OR BULKHEADS AND BAFFLES WHEN USED AS TANK REINFORCEMENT) USING MILD STEEL (MS), HIGH STRENGTH Low ALLOY STEEL (HSLA), AUSTENITIC STAINLESS STEEL (SS), OR ALUMINUM (AL)-EXPRESSED IN DECIMALS OF AN INCH AFTER FORMING Volume capacity in gallons per inch 10 or Over 10 Over 14 Over 18 Over 22 Over 26 less to 14 to 18 to 22 to 26 to 30 Over 30 Thickness (MS) 0.100 0.100 0.115 0.129 0.129 0.143 0.156 Thickness (HSLA) 0.100 0.100 0.115 0.129 0.129 0.143 0.156 Thickness (SS) 0.100 0.100 0.115 0.129 0.129 0.143 0.156 Thickness (AL) 0.160 0.160 0.173 0.187 0.194 0.216 0.237 TABLE II-SPECIFIED MINIMUM THICKNESS OF SHELL USING MILD STEEL (MS), HIGH STRENGTH Low ALLOY STEEL (HSLA), AUSTENITIC STAINLESS STEEL (SS), OR ALUMINUM (AL)-EXPRESSED IN DECIMALS OF AN INCH AFTER FORMING Volume capacity in gallons per inch 10 or Over 10 Over 14 Over 18 Over 22 Over 26 less to 14 to 18 to 22 to 26 to 30 Over 30 Thickness (MS) 0.100 0.100 0.115 0.129 0.129 0.143 0.156 Thickness (HSLA) 0.100 0.100 0.115 0.129 0.129 0.143 0.156 Thickness (SS) 0.100 0.100 0.115 0.129 0.129 0.143 0.156 Thickness (AL) 0.151 0.151 0.160 0.173 0.194 0.216 0.237 (b) [Reserved] [Amdt. 178-89, 54 FR 25030, June 12, 1989, as amended at 55 FR 37064, Sept. 7. 1990; Amdt. 178- 104, 59 FR 49135, Sept. 26, 1994; 68 FR 19285, Apr. 18, 2003] $ 178.347-3 Manhole assemblies. 40 psig or test pressure of the tank, Each manhole assembly must conwhichever is greater. form to § 178.345-5, except that each [Amdt. 178-89, 54 FR 25030, June 12, 1989. Remanhole assembly must be capable of designated by Amdt. 178-112, 61 FR 18934, withstanding internal fluid pressures of Apr. 29, 1996] 996 Pipeline and Hazardous Materials Safety Admin., DOT § 178.348-1 § 178.347-4 Pressure relief. the specific requirements of this section. (a) Each cargo tank must be equipped with a pressure and vacuum relief sys- (b) The MAWP of each cargo tank tem in accordance with $178.345-10 and must be at least 5 psig. this section. (c) The MAWP for each cargo tank (b) Type and Construction. Vacuum redesigned to be loaded by vacuum must lief devices are not required for cargo be at least 25 psig Internal and 15 psig external. tanks designed to be loaded by vacuum or built to withstand full vacuum. (d) Each cargo tank having a MAWP (c) Pressure settings of relief valves. greater than 15 psig must be of circular cross-section. The setting of pressure relief valves must be in accordance with $178.345- (e) Each cargo tank having a- (1) MAWP greater than 15 psig must 10(d). be "constructed and certified in con- (d) Venting capacities. (1) The vacuum formance with Section VIII of the relief system must limit the vacuum to ASME Code" (IBR, see $171.7 of this less than 80 percent of the design vacusubchapter); or um capability of the cargo tank. (2) MAWP of 15 psig or less must be (2) If pressure loading or unloading "constructed in accordance with Secdevices are provided, the relief system tion VIII of the ASME Code," except as must have adequate vapor and liquid modified herein: capacity to limit the tank pressure to (i) The recordkeeping requirements the cargo tank test pressure at maxcontained in Section VIII of the ASME imum loading or unloading rate. The Code do not apply. Parts UG-90 maximum loading or unloading rate through 94 in Section VIII do not must be included on the metal speciapply. Inspection and certification fication plate. must be made by an inspector reg- [Amdt. 178-89, 54 FR 25030, June 12, 1989, as istered in accordance with subpart F of amended at 55 FR 37064, Sept. 7, 1990. Redespart 107. ignated by Amdt. 178-112, 61 FR 18934, Apr. (ii) Loadings must be as prescribed in 29. 1996] § 178.345-3. § 178.347-5 Pressure and leakage test. (iii) The knuckle radius of flanged heads must be at least three times the (a) Each cargo tank must be tested in material thickness, and in no case less accordance with $178.345-13 and this than 0.5 inch. Stuffed (inserted) heads section. may be attached to the shell by a fillet (b) Pressure test. Test pressure must weld. The knuckle radius and dish rabe as follows: dius versus diameter limitations of (1) Using the hydrostatic test meth- UG-32 do not apply for cargo tank od, the test pressure must be at least 40 motor vehicles with a MAWP of 15 psig psig or 1.5 times tank MAWP, whichor less. Shell sections of cargo tanks ever is greater. designed with a non-circular cross sec- (2) Using the pneumatic test method, tion need not be given a preliminary the test pressure must be 40 psig or 1.5 curvature, as prescribed in UG-79(b). times tank MAWP, whichever is great- (iv) Marking, certification, data reer, and the inspection pressure is tank ports, and nameplates must be as pre- MAWP. scribed in §§ 178.345-14 and 178.345-15. [Amdt. 178-89, 54 FR 25030, June 12, 1989. Re- (v) Manhole closure assemblies must designated by Amdt. 178-112. 61 FR 18934, conform to $$178.345-5. Apr. 29, 1996] (vi) Pressure relief devices must be as prescribed in $178.348-4. $ 178.348 Specification DOT 412; cargo (vii) The hydrostatic or pneumatic tank motor vehicle. test must be as prescribed in 178.348-5. (viii) The following paragraphs in § 178.348-1 General requirements. parts UG and UW in Section VIII of the (a) Each specification DOT 412 cargo ASME Code do not apply: UG-11, UGtank motor vehicle must conform to 12, UG-22(g), UG-32(e), UG-34, UG-35, the general design and construction re- UG-44, UG-76, UG-77, UG-80, UG-81, quirements in $178.345 in addition to UG-96, UG-97, UW-13(b)(2). UW-13.1(f). 997 $ 178.348-2 49 CFR Ch. I (10-1-06 Edition) and the dimensional requirements tanks must conform to § 178.345-2, but found in Figure UW-13.1. in no case may the thickness be less [Amdt. 178-89, 54 FR 25031, June 12, 1989, as than that determined by the minimum amended at 55 FR 37065, Sept. 7, 1990; Amdt. thickness requirements in § 178.320(a). 178-89, 56 FR 27877, June 17, 1991; 65 FR 58632, The following Tables I and II identify Sept. 29, 2000; 68 FR 19285, Apr. 18, 2003; 68 fR the "Specified Minimum Thickness" 75756, Dec. 31, 2003] values to be employed in that deter- § 178.348-2 Material and thickness of mination. material. (a) The type and thickness of material for DOT 412 specification cargo 998 TABLE I-SPECIFIED MINIMUM THICKNESS OF HEADS (OR BULKHEADS AND BAFFLES WHEN USED AS TANK REINFORCEMENT) USING MILD STEEL (MS), HIGH STRENGTH Low ALLOY STEEL (HSLA), AUSTENITIC STAINLESS STEEL (SS), OR ALUMINUM (AL)-EXPRESSED IN DECIMALS OF AN INCH AFTER FORMING Volume capacity (gallons per inch) 10 or less Over 10 to 14 Over 14 to 18 18 and over Lading density at 60 °F in pounds per gallon 10 lbs Over Over Over 10 lbs Over Over Over 10 lbs Over Over 10 lbs Over Over and 10 to 13 to 16 lbs and 10 to 13 to 16 lbs and 10 to 13 to and 10 to 13 to less 13 lbs 16 lbs less 13 lbs 16 lbs less 13 lbs 16 lbs less 13 lbs 16 lbs Thickness (inch), steel .100 .129 157 .187 .129 .157 .187 .250 .157 .250 .250 .157 .250 .312 Thickness (inch), aluminum .144 .187 .227 .270 .187 .227 .270 .360 .227 .360 .360 .227 .360 .450 TABLE II-SPECIFIED MINIMUM THICKNESS OF SHELL USING MILD STEEL (MS), HIGH STRENGTH Low ALLOY STEEL (HSLA), AUSTENITIC STAINLESS STEEL (SS), OR ALUMINUM (AL)-EXPRESSED IN DECIMALS OF AN INCH AFTER FORMING Volume capacity in gallons per inch 10 or less Over 10 to 14 Over 14 to 18 18 and over Lading density at 60 °F in pounds per gallon 10 lbs Over Over Over 10 lbs Over Over Over 10 lbs Over Over 10 lbs Over Over 666 and 10 to 13 to 16 lbs and 10 to 13 to 16 lbs and 10 to 13 to and 10 to 13 to less 13 lbs 16 lbs less 13 lbs 16 lbs less 13 lbs 16 lbs less 13 lbs 16 lbs Thickness (steel): Pipeline and Hazardous Materials Safety Admin., DOT Distances between heads (and bulkheads baffles and ring stiffeners when used as tank reinforcement): 36 in. or less .100 .129 .157 .187 .100 .129 .157 .187 .100 .129 .157 .129 .157 .187 Over 36 in. to 54 inches .100 .129 .157 .187 .100 .129 .157 .187 .129 .157 .187 .157 250 .250 Over 54 in. to 60 Inches .100 .129 .157 .187 .129 .157 .187 .250 .157 .250 .250 .187 .250 .312 Thickness (aluminum): Distances between heads (and bulkheads baffles and ring stiffeners when used as tank reinforcement): 36 in. or less .144 .187 .227 .270 .144 .187 .227 .270 .144 .187 .227 .187 .227 270 Over 36 in. to 54 inches .144 .187 .227 .270 .144 .187 .227 .270 .187 .227 .270 .157 .360 .360 Over 54 in. to 60 inches .144 .187 .227 .270 .187 .227 .270 .360 .227 .360 .360 .270 .360 .450 178.348-2 § 178.348-3 49 CFR Ch. I (10-1-06 Edition) (b) [Reserved] [Amdt. 178-89, 54 FR 25031, June 12, 1989; 54 FR 28750. July 7. 1989, as amended at 55 FR 37065, Sept. 7. 1990; 68 FR 19285, Apr. 18, 2003] § 178.348-3 Pumps, piping, hoses and formula in § 178.270-11(d)(3) is acceptconnections. able. Each pump and all piping, hoses and [Amdt. 178-89. 54 FR 25032, June 12, 1989, as connections on each cargo tank motor amended at 55 FR 37065, Sept. 7, 1990: Amdt. vehicle must conform to $178.345-9, ex- 178-104, 59 FR 49135, Sept. 26, 1994. Redesigcept that the use of nonmetallic pipes, nated by Amdt. 178-112, 61 FR 18934, Apr. 29, 1996] valves, or connections are authorized on DOT 412 cargo tanks. § 178.348-5 Pressure and leakage test. [Amdt. 178-89, 55 FR 37065. Sept. 7. 1990. Re- (a) Each cargo tank must be tested in designated by Amdt. 178-112, 61 FR 18934, accordance with § 178.345-13 and this Apr. 29, 1996) section. (b) Pressure test. Test pressure must § 178.348-4 Pressure relief. be as follows: (a) Each cargo tank must be equipped (1) Using the hydrostatic test methwith a pressure and vacuum relief sysod, the test pressure must be at least tem in accordance with § 178.345-10 and 1.5 times MAWP. this section. (2) Using the pneumatic test method, (b) Type and construction. Vacuum rethe test pressure must be at least 1.5 lief devices are not required for cargo times tank MAWP, and the inspection tanks designed to be loaded by vacuum pressure is tank MAWP. or built to withstand full vacuum. [Amdt. 178-89, 54 FR 25032. June 12, 1989. Re- (c) Pressure settings of relief valves. designated by Amdt. 178-112, 61 FR 18934, The setting of the pressure relief de- Apr. 29, 1996] vices must be in accordance with § 178.345-10(d), except as provided in Subpart K-Specifications for paragraph (d)(3) of this section. Packagings for Class 7 (Ra- (d) Venting capacities. (1) The vacuum dioactive) Materials relief system must limit the vacuum to less than 80 percent of the design vacu- $ 178.350 Specification 7A; general um capability of the cargo tank. packaging, Type A. (2) If pressure loading or unloading (a) Each packaging must meet all apdevices are provided, the pressure relief plicable requirements of subpart B of system must have adequate vapor and part 173 of this subchapter and be deliquid capacity to limit tank pressure signed and constructed so that it meets to the cargo tank test pressure at the the requirements of 173.403, 173.410, maximum loading or unloading rate. 173.412, 173.415 and 173.465 of this sub- The maximum loading and unloading chapter for Type A packaging. rates must be included on the metal (b) Each Specification 7A packaging must be marked on the outside "USA specification plate. DOT 7A Type A." (3) Cargo tanks used in dedicated (c) Each Specification 7A packaging service for materials classed as corromust comply with the marking resive material, with no secondary hazquirements of $178.3. In paragraph ard, may have a total venting capacity 178.3(a)(2), the term "packaging manuwhich is less than required by 178.345- facturer" means the person certifying 10(e). The minimum total venting cathat the package meets all requirepacity for these cargo tanks must be ments of this section. determined in accordance with the formula contained in § 178.270-11(d) (3). Use [Amdt. 178-109, 60 FR 50336, Sept. 28, 1995; 60 FR 54409, Oct. 23, 1995, as amended at 69 FR of the approximate values given for the 3696, Jan. 26, 2004; 70 FR 56099, Sept. 23, 2005] 1000 Pipeline and Hazardous Materials Safety Admin., DOT § 178.356-2 § 178.356 Specification 20PF phenolicmaterial, are a part of this specificafoam insulated, metal overpack. tion. § 178.356-1 General requirements. [Amdt. 178-35, 39 FR 45247, Dec. 31, 1974. Redesignated by Amdt. 178-97. 55 FR 52716, Dec. (a) Each overpack must meet all of 21, 1990; 65 FR 58632, Sept. 29, 2000; 66 FR the applicable requirements of § 173.24 45386, 45389, Aug. 28, 2001: 68 FR 75757. Dec. 31, of this subchapter. 2003] (b) The maximum gross weight of the package, including the inner cylinder § 178.356-2 Materials of construction and its contents, must not exceed the and other requirements. following: (a) Phenolic foam insulation must be (1) Specification 20PF-1-138 kg (300 fire-resistant and fabricated in accordpounds). ance with USDOE Material and Equip- (2) Specification 20PF-2-320 kg (700 ment Specification SP-9, Rev. 1 and pounds). Supplement (IBR, see $171.7 of this sub- (3) Specification 20PF-3-455 kg (1000 chapter). which is a part of this specipounds). fication. (Note: Packagings manufac- (c) The general configuration of the tured under USAEC Specification SP-9 overpack must be a right cylinder, conand Rev. 1 thereto are authorized for sisting of an insulated base section, a continued manufacture and use.) A 13.7 steel liner lid, and an insulated top seccm (5.4-inch) minimum thickness of tion. The inner liner and outer shell foam must be provided over the entire must be at least 16-gauge and 18-gauge liner except: steel, respectively, with the inter- (1) Where wood spacers replace the vening cavity filled with a molded-infoam; or place, fire-resistant, phenolic-foam in- (2) At protrusions of liner or shell, sulation interspersed with wooden such as flanges, baffles, etc., where members for bracing and support Wood minimum insulation thickness is 9 cm pieces must be securely attached to (3.5 inches); or both the liner and shell. No hole is per- (3) Where alternate top section (specmitted in the liner. Each joint between ification 20PF-1) is used. Foam must sections must be stepped a minimum of 5 cm (2 inches) and gaps between matnot interfere with proper seating of ing surfaces must not exceed 5 mm (0.2 screws in inner liner flange assembly. inch). Gaps between foam surface of Average density of insulation must be top section and liner lid must not ex- 0.13 g/cc (8 pounds per cubic foot (pcf) ceed 1 cm (0.4 inch) or 5 cm (2 inches) minimum for bottom section and 0.16 g/ where taper is required for mold strip- CC (10 pcf) minimum for top section, exping. For the specification 20PF-1, the cept 0.1 g/cc (6.5 pcf) for the specificatop section may consist of a plug of tion 20PF-1 top section. foam insulation and a steel cover. The (b) Gaskets must be as follows: liner and shell closures must each be (1) Inner liner flange-Neoprene rubgasketed against moisture penetration. ber of 30 to 60 type A durometer hard- The liner must have a bolted flange ness or other equivalent gasket mateclosure. Shell closure must conform to rial which is compatible with the speparagraph (d) of this section. cific contents. (d) Drums over 5 gallons capacity (2) Outer shell-Synthetic rubber must be closed by means of 12-gauge conforming to MIL-R-6855 (available bolted ring with drop forged lugs, one from the Naval Publications Forms of which is threaded, and having 3/8 Center. 5801 Tabor Avenue, Philadelinch bolt and nut for drums not over 30 phia, Pennsylvania 19120) class 2, grade gallons capacity and 5/8 inch bolt and 60. nut for drums over 30 gallons capacity. (3) Support and pressure pads for Five gallon drums must be of lug type inner liner top and bottom must be closure with cover having at least 16 sponge rubber or equivalent. lugs. (c) Alternate top section (specifica- (e) Drawings in DOE CAPE-1662, Rev. tion 20PF-1 only). Average insulation 1 and Supplement 1 (IBR, see $171.7 of density must be 0.16 g/cc (10 pcf minthis subchapter), which include bills of imum). Thickness of plug must be 11 1001 $ 178.356-3 49 CFR Ch. I (10-1-06 Edition) cm (4.3 inches) minimum, except thickprior to installation. Seam welds of the ness may be reduced to 10 cm (4 inches) liner must be covered for a distance of to clear bolt heads. A flush mounted at least 15 cm (6 inches) on either side top lifting device must be securely fasof the seam with soapsuds, heavy oil, tened to a wood block encapsulated by or equivalent material, and interior air the foam. pressure applied to at least 776 mm Hg (d) Vent holes 5 mm (0.2-inch) diame- (15 p.s.i.g.) above atmospheric pressure ter must be drilled in the outer shell to must be held for at least 30 seconds. provide pressure relief during the insulation foaming and in the event of a Liners failing to pass this test may not fire. These holes, which must be drilled be used until repairs are made, and in all areas of the shell that mate with retests successfully passed. the foam insulation, must be spaced in (b) [Reserved] accordance with DOE CAPE-1662, Rev. [Amdt. 178-35, 39 FR 45247, Dec. 31, 1974. Re. 1 and Supplement 1 (IBR, see $171.7 of designated by Amdt. 178-97, 55 FR 52716, Dec. this subchapter). 21, 1990; 66 FR 45387, Aug. 28, 2001; 67 FR 61016, (e) Welding must be by a fusion weld- Sept. 27, 2002] ing process in accordance with American Welding Society Codes B-3.0 and § 178.356-4 Required markings. D-1.0 (IBR, see $171.7 of this sub- (a) Marking must be as prescribed in chapter). Body seams and joints for the § 178.3. liner or shell must be continuous welds. (b) Marking on the outside of each (f) Waterproofing. Each screw hole in overpack must be as follows: the outer shell must be sealed with ap- (1) "USA-DOT-20PF-1" or "-2," as appropriate resin-type sealing material, propriate, and if the entire liner is or equivalent, during installation of made of stainless steel, additional the screw. All exposed foam surfaces, marking such as "3041-SS" to indicate including any vent hole, must be sealed the type of stainless steel used. with waterproofing material as pre- (2) "TARE WT: XXX lbs." where XXX is scribed in USDOE Material and Equipthe tare weight of the assembled overment Specification SP-9, Rev. 1 and pack without the inner container. Supplement, or equivalent. (3) Year of manufacture. [Amdt. 178-35, 39 FR 45247. Dec. 31, 1974, as [Amdt. 178-35, 39 FR 45247, Dec. 31, 1974. Reamended by Amdt. 178-56, 44 FR 49458, Aug. 23, 1979. Redesignated by Amdt. 178-97, 55 FR designated by Amdt. 178-97. 55 FR 52716, Dec. 52716, Dec. 21, 1990; 66 FR 45387, Aug. 28, 2001; 21, 1990, as amended at 63 FR 37462, July 10. 68 FR 75757, Dec. 31, 2003] 1998] § 178.356-3 Tests. § 178.356-5 Typical assembly detail. (a) Leakage test-Each inner liner (a) Specifications 20PF-1. assembly must be tested for leakage 1002 Pipeline and Hazardous Materials Safety Admin., DOT § 178.356-5 12" DIA 16 GA. STEEL COVER FLUSH LIFTING RING CLOSING RING, BOLT of WOOD BLOCKS 1/4 STEEL PLATE NEOPRENE GASKET 10 DIA SPONGE RUBBER 4 PHENOLIC FOAM 48 36" 16. GA. STEEL IS GAGE STEEL DRUM 21" = 5"Ф CYLINDER 2 is DIA MEOPRENE PAD " GAGE STEEL 5"- 3" 4 22 T " INSIDE DIA. WOOD SPACERS (b) Specification 20PF-2. 1003 § 178.356-5 49 CFR Ch. I (10-1-06 Edition) NOTCHED WOOD SPACER BLOCKS 2 16 GA, STEEL 6" 16 STEEL R. E In BOLT TYPE 1" # CLOSING RING 3 3'4" SPONGE RUBBER GASKET LIFTING LUG WOOD BLOCK 5'- 5'-9' - INSIDE HEIGHT 18 GA. STEEL SHELL 16 GA. STEEL LINER 9 into I.D. 8 6 " FIRE RESISTANT PHENOLIC FOAM II GA. STEEL PL = NOTCHED WOOD SPACER BLOCKS REF. - 10 2 1.D. (c) Specification 20PF-3. 1004 Pipeline and Hazardous Materials Safety Admin., DOT § 178.356-5 NOTCHED WOOD SPACER BLOCKS 16 GA. STEEL in STEEL L 16 I GASKET into SPONGE RUBBER BOLT TYPE CLOSING RING LIFTING LUG WOOD BLOCK 18 GA. STEEL DRUM IS GA. STEEL LINER 4'-11" INSIDE HEIGHT 1-1/- INSIDE DIA. 5 be FIRE RESISTANT PHENOLIC FOAM # GA. STEEL 2 NOTCHED WOOD SPACER BLOCKS REF. 2'-0" INSIDE DIA. [Amdt. 178-35, 39 FR 45247, Dec. 31, 1974. Redesignated by Amdt. 178-97. 55 FR 52716, Dec. 21, 1990] 1005 § 178.358 49 CFR Ch. I (10-1-06 Edition) § 178.358 Specification 21PF fire and (d) Specification 21PF-1 overpacks in shock resistant, phenolic-foam insuuse or under construction before April lated, metal overpack. 1. 1989, must be modified to Specification 21PF-IA before April 1, 1991. All § 178.358-1 General requirements. new construction to Specification (a) Each overpack must meet all of 2IPF-1 beginning after March 31, 1989. the applicable requirements of §§ 173.24, must meet Specification 21PF-1B. Use 173.411, and 173.412 of this subchapter. of unmodified 21PF-1 overpacks after (1) Specification 21PF-1 overpacks in- March 31, 1991, is prohibited. cludes the series of 21PF-1, 21PF-1A, [Amdt. 178-35, 39 FR 45250, Dec. 31, 1974; 40 FR and 21PF-1B models. Details of the 2435, Jan. 13, 1975, as amended by Amdt. 178- three models are included in DOE 90, 53 FR 36551. Sept. 20, 1988. Redesigntated CAPE-1662, Rev. 1 and Supplement 1 by Amdt. 178-97, 55 FR 52716, Dec. 21, 1990; 66 (IBR, see $171.7 of this subchapter). FR 45387, Aug. 28, 2001; 68 FR 75757, Dec. 31, (2) Drawings in CAPE-1662, Rev. 1 and 2003] Supplement 1, that include bills of ma- § 178.358-2 Materials of construction terials, and KSS-471 (IBR, see $171.7 of and other requirements. this subchapter), are a part of this specification. (a) Phenolic foam insulation must be (b) Each overpack is authorized for fire resistant and fabricated in accorduse in applications where the maxance with USDOE Material and Equipimum gross weight of the package, inment Specification SP-9, Rev. 1 and cluding the inner container and con- Supplement (IBR, see $171.7 of this subtents does not exceed 3725 kg (8200 chapter), which is a part of this specipounds), (horizontally-loaded specificafication. (Note: Packagings manufaction 21 PF-1 unit), or 3900 kg (8600 tured under USAEC Specification SP-9, pounds). (end-loaded specification 21 and Rev. 1 thereto are authorized for PF-2 unit). continued manufacture and use.) A 14 (c) The general configuration of the cm (5.5-inch) minimum thickness of overpack must be a right cylinder, confoam must be provided over the entire sisting of a steel inner liner (at least liner except where: 16-gauge) and steel outer shell (at least (1) Wood spacers replace the foam 14-gauge) with the intervening cavity material; or filled with a molded-in-place, fire-re- (2) At protrusions of liner or shell, sistant, phenolic foam insulation and such as flanges, baffles, etc., where the interspersed wooden members for bracminimum thickness of foam, wood, or a ing and support. Two specific configucombination of these is 10 cm (4 rations are authorized; a horizontal inches). loading unit (specification 21PF-1) con- (3) Solid wood or laminated wood solsisting of insulated base and top secidly glued may be used to replace the tions jointed in a longitudinal periphfoam between liner and shell (i.e., in eral closure joint; or an end-loading ends of overpack). In this case, minunit (specification 21PF-2), consisting imum wood thickness is 10 cm (4 of an insulated main section, a steel inches). Average density of insulation plate liner lid, and an insulated end must be 0.1g/cc (6.75 pounds per cubic cap. For either type each joint between foot (pcf)) minimum, except that 0.13 g/ sections must be stepped at least 1.8 CC (8 pcf) is required in the removable cm (0.75-inch) and gaps between mating end cap of the specification 21PF-2, surfaces may not exceed 5 mm (0.2- which must have a minimum foam inch). Bolted closures, which must each thickness of 12.7 cm (5 inches). be gasketed against moisture penetra- (b) Gaskets for inner liner, outer tion, must be in accordance with shell, or where otherwise specified in CAPE-1662. Each bolt must be equipped DOE CAPE-1662, Rev. 1 (IBR, see $171.7 with a locking device to prevent loosof this subchapter). must be as speciening from vibration. Outer steel bracfied in DOE CAPE-1662, Rev. 1. ing and support framework must be at- (c) Support and pressure pads for the tached to the shell to facilitate normal inner liner must be of neoprene, sponge handling. rubber, or equivalent. 1006 Pipeline and Hazardous Materials Safety Admin., DOT § 178.358-3 (d) Fire-retardant (intumescent) 1662, Revision 1, Supplement 1. for locapaint must be applied to any wood tions. blocking which is located at any joint (2) Weigh each packaging element in the shell. (top and bottom halves) separately to (e) Vent holes 5 mm (0.2-inch) diamean accuracy of +2.3 kg (+5 pounds) and ter must be drilled in the outer shell to record the weights. If this measured provide pressure relief during the insuweight exceeds the initially measured lation foaming and in the event of a weight at the time of fabrication by fire. These holes, which must be drilled in all areas of the shell which made 11.3 kg (25 pounds) (indicating a signifiwith the foam insulation, must be cant retained water content), the packspaced in accordance with CAPE-1662. aging element must be dried. (f) Welding must be by a fusion proc- (3) Place overpack element in drying ess in accordance with the American oven; maintain temperature between Welding Society Codes B-3.0 and D-1.0 87.8-98.9 °C (190° and 210 °F) for a min- (IBR, see $171.7 of this subchapter). imum of 72 hours. The oven should Body seams and joints for the liner and have a provision for air exchange or shell must be continuous welds. other means of removing moisture (g) Waterproofing. Each screw hole in driven from the foam structure. the outer shell must be sealed with ap- (4) Drying may be discontinued after propriate resin-type sealing material, 72 hours if the weight of the packaging or equivalent, during installation of element does not exceed the initially the screw. All exposed foam surfaces, measured tare weight of that element including any vent hole, must be sealed at the time of fabrication by more than with either: 11.3 kg (25 pounds). If the weight of the (1) Waterproofing material as prepackaging element exceeds the initial scribed in USDOE Material and Equipfabricated weight (indicating a signifiment Specification SP-9, Rev. 1 and cant remaining water content) by more Supplement. or than 11.3 kg (25 pounds), drying must (2) As specified in CAPE-1662, Revibe continued until the weight differension 1. tial is not higher than 11.3 kg (25 [Amdt. 178-35, 39 FR 45250, Dec. 31, 1974, as pounds), or until the rate of weight loss amended by Amdt. 178-56, 44 FR 49459, Aug. is less than 1.1 kg (2.5 pounds) per day. 23, 1979; Amdt. 178-90, 53 FR 36551, Sept. 20, (5) As an alternate moisture meas- 1988. Redesigntated by Amdt. 178-97, 55 FR urement, a calibrated moisture meter 52716, Dec. 21. 1990; 66 FR 45387, Aug. 28, 2001; 68 FR 75757. Dec. 31, 2003] reading for 20 percent maximum water content may be used to indicate an end § 178.358-3 Modification of Specificapoint in the drying cycle, which is detion 21PF-1 overpacks. tailed in report "Renovation of DOT (a) Each Specification 21PF-1 over- Specification 21PF-1 Protective Shippack for which construction began or ping Packages," Report No. K-2057, Rewas completed before April 1, 1989, in vision 1, November 21, 1986, available conformance with drawing E-S-31536-J, from the USDOE and part of USDOE Rev. 1 of DOE CAPE-1662 (IBR, see Report No. KSS-471 (IBR, see $171.7 of $171.7 of this subchapter). must be this subchapter). modified in conformance with drawing (6) Following drying, each overpack SIE-31536-J1-D of DOE CAPE-1662, element (top and bottom halves) must Rev. 1, Supplement 1, before April 1, be weighed and the weight in both 1991. pounds and kilograms must be en- (b) Each such existing Specification graved on the identification plate re- 21PF-1 overpack must be dried and quired by § 178.358-5(c). weighed in accordance with the fol- (c) After modification as provided for lowing procedures: herein, each Specification 21PF-1 over- (1) Drill out or otherwise clean the pack must be marked "USA-DOT-21PFplug material from the vent holes originally provided for foam expansion. See drawing S1E-31536-J1-D of CAPE- 1007 178.358-4 49 CFR Ch. I (10-1-06 Edition) 1A". See the marking requirements of (2) For Specification 21PF-1 and $178.358-5. 21PF-2 only, "TARE WT: *** lbs. [Amdt. 178-90. 53 FR 36551, Sept. 20, 1988. (* * kg)" where *** is the tare Redesigntated by Amdt. 178-97, 55 FR 52716, weight in pounds and kilograms, re- Dec. 21, 1990; Amdt. 178-110, 60 FR 49111, Sept. spectively, of the assembled overpack 21, 1995; 63 FR 37462, July 10, 1998; 66 FR 45389, without the inner product container. Aug. 28, 2001; 68 FR 75757, Dec. 31, 2003] (3) For Specification 21PF-1A and § 178.358-4 Construction of Specifica- 21PF-1B only: "TARE WT. of Cover: tion 21PF-1B overpacks. *** lbs (* kg) TARE WT. of BOT- TOM: *** lbs kg)" where (a) Each Specification 21PF-1 overpack for which construction began *** is the tare weight in pounds and after March 31, 1989, must meet the rekilograms, respectively, of the sepaquirements of Specification 21PF-1B, rate halves of the overpack without the in conformance with drawings E-S- inner product container. For Specifica- 31536-J-P, and S1E-31536-J2-B of DOE tion 21PF-1A overpacks, the previous CAPE-1662, Rev. 1, Supplement 1 (IBR, tare weight must be changed to reflect see $171.7 of this subchapter). the modified tare weight value or must (b) With the exception of the closure be covered or removed. nuts and bolts, all metal parts of the (4) Year of manufacture followed by Specification 21PF-1B must be of stainthe year of modification, if applicable. less steel as shown on the drawings re- (5) The name or symbol of maker or ferred to in paragraph (a) of this secparty certifying compliance with specition. fication requirements. A symbol, if [Amdt. 178-90, 53 FR 36551, Sept. 20, 1988. used, must be registered with the Asso- Redesigntated by Amdt. 178-97. 55 FR 52716, ciate Administrator. Dec. 21, 1990; 68 FR 75757, Dec. 31, 2003) (c) For Specification 21PF-1A and -1B only. the markings required by this § 178.358-5 Required markings. section must be affixed to each over- (a) Markings must be as prescribed in pack by inscription upon a metal iden- $178.3. tification plate 11 inches wide X 15 (b) Specification marking on the outinches long (28 cm X 38 cm). fabricated side of each overpack must be as folof 16 to 20 gauge stainless steel sheet, lows: "USA-DOT-21PF-1", "1A", "1B", ASTM A-240/A 240M (IBR, see $171.7 of or "2", as appropriate. this subchapter), Type 304L. (1) For Specifications 21PF-1 and 21PF-2 only, if the inner shell is con- [Amdt. 178-90, 53 FR 36552, Sept. 20, 1988. structed of stainless steel, additional Redesigntated by Amdt. 178-97. 55 FR 52716, Dec. 21. 1990, and amended at Amdt. 178-97, 56 marking such as "304L-SS" are to be FR 66287, Dec. 20, 1991; 63 FR 37462, July 10. marked on the outside of the overpack 1998; 66 FR 45386, Aug. 28, 2001; 67 FR 51660. to indicate the type of stainless steel Aug. 8, 2002; 68 FR 75748, Dec. 31, 2003; 69 FR used. 54046, Sept. 7. 2004] 178.358-6 Typical assembly detail. (a) Specification 21PF-1 (horizontal loading overpack). 1008 Pipeline and Hazardous Materials Safety Admin., DOT § 178.358-6 14 GA STEEL 16 GA. STEEL FIRE RESISTANT RUBBER PADS ANGLE STIFFENERS PHENOLIC FOAM INSIDE DIA CLOSURE BOLTS 14 GA. STEEL 3'-7" 7" INSIDE as GASKETS LAMINATED WOOD T-6% BASE SUPPORT I 6'-10'," 1-1" (b) Specification 21PF-1A and 21PF-1B (horizontal loading overpack). 1009 1010 (c) Specification 21PF-2 (end loading overpack). OVERPACK OVERPACK DOT SPECIFICATION 21PF-1B DOT SPECIFICATION 21PF-1A DETAIL INIOT JOINT DETAIL Jill NEW 07 LNIOP JELS MEMOT TESTS CARSON STEEL CARBON STEEL STAINLESS STEEL (3018.(no) 000AL (30%) COOM (3015 100) (3015) 073M WES STEEL COVER 073M 013M STEEL COVERS 0134 HOURS MEN HIGHT IVES 1V38 SERVICES 13NSVD TV38 S13XSV9 MEN 1 MEN LIVE 000M 13315 13315 NORMY3 STAINLESS STEEL 13318 SSE 000M 1 alls as #3ddlt OVERPACK OVERPACK DOT SPECIFICATION 21PF-1B DOT SPECIFICATION 21PF-1A SECTION SECTION -1-1 1804403 3348 W130 333 2'-8-%" 000A 31300 TIMES Leage 338 ves MISM 1'- L INSIDE DIA. TEELS VS 21 MYOI SUBMITTED 37SNV seve UNITED FIRE RESISTANT TELLS wa 91. THE vs #1 49 CFR Ch. I (10-1-06 Edition) § Pipeline and Hazardous Materials Safety Admin., DOT § 178.358-6 '," MEDPRENE '," COVER FL WOOD BLOCK ',," , 2 CAP '." RUBBER GASKET 5.1/1" FIRE RESISTANT PHENOLIC FOAM 6" c SCH 40 PIPE 3'-7" O.D. CONTAINER 2'-7-'," INSIDE DIA. 16 GA. SHEET METAL 14 GA. SHEET METAL 7'-2%" OUTER SHELL 5'-4" 6'-10%" TOP TO BOTOM INNER CONTAINER MEDPRENE CORNER BUMPER y MEDPRENE %" SHEET METAL LAMINATED WOOD 2-3"C's 4.1 * # 2" * SCH. 40 PIPE [Amdt. 178-90, 53 FR 36552, Sept. 20, 1988. Redesignated by Amdt. 178-97, 55 FR 52716, Dec. 21, 1990] 1011 § 178.360 49 CFR Ch. I (10-1-06 Edition) § 178.360 Specification 2R; inside con- $ 178.360-2 Manufacture. tainment vessel. The ends of the vessel must be fitted § 178.360-1 General requirements. with screw-type closures or flanges (see 178.360-4). except that one or both (a) Each vessel must be made of ends of the vessel may be permanently stainless steel, malleable iron, or brass, closed by a welded or brazed plate. or other material having equivalent Welded or brazed side seams are auphysical strength and fire resistance. thorized. (b) Each vessel must meet all of the [Amdt. 178-35, 39 FR 45245, Dec. 31, 1974. Reapplicable requirements of § 173.24 (c) designated by Amdt. 178-97, 55 FR 52716, Dec. and (d) of this subchapter. Letters and 21, 1990, as amended at 63 FR 37462, July 10, numerals at least 6 mm (1/4-inch) in 1998] height are authorized for the marking § 178.360-3 Dimensions. of a vessel not exceeding 5 cm (2 inches) inside diameter. (a) The inside diameter of the vessel may not exceed 30 cm (12 inches) exclu- [Amdt. 178-35, 39 FR 45245, Dec. 31, 1974. Resive of flanges for handling or fastening designated by Amdt. 178-97, 55 FR 52716, Dec. devices and must have wall thickness 21, 1990; 66 FR 45387. Aug. 28, 2001] and length in accordance with the following: Inside diameter Threaded closure Length maximum maximum Wall thickness minimum-Flanged closure Inches Mm Inches Cm Inches Cm 2 5 3/3z 2.5 Not less than that prescribed for schedule 40 pipe 16 41 6 15 1/8 3.2 72 183 12 30 1/4 6.5 72 183 (b) [Reserved] [Amdt. 178-35, 39 FR 45245. Dec. 31, 1974. Redesignated by Amdt. 178-97. 55 FR 52716, Dec. 21, 1990; 66 FR 45387, Aug. 28, 2001] § 178.360-4 Closure devices. § 171.7 of this subchapter). A torque (a) Each closure device must be as wrench must be used in securing the follows: flange with a corresponding torque of no more than twice the force necessary (1) Screw-type cap or plug: number of threads per inch must not be less than to seal the selected gasket. Gasket ma- United States standard pipe threads terial must be capable of withstanding and must have sufficient length of up to 149 °C (300 °F) without loss of effithread to engage at least 5 threads ciency. The flange, whether of ferrous when securely tightened. Pipe threads or nonferrous metal, must be conmust be luted with an appropriate nonstructed from the same metal as the hardening compound which must be cavessel and must meet the dimensional pable of withstanding up to 149 °C (300 and fabrication specifications for weld- °F) without loss of efficiency. Tighted construction as follows: ening torque must be adequate to (i) Pipe flanges described in Tables maintain leak tightness with the spe- 13, 14, 16, 17, 19, 20, 22, 23, 25 and 26 of cific luting compound. ANSI B16.5 (IBR, see $171.7 of this sub- (2) An opening may be closed by a sechapter). curely bolted flange and leak-tight gas- (ii) For nominal pipe sizes, 6, 8, 10, ket. Each flange must be welded or and 12 inches, AWWA Standard C207-55, brazed to the body of the 2R vessel per Table 1, class B, may be used in place (ANSI) Standard B16.5 or (AWWA) of the tables prescribed by paragraph Standard C207-55, section 10 (IBR, see (a)(2)(i) of this section. 1012 Pipeline and Hazardous Materials Safety Admin., DOT $ 178.503 (iii) Sizes under 6 inches, nominal AWWA C207-55, Table 1, class B, may pipe size, the following table with the be used in place of paragraph (a)(2)(i) of same configuration as illustrated in this section. Nominal pipe size Flange O.D. Number Bolt circle diameter Diameter of bolts Flange thickness Inches Cm Inches Cm of bolts Inches Cm Inches Cm Inches Cm 2 5 6 15 4 4% 11.8 ½ 1.2 % 1.6 2½ 6.2 7 17.5 4 51/2 13.8 1/2 % 3 7.5 7½ 18.8 4 6 15 ½ % 3½ 8.8 81/2 21.3 8 7 17.5 ½ % 4 10 9 22.5 8 7½ 18.8 ½ 5/8 5 12.6 10 25.4 8 8½ 21.3 ½ % (iv) Cast iron flanges prohibited. (iii) "C" means natural wood. (b) [Reserved] (iv) "D" means plywood. [Amdt. 178-35. 39 FR 45245, Dec. 31, 1974; 40 FR (v) "F" means reconstituted wood. 2435. Jan. 13, 1975, as amended at 40 FR 44327. (vi) "G" means fiberboard. Sept. 26, 1975. Redesignated by Amdt. 178-97. (vii) "H" means plastic. 56 FR 66284, Dec. 20, 1991; 68 FR 75757, Dec. 31, (viii) "L" means textile. 2003) (ix) "M" means paper, multi-wall. Subpart L-Non-bulk (x) "N" means metal (other than Performsteel or aluminum). ance-Oriented Packaging (xi) "P" means glass, porcelain or Standards stoneware. (3) A numeral indicating the category SOURCE: Amdt. 178-97, 55 FR 52717, Dec. 21, of packaging within the kind to which 1990, unless otherwise noted. the packaging belongs. For example, for steel drums ("1A"). "1" indicates a § 178.500 Purpose, scope and definitions. non-removable head drum (i.e., "1A1") and "2" indicates a removable head (a) This subpart prescribes certain redrum (i.e., "1A2"). quirements for non-bulk packagings for (b) For composite packagings, two hazardous materials. Standards for capital letters are used in sequence in these packagings are based on the UN the second position of the code, the Recommendations. first indicating the material of the (b) Terms used in this subpart are deinner receptacle and the second, that of fined in $171.8 of this subchapter. the outer packaging. For example, a § 178.502 Identification codes for packplastic receptacle in a steel drum is agings. designated "6HA1". (c) For combination packagings, only (a) Identification codes for desigthe code number for the outer packnating kinds of packagings consist of aging is used. the following: (d) Identification codes are set forth (1) A numeral indicating the kind of packaging, as follows: in the standards for packagings in (i) "1" means a drum. §§ 178.504 through 178.523 of this sub- (ii) "2" means a wooden barrel. part. (iii) "3" means a jerrican. [Amdt. 178-97, 55 FR 52717. Dec. 21, 1990, as (iv) "4" means a box. amended by Amdt. 178-106, 59 FR 67519, Dec. (v) "5" means a bag. 29, 1994] (vi) "6" means a composite packaging. § 178.503 Marking of packagings. (vii) "7" means a pressure receptacle. (a) A manufacturer must mark every (2) A capital letter indicating the packaging that is represented as manumaterial of construction, as follows: factured to meet a UN standard with (i) "A" means steel (all types and the marks specified in this section. The surface treatments). markings must be durable, legible and (ii) "B" means aluminum. placed in a location and of such a size 1013 § 178.503 49 CFR Ch. I (10-1-06 Edition) relative to the packaging as to be readimal but may be omitted when the speily visible, as specified in $178.3(a). Excific gravity does not exceed 1.2; and cept as otherwise provided in this sec- (ii) For packagings intended to contion, every reusable packaging liable tain solids or inner packagings, the to undergo a reconditioning process designation shall be the maximum which might obliterate the packaging gross mass in kilograms; marks must bear the marks specified (5)(i) For single and composite packin paragraphs (a)(1) through (a)(6) and agings intended to contain liquids, the (a) of this section in a permanent test pressure in kilopascals rounded form (e.g. embossed) able to withstand down to the nearest 10 kPa of the hythe reconditioning process. A marking drostatic pressure test that the packmay be applied in a single line or in aging design type has successfully multiple lines provided the correct sepassed; quence is used. As illustrated by the (ii) For packagings intended to conexamples in paragraph (e) of this sectain solids or inner packagings, the lettion, the following information must ter "S"; be presented in the correct sequence. Slash marks should be used to separate (6) The last two digits of the year of this information. A packaging conmanufacture. Packagings of types 1H and 3H shall also be marked with the forming to a UN standard must be marked as follows: month of manufacture in any appropriate manner; this may be marked on (1) The United Nations symbol as ilthe packaging in a different place from lustrated in paragraph (e) (1) of this secthe remainder of the markings; tion (for embossed metal receptacles. (7) The state authorizing allocation the letters UN may be applied in place of the mark. The letters 'USA' indicate of the symbol); that the packaging is manufactured (2) A packaging identification code and marked in the United States in designating the type of packaging, the compliance with the provisions of this material of construction and, when apsubchapter; propriate, the category of packaging under $$178.504 through 178.523 of this (8) The name and address or symbol subpart within the type to which the of the manufacturer or the approval packaging belongs. The letter "V" agency certifying compliance with submust follow the packaging identificapart L and subpart M of this part. tion code on packagings tested in ac- Symbols, if used, must be registered with the Associate Administrator; cordance with §178.601(g)(2); for example, "4GV". The letter "W" must fol- (9) For metal or plastic drums or low the packaging identification code jerricans intended for reuse or recondion packagings when required by an aptioning as single packagings or the proval under the provisions of outer packagings of a composite pack- $ 178.601(h) of this part; aging, the thickness of the packaging (3) A letter identifying the performmaterial, expressed in mm (rounded to the nearest 0.1 mm). as follows: ance standard under which the packaging design type has been successfully (i) Metal drums or jerricans must be tested, as follows: marked with the nominal thickness of (i) X-for packagings meeting Packthe metal used in the body. The marked nominal thickness must not ing Group I, II and III tests; exceed the minimum thickness of the (ii) Y-for packagings meeting Packsteel used by more than the thickness ing Group II and III tests; or tolerance stated in ISO 3574 (IBR, see (iii) Z-for packagings only meeting $171.7 of this subchapter). (See appen- Packing Group III tests; dix C of this part.) The unit of measure (4) A designation of the specific gravis not required to be marked. When the ity or mass for which the packaging denominal thickness of either head of a sign type has been tested, as follows: metal drum is thinner than that of the (i) For packagings without inner body, the nominal thickness of the top packagings intended to contain liquids, head, body, and bottom head must be the designation shall be the specific marked (e.g., "1.0-1.2-1.0" or "0.9-1.0- gravity rounded down to the first dec- 1.0"). 1014 Pipeline and Hazardous Materials Safety Admin., DOT § 178.503 (ii) Plastic drums or jerricans must appear on the top head or the side of be marked with the minimum thickthe metal drum, the reconditioner ness of the packaging material. Minmust apply them in a durable form folimum thicknesses of plastic must be as lowed by the markings in paragraph determined in accordance with (c)(1) of this section. These markings § 173.28(b) The unit of measure is not may identify a different performance required to be marked; capability than that for which the (10) In addition to the markings preoriginal design type had been tested scribed in paragraphs (a)(1) through and marked, but may not identify a (a) of this section, every new metal greater performance capability. The drum having a capacity greater than markings applied in accordance with 100 L must bear the marks described in this paragraph may be different from paragraphs (a)(1) through (a)(6), and those which are permanently marked (a)(9)(i) of this section, in a permanent on the bottom of a drum in accordance form, on the bottom. The markings on with paragraph (a)(10) of this section. the top head or side of these pack- (d) Marking of remanufactured packagings need not be permanent, and agings. For remanufactured metal need not include the thickness mark drums, if there is no change to the described in paragraph (a)(9) of this packaging type and no replacement or section. This marking indicates a removal of integral structural compodrum's characteristics at the time it nents, the required markings need not was manufactured, and the information be permanent (e.g., embossed). Every in paragraphs (a)(1) through (a) of other remanufactured drum must bear this section that is marked on the top the marks required in paragraphs (a)(1) head or side must be the same as the through (a)(6) of this section in a perinformation in paragraphs (a)(1) manent form (e.g., embossed) on the through (a)(6) of this section permatop head or side. If the metal thickness nently marked by the original manumarking required in paragraph (a)(9)(i) facturer on the bottom of the drum; of this section does not appear on the and bottom of the drum, or if it is no (11) Rated capacity of the packaging longer valid, the remanufacturer also expressed in liters may be marked. must mark this information in perma- (b) For a packaging with a removable nent form. head, the markings may not be applied (e) The following are examples of only to the removable head. symbols and required markings: (c) Marking of reconditioned pack- (1) The United Nations symbol is: agings. (1) If a packaging is reconditioned, it shall be marked by the reconditioner near the marks required in paragraphs (a)(1) through (6) of this section with the following additional information: (i) The name of the country in which the reconditioning was performed (in the United States, use the letters "USA"); (ii) The name and address or symbol of the reconditioner. Symbols, if used, must be registered with the Associate Administrator; (iii) The last two digits of the year of reconditioning; (iv) The letter "R"; and (v) For every packaging successfully passing a leakproofness test, the additional letter "L". (2) Examples of markings for a new (2) When, after reconditioning, the packaging are as follows: markings required by paragraph (a)(1) (i) For a fiberboard box designed to through (a)(5) of this section no longer contain an inner packaging: 1015 § 178.504 49 CFR Ch. I (10-1-06 Edition) must be durable, legible, and must be readily visible, as specified in $178.3(a). DC u 4G/Y145/S/83 An infectious substance packaging that successfully passes the tests conforming to the UN standard must be marked as follows: n (1) The United Nations symbol as il- USA/RA lustrated in paragraph (e) of this section. (2) The code designating the type of (as in $178.503 (a)(1) through (a)(9) of packaging and material of constructhis subpart). tion according to the identification (ii) For a steel drum designed to concodes for packagings specified in tain liquids: $178.502. (3) The text "CLASS 6.2". (4) The last two digits of the year of manufacture of the packaging. 1A1/Y1.4/150/83 (5) The country authorizing the alloun cation of the mark. The letters "USA" indicate the packaging is manufac- USA/VL824 tured and marked in the United States in compliance with the provisions of this subchapter. 1.0 (6) The name and address or symbol of the manufacturer or the approval (as in $178.503 (a) through (a)(10) of agency certifying compliance with subthis subpart). parts L and M of this part. Symbols, if (iii) For a steel drum to transport used, must be registered with the Assosolids or inner packagings: ciate Administrator for Hazardous Materials Safety. (7) For packagings meeting the re- 1A2/Y150/S/83 quirements of $178.609(i)(3), the letter Un "U" must be inserted immediately following the marking designating the type of packaging and material re- USA/VL825 quired in paragraph (f)(2) of this section. [Amdt. 178-97. 55 FR 52717, Dec. 21, 1990, as amended at 56 FR 66284, Dec. 20, 1991: Amdt. (as in $178.503 (a)(1) through (a)(8) of 178-102, 59 FR 28493, June 2, 1994; Amdt. 178- this subpart). 106, 59 FR 67520, 67521. Dec. 29, 1994; Amdt. (3) Examples of markings for recondi- 178-107, 60 FR 26806, May 18, 1995; 62 FR 51561, tioned packagings are as follows: Oct. 1, 1997; 66 FR 45386, Aug. 28, 2001; 67 FR 61016, Sept. 27, 2002; 67 FR 53143. Aug. 14, 2002; 68 FR 75757, Dec. 31, 2003] 1A1/Y1.4/150/92 u § 178.504 Standards for steel drums. USA/RB/93 RL (a) The following are identification codes for steel drums: n (1) 1A1 for a non-removable head steel drum; and (2) 1A2 for a removable head steel (as in § 178.503(c)(1)). drum. (f) A manufacturer must mark every (b) Construction requirements for UN specification package represented steel drums are as follows: as manufactured to meet the require- (1) Body and heads must be conments of $178.609 for packaging of instructed of steel sheet of suitable type fectious substances with the marks and adequate thickness in relation to specified in this section. The markings the capacity and intended use of the 1016 Pipeline and Hazardous Materials Safety Admin., DOT $ 178.505 drum. Minimum thickness and mark- (9) Maximum net mass: 400 kg (882 ing requirements in $$173.28(b)(4) and pounds). 178.503(a)(9) of this subchapter apply to [Amdt. 178-97, 55 FR 52717. Dec. 21. 1990, as drums intended for reuse. amended at 56 FR 66284, Dec. 20, 1991; Amdt. (2) Body seams must be welded on 178-110, 60 FR 49111. Sept. 21, 1995) drums designed to contain more than 40 L (11 gallons) of liquids. Body seams $ 178.505 Standards for aluminum drums. must be mechanically seamed or welded on drums intended to contain only (a) The following are the identificasolids or 40 L (11 gallons) or less of liqtion codes for aluminum drums: uids. (1) 1B1 for a non-removable head alu- (3) Chimes must be mechanically minum drum; and (2) 1B2 for a removable head aluseamed or welded. Separate reinforcing minum drum. rings may be applied. (b) Construction requirements for (4) The body of a drum of a capacity aluminum drums are as follows: greater than 60 L (16 gallons) may have (1) Body and heads must be conat least two expanded rolling hoops or structed of aluminum at least 99 pertwo separate rolling hoops. If there are cent pure or an aluminum base alloy. separate rolling hoops, they must be Material must be of suitable type and fitted tightly on the body and so seadequate thickness in relation to the cured that they cannot shift. Rolling capacity and the intended use of the hoops may not be spot-welded. drum. Minimum thickness and mark- (5) Openings for filling, emptying and ing requirements in $173.28(b)(4) and venting in the bodies or heads of non- 178.503(a)(9) of this subchapter apply to removable head (1A1) drums may not drums intended for reuse. exceed 7.0 cm (3 inches) in diameter. (2) All seams must be welded. Chime Drums with larger openings are considseams, if any, must be reinforced by ered to be of the removable head type the application of separate reinforcing (1A2). Closures for openings in the bodrings. ies and heads of drums must be SO de- (3) The body of a drum of a capacity signed and applied that they will regreater than 60 L (16 gallons) may have main secure and leakproof under norat least two expanded rolling hoops or mal conditions of transport. Closure two separate rolling hoops. If there are separate rolling hoops, the hoops must flanges may be mechanically seamed or be fitted tightly on the body and so sewelded in place. Gaskets or other sealcured that they cannot shift. Rolling ing elements must be used with clohoops may not be spot-welded. sures unless the closure is inherently (4) Openings for filling, emptying, or leakproof. venting in the bodies or heads of non- (6) Closure devices for removable removable head (1B1) drums may not head drums must be so designed and exceed 7.0 cm (3 inches) in diameter. applied that they will remain secure Drums with larger openings are considand drums will remain leakproof under ered to be of the removable head type normal conditions of transport. Gas- (1B2). Closures for openings in the bodkets or other sealing elements must be ies and heads of drums must be so deused with all removable heads. signed and applied that they will re- (7) If materials used for body, heads, main secure and leakproof under norclosures, and fittings are not in themmal conditions of transport. Closure selves compatible with the contents to flanges may be welded in place so that be transported, suitable internal prothe weld provides a leakproof seam. tective coatings or treatments must be Gaskets or other sealing elements applied. These coatings or treatments must be used with closures unless the must retain their protective properties closure is inherently leakproof. (5) Closure devices for removable under normal conditions of transport. head drums must be so designed and (8) Maximum capacity of drum: 450 L applied that they remain secure and (119 gallons). drums remain leakproof under normal conditions of transport. Gaskets or 1017 § 178.506 49 CFR Ch. I (10-1-06 Edition) other sealing elements must be used (5) Closure devices for removable with all removable heads. head drums must be so designed and (6) Maximum capacity of drum: 450 L applied that they remain secure and (119 gallons). drums remain leakproof under normal (7) Maximum net mass: 400 kg (882 conditions of transport. Gaskets or pounds). other sealing elements must be used [Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, as with all removable heads. amended at 56 FR 66284, Dec. 20, 1991; Amdt. (6) Maximum capacity of drum: 450 L 178-102, 59 FR 28494, June 2, 1994] (119 gallons). (7) Maximum net mass: 400 kg (882 § 178.506 Standards for metal drums pounds). other than steel or aluminum. (a) The following are the identifica- [Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, as tion codes for metal drums other than amended at 56 FR 66285, Dec. 20, 1991; Amdt. 178-102, 59 FR 28494, June 2, 1994] steel or aluminum: (1) 1N1 for a non-removable head § 178.507 Standards for plywood metal drum; and drums. (2) 1N2 for a removable head metal drum. (a) The identification code for a plywood drum is 1D. (b) Construction requirements for metal drums other than steel or alu- (b) Construction requirements for minum are as follows: plywood drums are as follows: (1) Body and heads must be con- (1) The wood used must be well-seastructed of metal (other than steel or soned, commercially dry and free from aluminum) of suitable type and adeany defect likely to lessen the effecquate thickness in relation to the cativeness of the drum for the purpose inpacity and the intended use of the tended. A material other than plywood, drum. Minimum thickness and markof at least equivalent strength and duing requirements in §§ 173.28(b) and rability, may be used for the manufacture of the heads. 178.503(a)(9) of this subchapter apply to drums intended for reuse. (2) At least two-ply plywood must be (2) All seams must be welded. Chime used for the body and at least three-ply seams, if any, must be reinforced by plywood for the heads; the plies must the application of separate reinforcing be firmly glued together, with their rings. grains crosswise. (3) The body of a drum of a capacity (3) The body and heads of the drum greater than 60 L (16 gallons) may have and their joints must be of a design apat least two expanded rolling hoops or propriate to the capacity of the drum and its intended use. two separate rolling hoops. If there are separate rolling hoops, the hoops must (4) In order to prevent sifting of the be fitted tightly on the body and so secontents, lids must be lined with kraft cured that they cannot shift. Rolling paper or some other equivalent matehoops may not be spot-welded. rial which must be securely fastened to (4) Openings for filling, emptying, or the lid and extend to the outside along venting in the bodies or heads of nonits full circumference. removable head (IN1) drums may not (5) Maximum capacity of drum: 250 L exceed 7.0 cm (3 inches) in diameter. (66 gallons). Drums with larger openings are consid- (6) Maximum net mass: 400 kg (882 ered to be of the removable head type pounds). (1N2). Closures for openings in the bod- [Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, as ies and heads of drums must be so deamended at 57 FR 45465, Oct. I. 1992] signed and applied that they will remain secure and leakproof under nor- § 178.508 Standards for fiber drums. mal conditions of transport. Closure (a) The identification code for a fiber flanges may be welded in place so that drum is IG. the weld provides a leakproof seam. (b) Construction requirements for Gaskets or other sealing elements fiber drums are as follows: must be used with closures unless the (1) The body of the drum must be closure is inherently leakproof. constructed of multiple plies of heavy 1018 Pipeline and Hazardous Materials Safety Admin., DOT § 178.509 paper or fiberboard (without corruga- (2) If protection against ultra-violet tions) firmly glued or laminated toradiation is required, it must be progether and may include one or more vided by the addition of carbon black protective layers of bitumen, waxed or other suitable pigments or inhibikraft paper, metal foil, plastic matetors. These additives must be compatrial, or similar materials. ible with the contents and remain ef- (2) Heads must be of natural wood, flfective throughout the life of the packberboard, metal, plywood, plastics, or aging. Where use is made of carbon other suitable material and may inblack, pigments or inhibitors other clude one or more protective layers of than those used in the manufacture of bitumen, waxed kraft paper, metal foil, the design type, retesting may be omitplastic material, or similar material. ted if the carbon black content does (3) The body and heads of the drum not exceed 2 percent by mass or if the and their joints must be of a design appigment content does not exceed 3 perpropriate to the capacity and intended cent by mass; the content of inhibitors use of the drum. of ultra-violet radiation is not limited. (4) The assembled packaging must be sufficiently water-resistant so as not (3) Additives serving purposes other to delaminate under normal conditions than protection against ultra-violet raof transport. diation may be included in the com- (5) Maximum capacity of drum: 450 L position of the plastic material pro- (119 gallons). vided they do not adversely affect the (6) Maximum net mass: 400 kg (882 chemical and physical properties of the pounds). packaging material. (4) The wall thickness at every point [Amdt. 178-97, 55 FR 52717, Dec. 21, 1990. as of the packaging must be appropriate amended by Amdt. 178-106, 59 FR 67521, Dec. to its capacity and its intended use, 29, 1994] taking into account the stresses to § 178.509 Standards for plastic drums which each point is liable to be exand jerricans. posed. Minimum thickness and mark- (a) The following are identification ing requirements in $173.28(b)(4) and codes for plastic drums and jerricans: 178.503(a)(9) of this subchapter apply to drums intended for reuse. (1) 1H1 for a non-removable head plastic drum; (5) Openings for filling, emptying and (2) 1H2 for a removable head plastic venting in the bodies or heads of nondrum; removable head (1H1) drums and (3) 3H1 for a non-removable head jerricans (3H1) may not exceed 7.0 cm (3 jerrican; and inches) in diameter. Drums and (4) 3H2 for a removable head jerrican. jerricans with larger openings are considered to be of the removable head (b) Construction requirements for plastic drums and jerricans are as foltype (1H2 and 3H2). Closures for openlows: ings in the bodies or heads of drums (1) The packaging must be manufacand jerricans must be so designed and tured from suitable plastic material applied that they remain secure and and be of adequate strength in relation leakproof under normal conditions of to its capacity and intended use. No transport. Gaskets or other sealing eleused material other than production ments must be used with closures unresidues or regrind from the same manless the closure is inherently leakproof. ufacturing process may be used unless (6) Closure devices for removable approved by the Associate Adminishead drums and jerricans must be so trator. The packaging must be adedesigned and applied that they remain quately resistant to aging and to degsecure and leakproof under normal conradation caused either by the subditions of transport. Gaskets must be stance contained or by ultra-violet raused with all removable heads unless diation. Any permeation of the subthe drum or jerrican design is such stance contained may not constitute a that when the removable head is propdanger under normal conditions of erly secured, the drum or jerrican is intransport. herently leakproof. 1019 § 178.510 49 CFR Ch. I (10-1-06 Edition) (7) Maximum capacity of drums and (4) 3B2 for a removable head alujerricans: 1H1, 1H2: 450 L (119 gallons): minum jerrican. 3H1, 3H2: 60 L (16 gallons). (b) Construction requirements for (8) Maximum net mass: 1H1, 1H2: 400 aluminum and steel jerricans are as kg (882 pounds); 3H1, 3H2: 120 kg (265 follows: pounds). (1) For steel jerricans the body and [Amdt. 178-97. 55 FR 52717, Dec. 21, 1990, as heads must be constructed of steel amended by Amdt. 178-102. 59 FR 28494, June sheet of suitable type and adequate 2, 1994; 64 FR 10782. Mar. 5. 1999; 66 FR 45386, thickness in relation to the capacity of Aug. 28, 2001] the jerrican and its intended use. Min- § 178.510 Standards for wooden barimum thickness and marking requirerels. ments in 55173.28(b)(4) and 178.503(a)(9) of this subchapter apply to jerricans (a) The following are identification intended for reuse. codes for wooden barrels: (2) For aluminum jerricans the body (1) 2C1 for a bung type wooden barrel; and heads must be constructed of aluand minum at least 99% pure or of an alu- (2) 2C2 for a slack type (removable minum base alloy. Material must be of head) wooden barrel. (b) Construction requirements for a type and of adequate thickness in rewooden barrels are as follows: lation to the capacity of the jerrican and to its intended use. (1) The wood used must be of good quality, straight-grained, well-sea- (3) Chimes of all jerricans must be soned and free from knots, bark, rotten mechanically seamed or welded. Body wood, sapwood or other defects likely seams of jerricans intended to carry to lessen the effectiveness of the barrel more than 40 L (11 gallons) of liquid for the purpose intended. must be welded. Body seams of (2) The body and heads must be of a jerricans intended to carry 40 L (11 galdesign appropriate to the capacity and lons) or less must be mechanically intended use of the barrel. seamed or welded. (3) Staves and heads must be sawn or (4) Openings in jerricans (3A1) may cleft with the grain so that no annual not exceed 7.0 cm (3 inches) in diamering extends over more than half the ter. Jerricans with larger openings are thickness of a stave or head. considered to be of the removable head (4) Barrel hoops must be of steel or type. Closures must be so designed that iron of good quality. The hoops of 2C2 they remain secure and leakproof barrels may be of a suitable hardwood. under normal conditions of transport. (5) For wooden barrels 2C1, the di- Gaskets or other sealing elements ameter of the bung-hole may not exmust be used with closures, unless the ceed half the width of the stave in closure is inherently leakproof. which it is placed. (5) If materials used for body, heads, (6) For wooden barrels 2C2, heads closures and fittings are not in themmust fit tightly into crozes. selves compatible with the contents to (7) Maximum capacity of barrel: 250 L be transported, suitable internal pro- (66 gallons). tective coatings or treatments must be (8) Maximum net mass: 400 kg (882 applied. These coatings or treatments pounds). must retain their protective properties § 178.511 Standards for aluminum and under normal conditions of transport. steel jerricans. (6) Maximum capacity of jerrican: 60 (a) The following are identification L (16 gallons). codes for aluminum and steel jerricans: (7) Maximum net mass: 120 kg (265 (1) 3A1 for a non-removable head pounds). steel jerrican; (Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, as (2) 3A2 for a removable head steel amended by Amdt. 178-102, 59 FR 28494, June jerrican; 2, 1994; Amdt. 178-119. 62 FR 24742, May 6, (3) 3B1 for a non-removable head alu- 1997) minum jerrican; and 1020 Pipeline and Hazardous Materials Safety Admin., DOT § 178.515 § 178.512 Standards for steel or alusidered equivalent to one piece when minum boxes. one of the following methods of glued (a) The following are identification assembly is used: Linderman joint, codes for steel or aluminum boxes: tongue and groove joint, ship lap or (1) 4A for a steel box; and rabbet joint, or butt joint with at least (2) 4B for an aluminum box. two corrugated metal fasteners at each (b) Construction requirements for joint. steel or aluminum boxes are as follows: (4) Maximum net mass: 400 kg (882 (1) The strength of the metal and the pounds). construction of the box must be appropriate to the capacity and intended use [Amdt. 178-97. 55 FR 52717, Dec. 21, 1990, as of the box. amended by Amdt. 178-106, 59 FR 67521, Dec. 29, 1994] (2) Boxes must be lined with fiberboard or felt packing pieces or must § 178.514 Standards for plywood boxes. have an inner liner or coating of suitable material in accordance with sub- (a) The identification code for a plypart C of part 173 of this subchapter. If wood box is 4D. a double seamed metal liner is used, (b) Construction requirements for steps must be taken to prevent the inplywood boxes are as follows: gress of materials, particularly explo- (1) Plywood used must be at least 3 sives, into the recesses of the seams. ply. It shall be made from well-sea- (3) Closures may be of any suitable soned rotary cut, sliced or sawn veneer, type, and must remain secure under commercially dry and free from defects normal conditions of transport. that would materially lessen the (4) Maximum net mass: 400 kg (882 strength of the box. The strength of the pounds). material used and the method of con- [Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, as struction must be appropriate to the amended by Amdt. 178-106, 59 FR 67521, Dec. capacity and intended use of the box. 29, 1994) All adjacent plies must be glued with water-resistant adhesive. Other suit- $ 178.513 Standards for boxes of natable materials may be used together ural wood. with plywood in the construction of (a) The following are the identificaboxes. Boxes must be nailed or secured tion codes for boxes of natural wood: to corner posts or ends or assembled (1) 4C1 for an ordinary box; and with other equally suitable devices. (2) 4C2 for a box with sift-proof walls. (2) Maximum net mass: 400 kg (882 (b) Construction requirements for pounds). boxes of natural wood are as follows: (1) The wood used must be well-sea- § 178.515 Standards for reconstituted soned, commercially dry and free from wood boxes. defects that would materially lessen (a) The identification code for a rethe strength of any part of the box. The constituted wood box is 4F. strength of the material used and the (b) Construction requirements for remethod of construction must be approconstituted wood boxes are as follows: priate to the capacity and intended use of the box. The tops and bottoms may (1) The walls of boxes must be made be made of water-resistant reconstiof water-resistant, reconstituted wood tuted wood such as hard board, particle such as hardboard, particle board, or board or other suitable type. other suitable type. The strength of (2) Fastenings must be resistant to the material used and the method of vibration experienced under normal construction must be appropriate to conditions of transportation. End grain the capacity of the boxes and their innailing must be avoided whenever practended use. ticable. Joints which are likely to be (2) Other parts of the box may be highly stressed must be made using made of other suitable materials. clenched or annular ring nails or equiv- (3) Boxes must be securely assembled alent fastenings. by means of suitable devices. (3) Each part of the 4C2 box must be (4) Maximum net mass: 400 kg (882 one piece or equivalent. Parts are conpounds). 1021 § 178.516 49 CFR Ch. I (10-1-06 Edition) $ 178.516 Standards for fiberboard (b) Construction requirements for boxes. plastic boxes are as follows: (a) The identification code for a fi- (1) The box must be manufactured berboard box is 4G. from suitable plastic material and be (b) Construction requirements for fiof adequate strength in relation to its berboard boxes are as follows: capacity and intended use. The box (1) Strong, solid or double-faced cormust be adequately resistant to aging rugated fiberboard (single or multiand to degradation caused either by wall) must be used, appropriate to the the substance contained or by ultracapacity and intended use of the box. violet radiation. The water resistance of the outer surface must be such that the increase in (2) An expanded plastic box must conmass, as determined in a test carried sist of two parts made of a molded exout over a period of 30 minutes by the panded plastic material: a bottom sec- Cobb method of determining water abtion containing cavities for the inner sorption, is not greater than 155 g per receptacles, and a top section covering square meter (0.0316 pounds per square and interlocking with the bottom secfoot)-see ISO 535 (IBR, see $171.7 of tion. The top and bottom sections must this subchapter). Fiberboard must have be so designed that the inner recepproper bending qualities. Fiberboard tacles fit snugly. The closure cap for must be cut, creased without cutting any inner receptacle may not be in through any thickness of fiberboard, contact with the inside of the top secand slotted so as to permit assembly tion of the box. without cracking, surface breaks, or (3) For transportation, an expanded undue bending. The fluting of corplastic box must be closed with a selfrugated fiberboard must be firmly adhesive tape having sufficient tensile glued to the facings. strength to prevent the box from open- (2) The ends of boxes may have a ing. The adhesive tape must be weathwooden frame or be entirely of wood or er-resistant and its adhesive compatother suitable material. Reinforceible with the expanded plastic material ments of wooden battens or other suitable material may be used. of the box. Other closing devices at (3) Manufacturing joints. (i) Manuleast equally effective may be used. facturing joints in the bodies of boxes (4) For solid plastic boxes, protection must beagainst ultra-violet radiation, if re- (A) Taped; quired, must be provided by the addi- (B) Lapped and glued; or tion of carbon black or other suitable (C) Lapped and stitched with metal pigments or inhibitors. These additives staples. must be compatible with the contents (ii) Lapped joints must have an apand remain effective throughout the propriate overlap. life of the box. Where use is made of (4) Where closing is effected by glucarbon black pigment or inhibitors ing or taping, a water resistant adheother than those used in the manufacsive must be used. ture of the tested design type, re- (5) Boxes must be designed so as to testing may be waived if the carbon provide a snug fit to the contents. black content does not exceed 2 percent (6) Maximum net mass: 400 kg (882 by mass or if the pigment content does pounds). not exceed 3 percent by mass; the con- [Amdt. 178-97. 55 FR 52717, Dec. 21, 1990, and tent of inhibitors of ultra-violet radiamended by Amdt. 178-99, 58 FR 51534, Oct. 1. ation is not limited. 1993; Amdt. 178-106, 59 FR 67521, Dec. 29, 1994; (5) Additives serving purposes other 68 FR 75758, Dec. 31, 2003] than protection against ultra-violet ra- § 178.517 Standards for plastic boxes. diation may be included in the com- (a) The following are identification position of the plastic material if they codes for plastic boxes: do not adversely affect the material of (1) 4H1 for an expanded plastic box: the box. Addition of these additives and does not change the design type. (2) 4H2 for a solid plastic box. 1022 Pipeline and Hazardous Materials Safety Admin., DOT § 178.520 (6) Solid plastic boxes must have clo- § 178.519 Standards for plastic film sure devices made of a suitable matebags. rial of adequate strength and so de- (a) The identification code for a plassigned as to prevent the box from unintic film bag is 5H4. tentionally opening. (b) Construction requirements for (7) Maximum net mass 4H1: 60 kg (132 plastic film bags are as follows: pounds): 4H2: 400 kg (882 pounds). (1) Bags must be made of a suitable plastic material. The strength of the § 178.518 Standards for woven plastic material used and the construction of bags. the bag must be appropriate to the ca- (a) The following are identification pacity and the intended use of the bag. codes for woven plastic bags: Joints and closures must be capable of (1) 5H1 for an unlined or non-coated withstanding pressures and impacts woven plastic bag; liable to occur under normal conditions (2) 5H2 for a sift-proof woven plastic of transportation. bag; and (2) Maximum net mass: 50 kg (110 (3) 5H3 for a water-resistant woven pounds). plastic bag. § 178.520 Standards for textile bags. (b) Construction requirements for (a) The following are identification woven plastic fabric bags are as folcodes for textile bags: lows: (1) 5L1 for an unlined or non-coated (1) Bags must be made from stretched textile bag; tapes or monofilaments of a suitable (2) 5L2 for a sift-proof textile bag: plastic material. The strength of the and material used and the construction of (3) 5L3 for a water-resistant textile the bag must be appropriate to the cabag. pacity and intended use of the bag. (b) Construction requirements for (2) If the fabric is woven flat, the textile bags are as follows: bags must be made by sewing or some (1) The textiles used must be of good other method ensuring closure of the quality. The strength of the fabric and bottom and one side. If the fabric is tuthe construction of the bag must be apbular, the bag must be closed by sewpropriate to the capacity and intended ing, weaving, or some other equally use of the bag. strong method of closure. (2) Bags, sift-proof, 5L2: The bag (3) Bags, sift-proof, 5H2 must be made must be made sift-proof, by appropriate sift-proof by appropriate means such as means, such as by the use of paper use of paper or a plastic film bonded to bonded to the inner surface of the bag the Inner surface of the bag or one or by a water-resistant adhesive such as more separate inner liners made of bitumen, plastic film bonded to the inner surface of the bag, or one or more paper or plastic material. inner liners made of paper or plastic (4) Bags, water-resistant, 5H3: To prematerial. vent the entry of moisture, the bag (3) Bags, water-resistant, 5L3: To premust be made waterproof by approvent entry of moisture, the bag must priate means, such as separate inner be made waterproof by appropriate liners of water-resistant paper (e.g., means, such as by the use of separate waxed kraft paper, double-tarred kraft inner liners of water-resistant paper paper or plastic-coated kraft paper). or (e.g., waxed kraft paper, tarred paper, plastic film bonded to the Inner or or plastic-coated kraft paper), or plasouter surface of the bag, or one or more tic film bonded to the inner surface of inner plastic liners. the bag, or one or more inner liners (5) Maximum net mass: 50 kg (110 made of plastic material or metalized pounds). film or foil. (4) Maximum net mass: 50 kg (110 [Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, and pounds). amended by Amdt. 178-99, 58 FR 51534, Oct. 1, 1993] [Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, as amended at 56 FR 66285, Dec. 20, 1991] 1023 § 178.521 49 CFR Ch. I (10-1-06 Edition) $ 178.521 Standards for paper bags. (6) 6HD1 for a plastic receptacle with- (a) The following are identification in a protective plywood drum; codes for paper bags: (7) 6HD2 for a plastic receptacle with- (1) 5M1 for a multi-wall paper bag; in a protective plywood box; and (8) 6HG1 for a plastic receptacle with- (2) 5M2 for a multi-wall water-resistin a protective fiber drum; ant paper bag. (9) 6HG2 for a plastic receptacle with- (b) Construction requirements for in a protective fiberboard box; paper bags are as follows: (10) 6HH1 for a plastic receptacle (1) Bags must be made of a suitable within a protective plastic drum; and kraft paper, or of an equivalent paper (11) 6HH2 for a plastic receptacle with at least three plies. The strength within a protective plastic box. of the paper and the construction of (b) Construction requirements for the bag must be appropriate to the cacomposite packagings with inner repacity and intended use of the bag. ceptacles of plastic are as follows: Seams and closures must be sift-proof. (1) Inner receptacles must be con- (2) Paper bags 5M2: To prevent the structed under the applicable construcentry of moisture, a bag of four plies or tion requirements prescribed in more must be made waterproof by the $178.509(b) (1) through (7) of this subuse of either a water-resistant ply as part. one of the two outermost plies or a (2) The inner plastic receptacle must water-resistant barrier made of a suitfit snugly inside the outer packaging, able protective material between the which must be free of any projections two outermost plies. A 5M2 bag of which may abrade the plastic material. three plies must be made waterproof by (3) Outer packagings must be conthe use of a water-resistant ply as the structed as follows: outermost ply. When there is danger of (i) 6HA1 or 6HB1: Protective packthe lading reacting with moisture, or when it is packed damp, a waterproof aging must conform to the requirements for steel drums in $178.504(b) of ply or barrier, such as double-tarred kraft paper, plastics-coated kraft this subpart, or aluminum drums in paper, plastics film bonded to the inner $178.505(b) of this subpart. surface of the bag, or one or more inner (ii) 6HA2 or 6HB2: Protective packplastics liners, must also be placed agings with steel or aluminum crate next to the substance. Seams and clomust conform to the requirements for sures must be waterproof. steel or aluminum boxes found in (3) Maximum net mass: 50 kg (110 $178.512(b) of this subpart. pounds). (iii) 6HC protective packaging must conform to the requirements for wood- [Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, as en boxes in $178.513(b) of this subpart. amended at 56 FR 66285, Dec. 20, 1991; Amdt. 178-106, 59 FR 67521, Dec. 29, 1994] (iv) 6HD1: Protective packaging must conform to the requirements for ply- § 178.522 Standards for composite wood drums, in $178.507(b) of this subpackagings with inner plastic repart. ceptacles. (v) 6HD2: Protective packaging must (a) The following are the identificaconform to the requirements of plytion codes for composite packagings wood boxes, in $178.514(b) of this subwith inner plastic receptacles: part. (1) 6HA1 for a plastic receptacle with- (vi) 6HG1: Protective packaging must in a protective steel drum; conform to the requirements for fiber (2) 6HA2 for a plastic receptacle withdrums, in $178.508(b) of this subpart. in a protective steel crate or box; (vii) 6HG2: protective packaging (3) 6HB1 for a plastic receptacle withmust conform to the requirements for in a protective aluminum drum. fiberboard boxes, in $178.516(b) of this (4) 6HB2 for a plastic receptacle withsubpart. in a protective aluminum crate or box. (viii) 6HH1: Protective packaging (5) 6HC for a plastic receptacle within must conform to the requirements for a protective wooden box. plastic drums, in $178.509(b). 1024 Pipeline and Hazardous Materials Safety Admin., DOT § 178.523 (ix) 6HH2: Protective packaging must ceptacles of glass, porcelain, or stoneconform to the requirements for plastic ware are as follows: boxes, in $178.517(b). (1) Inner receptacles must conform to (4) Maximum capacity of inner recepthe following requirements: tacles is as follows: 6HA1, 6HB1, 6HDI, (i) Receptacles must be of suitable 6HG1, 6HH1-250 L (66 gallons); 6HA2, form (cylindrical or pear-shaped), be 6HB2, 6HC, 6HD2, 6HG2, 6HH2-60 L (16 made of good quality materials free gallons). from any defect that could impair their (5) Maximum net mass is as follows: strength, and be firmly secured in the 6HA1, 6HB1, 6HD1, 6HG1, 6HHI-400kg outer packaging. (882 pounds); 6HB2, 6HC, 6HD2, 6HG2, (ii) Any part of a closure likely to 6HH2-75 kg (165 pounds). come into contact with the contents of the receptacle must be resistant to [Amdt. 178-97, 55 FR 52717, Dec. 21, 1990. as those contents. Closures must be fitted amended by Amdt. 178-106, 59 FR 67521, Dec. SO as to be leakproof and secured to 29, 1994] prevent any loosening during transpor- § 178.523 Standards for composite tation. Vented closures must conform packagings with inner glass, porto § 173.24(f) of this subchapter. celain, or stoneware receptacles. (2) Protective packagings must con- (a) The following are identification form to the following requirements: codes for composite packagings with (i) For receptacles with protective steel drum 6PA1, the drum must cominner receptacles of glass, porcelain, or stoneware: ply with $178.504(b) of this subpart. However, the removable lid required (1) 6PA1 for glass. porcelain, or stoneware receptacles within a protective for this type of packaging may be in steel drum; the form of a cap. (ii) For receptacles with protective (2) 6PA2 for glass, porcelain, or stonepackaging of steel crate or steel box ware receptacles within a protective 6PA2, the protective packaging must steel crate or box; conform to the following: (3) 6PB1 for glass, porcelain, or stone- (A) Section 178.512(b) of this subpart. ware receptacles within a protective (B) In the case of cylindrical recepaluminum drum; tacles, the protective packaging must, (4) 6PB2 for glass, porcelain, or stonewhen upright, rise above the receptacle ware receptacles within a protective and its closure; and aluminum crate or box; (C) If the protective crate surrounds (5) 6PC for glass, porcelain, or stone- a pear-shaped receptacle and is of ware receptacles within a protective matching shape, the protective packwooden box: aging must be fitted with a protective (6) 6PD1 for glass, porcelain, or stonecover (cap). ware receptacles within a protective (iii) For receptacles with protective plywood drum; aluminum drum 6PB1, the require- (7) 6PD2 for glass, porcelain, or stonements of $178.505(b) of this subpart ware receptacles within a protective apply to the protective packaging. wickerwork hamper; (iv) For receptacles with protective (8) 6PG1 for glass, porcelain, or stonealuminum box or crate 6PB2, the reware receptacles within a protective quirements of $178.512(b) of this subfiber drum; part apply to the protective packaging. (9) 6PG2 for glass, porcelain, or stone- (v) For receptacles with protective ware receptacles within a protective fiwooden box 6PC, the requirements of berboard box; § 178.513(b) of this subpart apply to the (10) 6PH1 for glass, porcelain, or protective packaging. stoneware receptacles within a protec- (vi) For receptacles with protective tive expanded plastic packaging; and plywood drum 6PD1, the requirements (11) 6PH2 for glass, porcelain, or of $178.507(b) of this subpart apply to stoneware receptacles within a protecthe protective packaging. tive solid plastic packaging. (vii) For receptacles with protective (b) Construction requirements for wickerwork hamper 6PD2, the composite packagings with inner rewickerwork hamper must be properly 1025 § 178.600 49 CFR Ch. I (10-1-06 Edition) made with material of good quality. (b) Responsibility. It is the responsi- The hamper must be fitted with a probility of the packaging manufacturer tective cover (cap) so as to prevent to assure that each package is capable damage to the receptacle. of passing the prescribed tests. To the (viii) For receptacles with protective extent that a package assembly funcfiber drum 6PG1, the drum must contion, including final closure, is perform to the requirements of 178.508(b) formed by the person who offers a hazof this subpart. ardous material for transportation, (ix) For receptacles with protective that person is responsible for perfiberboard box 6PG2, the requirements forming the function in accordance of $178.516(b) of this subpart apply to with $$173.22 and 178.2 of this subthe protective packaging. chapter. (x) For receptacles with protective (c) Definitions. For the purpose of this solid plastic or expanded plastic packsubpart: aging 6PH1 or 6PH2, the requirements (1) Design qualification testing is the of § 178.517(b) of this subpart apply to performance of the tests prescribed in the protective packaging. Solid protec- $178.603, § 178.604, $178.605, $178.606, tive plastic packaging must be manu- $178.607, § 178.608, or $ 178.609, as applicafactured from high-density polyble, for each new or different packethylene from some other comparable aging, at the start of production of plastic material. The removable lid rethat packaging. quired for this type of packaging may (2) Periodic retesting is the performbe a cap. (3) Quantity limitations are as folance of the drop, leakproofness, hydrolows: static pressure, and stacking tests, as (i) Maximum net capacity for packapplicable, as prescribed in $178.603, $178.604, $178.605, or § 178.606, respecaging for liquids: 60 L (16 gallons). (ii) Maximum net mass for packtively, at the frequency specified in agings for solids: 75 kg (165 pounds). paragraph (e) of this section. For infectious substances packagings required to meet the requirements of $178.609, Subpart M-Testing of Non-bulk periodic retesting is the performance of Packagings and Packages the tests specified in $178.609 at the frequency specified in paragraph (e) of SOURCE: Amdt. 178-97, 55 FR 52723, Dec. 21, this section. 1990, unless otherwise noted. (3) Production testing is the performance of the leakproofness test pre- $ 178.600 Purpose and scope. scribed in $178.604 of this subpart on This subpart prescribes certain testeach single or composite packaging ining requirements for performance-oritended to contain a liquid. ented packagings identified in subpart (4) A different packaging is one that L of this part. differs (i.e. is not identical) from a pre- [Amdt. 178-97, 55 FR 52717. Dec. 21, 1990, and viously produced packaging in strucamended by Amdt. 178-99, 58 FR 51534, Oct. 1, tural design, size, material of construc- 1993] tion, wall thickness or manner of construction but does not include: $ 178.601 General requirements. (i) A packaging which differs only in (a) General. The test procedures presurface treatment; scribed in this subpart are intended to (ii) A combination packaging which ensure that packages containing hazdiffers only in that the outer packardous materials can withstand normal aging has been successfully tested with conditions of transportation and are different inner packagings. A variety of considered minimum requirements. such inner packagings may be assem- Each packaging must be manufactured bled in this outer packaging without and assembled so as to be capable of further testing; successfully passing the prescribed (iii) A plastic packaging which differs tests and of conforming to the requireonly with regard to additives which ments of $173.24 of this subchapter at conform to § 178.509(b)( or $178.517(b) all times while in transportation. (4) or (5) of this part; 1026 Pipellne and Hazardous Materials Safety Admin., DOT § 178.601 (iv) A combination packaging with permitted in inner packagings of a inner packagings conforming to the tested combination package, without provisions of paragraph (g) of this secfurther testing of the package, protion; vided an equivalent level of perform- (v) Packagings which differ from the ance is maintained, as follows: design type only in their lesser design (i) Inner packagings of equivalent or height; or smaller size may be used provided- (vi) For a steel drum, variations in design elements which do not con- (A) The inner packagings are of simistitute a different design type under lar design to the tested inner packthe provisions of paragraph (g) of agings (i.e. shape-round, rectangular, this section. etc.); (d) Design qualification testing. The (B) The material of construction of packaging manufacturer shall achieve the inner packagings (glass, plastic, successful test results for the design metal, etc.) offers resistance to impact qualification testing at the start of and stacking forces equal to or greater production of each new or different than that of the originally tested inner packaging. packaging; (e) Periodic retesting. The packaging (C) The inner packagings have the manufacturer must achieve successful same or smaller openings and the clotest results for the periodic retesting sure is of similar design (e.g., screw at intervals established by the manucap, friction lid, etc.); facturer of sufficient frequency to en- (D) Sufficient additional cushioning sure that each packaging produced by material is used to take up void spaces the manufacturer is capable of passing and to prevent significant moving of the design qualification tests. Changes the inner packagings; in retest frequency are subject to the approval of the Associate Adminis- (E) Inner packagings are oriented trator for Hazardous Materials Safety. within the outer packaging in the same For single or composite packagings, manner as in the tested package; and, the periodic retests must be conducted (F) The gross mass of the package at least once every 12 months. For does not exceed that originally tested. combination packagings, the periodic (ii) A lesser number of the tested retests must be conducted at least once inner packagings. or of the alternative every 24 months. For infectious subtypes of inner packagings identified in stances packagings, the periodic paragraph (g)(1)(i) of this section, may retests must be conducted at least once be used provided sufficient cushioning every 24 months. is added to fill void space(s) and to pre- (f) Test samples. The manufacturer vent significant moving of the inner shall conduct the design qualification packagings. and periodic tests prescribed in this (2) Selective testing of combination subpart using random samples of packpackagings. Variation 2. Articles or agings, in the numbers specified in the inner packagings of any type, for solids appropriate test section. In addition, or liquids, may be assembled and transthe leakproofness test, when required, ported without testing in an outer shall be performed on each packaging produced by the manufacturer, and packaging under the following conditions: each packaging prior to reuse under $173.28 of this subchapter, by the re- (i) The outer packaging must have conditioner. been successfully tested in accordance (g) Selective testing. The selective with $178.603 with fragile (e.g. glass) testing of packagings that differ only inner packagings containing liquids at in minor respects from a tested type is the Packing Group I drop height: permitted as described in this section. (ii) The total combined gross mass of For air transport, packagings must inner packagings may not exceed onecomply with §173.27(c)(1) and (c)(2) of half the gross mass of inner packagings this subchapter. used for the drop test; (1) Selective testing of combination (iii) The thickness of cushioning mapackagings. Variation 1. Variations are terial between inner packagings and 1027 § 178.601 49 CFR Ch. I (10-1-06 Edition) between inner packagings and the outduced with reductions in external diside of the packaging may not be remensions (i.e., length, width or diameduced below the corresponding thickter) of up to 25 percent of the dimenness in the originally tested packaging; sions of a tested packaging may be and when a single inner packaging was used without further testing provided used in the original test, the thickness an equivalent level of performance is of cushioning between inner packmaintained. The packagings must, in agings may not be less than the thickall other respects (including wall ness of cushioning between the outside thicknesses), be identical to the tested of the packaging and the inner packdesign-type. The marked gross mass aging in the original test. When either (when required) must be reduced in fewer or smaller inner packagings are proportion to the reduction in volume. used (as compared to the inner pack- (4) Variation 4. Variations are peragings used in the drop test), sufficient mitted in outer packagings of a tested additional cushioning material must be design-type combination packaging, used to take up void spaces. without further testing, provided an (iv) The outer packaging must have equivalent level of performance is successfully passed the stacking test maintained, as follows: set forth in $178.606 of this subpart (i) Each external dimension (length, when empty, i.e., without either inner width and height) is less than or equal packagings or cushioning materials. to the corresponding dimension of the The total mass of identical packages tested design-type; must be based on the combined mass of (ii) The structural design of the testinner packagings used for the drop ed outer packaging (i.e. methods of test; construction, materials of construc- (v) Inner packagings containing liqtion, strength characteristics of mateuids must be completely surrounded rials of construction, method of closure with a sufficient quantity of absorbent and material thicknesses) is mainmaterial to absorb the entire liquid tained; contents of the inner packagings; (iii) The inner packagings are iden- (vi) When the outer packaging is intical to the inner packagings used in tended to contain inner packagings for the tested design type except that their liquids and is not leakproof, or is insize and mass may be less; and they are tended to contain inner packagings for oriented within the outer packaging in solids and is not siftproof, a means of the same manner as in the tested packcontaining any liquid or solid contents aging; in the event of leakage must be pro- (iv) The same type or design of abvided in the form of a leakproof liner, sorbent materials, cushioning mateplastic bag, or other equally efficient rials and any other components пес- means of containment. For packagings essary to contain and protect inner containing liquids, the absorbent matepackagings, as used in the tested derial required in paragraph (g)(2)(v) of sign type, are maintained. The thickthis section must be placed inside the ness of cushioning material between means of containing liquid contents; inner packagings and between inner and packagings and the outside of the (vii) Packagings must be marked in packaging may not be less than the accordance with $178.503 of this part as thicknesses in the tested design type having been tested to Packing Group I packaging: and performance for combination pack- (v) Sufficient additional cushioning agings. The marked maximum gross material is used to take up void spaces mass may not exceed the sum of the and to prevent significant moving of mass of the outer packaging plus one the inner packagings. half the mass of the filled inner pack- An outer packaging qualifying for use agings of the tested combination packin transport in accordance with all of aging. In addition, the marking rethe above conditions may also be used quired by § 178.503(a)(2) of this part without testing to transport inner must include the letter "V". packagings substituted for the origi- (3) Variation 3. Packagings other than nally tested inner packagings in accombination packagings which are procordance with the conditions set out in 1028 Pipeline and Hazardous Materials Safety Admin., DOT § 178.601 Variation 1 in paragraph (g)(1) of this the specific gravity of the liquid used section. in the design type tests of the pack- (5) Variation 5. Single packagings aging with replacement closure devices (i.e., non-bulk packagings other than or gasketing.) combination packagings), that differ (6) The provisions in Variations 1, 2, from a tested design type only to the and 4 in paragraphs (g)(1), (2) and (4) of extent that the closure device or this section for combination packgasketing differs from that used in the agings may be applied to packagings originally tested design type, may be containing articles, where the proviused without further testing, provided sions for inner packagings are applied an equivalent level of performance is analogously to the articles. In this maintained, subject to the following case, inner packagings need not comply conditions (the qualifying tests): with $173.27(c)(1) and (c)(2) of this sub- (i) A packaging with the replacement chapter. closure devices or gasketing must successfully pass the drop test specified in (7) Approval of selective testing. In ad- $178.603 in the orientation which most dition to the provisions of §178.601(g)(1) severely tests the integrity of the clothrough (g)(6) of this subpart, the Assosure or gasket; ciate Administrator may approve the (ii) When intended to contain liquids, selective testing of packagings that a packaging with the replacement clodiffer only in minor respects from a sure devices or gasketing must successtested type. fully pass the leakproofness test speci- (8) For a steel drum with a capacity fied in $178.604, the hydrostatic presgreater than 50 L (13 gallons) manufacsure test specified in $178.605, and the tured from low carbon, cold-rolled stacking test specified in $178.606. sheet steel meeting ASTM designations A 366/A 366M or A 568/A 568M variations Replacement closures and gasketings qualified under the above test requirein elements other than the following ments are authorized without addidesign elements are considered minor and do not constitute a different drum tional testing for packagings described in paragraph (g)(3) of this section. Redesign type, or "different packaging" placement closures and gasketings as defined in paragraph (c) of this secqualified under the above test requiretion for which design qualification ments also are authorized without adtesting and periodic retesting are reditional testing for different tested dequired. Minor variations authorized sign types packagings of the same type without further testing include as the originally tested packaging, prochanges in the identity of the supplier vided the original design type tests are of component material made to the more severe or comparable to tests same specifications, or the original which would otherwise be conducted on manufacturer of a DOT specification or UN standard drum to be remanufacthe packaging with the replacement closures or gasketings. (For example: tured. A change in any one or more of The packaging used in the qualifying the following design elements contests has a lesser packaging wall thickstitutes a different drum design type: ness than the packaging with replace- (i) The packaging type and category ment closure devices or gasketing; the of the original drum and the remanugross mass of the packaging used in the factured drum, i.e., 1A1 or 1A2; qualifying drop test equals or exceeds (ii) The style, (i.e., straight-sided or the mass for which the packaging with tapered); replacement closure devices or (iii) Except as provided in paragraph gasketing was tested; the packaging (g)(3) of this section, the rated used in the qualifying drop test was (marked) capacity and outside dimendropped from the same or greater sions; height than the height from which the (iv) The physical state for which the packaging with replacement closure packaging was originally approved devices or gasketing was dropped in de- (e.g., tested for solids or liquids); sign type tests; and the specific gravity (v) An increase in the marked level of of the substance used in the qualifying performance of the original drum (i.e., drop test was the same or greater than to a higher packing group, hydrostatic 1029 § 178.601 49 CFR Ch. I (10-1-06 Edition) test pressure, or specific gravity to safety reasons, the manufacturer shall which the packaging has been tested); design the packaging so that the treat- (vi) Type of side seam welding; ment or coating retains its protective (vii) Type of steel: properties even after withstanding the (viii) An increase greater than 10% or tests prescribed by this subpart. any decrease in the steel thickness of (k) Number of test samples. Provided the head, body, or bottom; the validity of the test results is not (ix) End seam type, (e.g., triple or affected and with the approval of the double seam); Associate Administrator, several tests (x) A reduction in the number of rollmay be performed on one sample. ing hoops which equal or exceed the di- (1) Record retention. Following each ameter over the chimes; design qualification test and each peri- (xi) The location, type or size, and odic retest on a packaging, a test rematerial of closures (other than the port must be prepared. The test report cover of UN 1A2 drums); and must be maintained at each location (xii) For UN 1A2 drums: where the packaging is manufactured (A) Gasket material (e.g., plastic), or and each location where the design properties affecting the performance of qualification tests are conducted, for the gasket; as long as the packaging is produced (B) Configuration or dimensions of and for at least two years thereafter, the gasket; and at each location where the periodic (C) Closure ring style including bolt retests are conducted until such tests size, (e.g., square or round back, 0.625" are successfully performed again and a bolt); and new test report produced. In addition, a (D) Closure ring thickness. copy of the test report must be main- (h) Approval of equivalent packagings. tained by a person certifying compli- A packaging having specifications difance with this part. The test report ferent from those in §§ 178.504-178.523 of must be made available to a user of a this part, or which is tested using packaging or a representative of the methods or test intervals, other than Department upon request. The test rethose specified in subpart M of this port, at a minimum, must contain the part, may be used if approved by the following information: Associate Administrator. Such pack- (1) Name and address of test facility; agings must be shown to be equally ef- (2) Name and address of applicant fective, and testing methods used must (where appropriate); be equivalent. (3) A unique test report identifica- (i) Proof of compliance. Notwithtion; standing the periodic retest intervals (4) Date of the test report; specified in paragraph (e) of this sec- (5) Manufacturer of the packaging: tion, the Associate Administrator may (6) Description of the packaging deat any time require demonstration of sign type (e.g. dimensions, materials, compliance by a manufacturer, closures, thickness, etc.), including through testing in accordance with methods of manufacture (e.g. blow this subpart, that packagings meet the molding) and which may include drawrequirements of this subpart. As reing(s) and/or photograph(s); quired by the Associate Administrator, (7) Maximum capacity; the manufacturer shall either- (8) Characteristics of test contents, (1) Conduct performance tests, or e.g. viscosity and relative density for have tests conducted by an indeliquids and particle size for solids; (9) Test descriptions and results; and pendent testing facility, in accordance (10) Signed with the name and title of with this subpart; or (2) Supply packagings, in quantities signatory. sufficient to conduct tests in accord- [Amdt. 178-97. 55 FR 52723. Dec. 21, 1990. as ance with this subpart, to the Assoamended at 56 FR 66285, Dec. 20. 1991: 57 FR ciate Administrator or a designated 45465, Oct. 1, 1992; Amdt. 178-102, 59 FR 28494, representative of the Associate Admin- June 2, 1994; Amdt. 178-106, 59 FR 67521. 67522, Dec. 29, 1994; Amdt. 178-117. 61 FR 50628, Sept. istrator. 26, 1996; 66 FR 45386, Aug. 28, 2001: 67 FR 53143, (j) Coatings. If an inner treatment or Aug. 14, 2002; 68 FR 75758, Dec. 31, 2003; 68 FR coating of a packaging is required for 61942, Oct. 30, 2003] 1030 Pipeline and Hazardous Materials Safety Admin., DOT § 178.603 § 178.602 Preparation of packagings should fall within these limits. Shortand packages for testing. term fluctuations and measurement (a) Except as otherwise provided in limitations may cause individual measthis subchapter, each packaging and urements to vary by up to ±5 percent package must be closed in preparation relative humidity without significant for testing and tests must be carried impairment of test reproducibility; out in the same manner as if prepared (2) At 65 percent +2 percent relative for transportation, including inner humidity, and at a temperature of 20 packagings in the case of combination °C±2 °C (68 °F+4 °F). or 27 °C±2 °C (81 packagings. °F+4 °F). Average values should fall (b) For the drop and stacking test, within these limits. Short-term flucinner and single-unit receptacles other tuations and measurement limitations than bags must be filled to not less may cause individual measurements to than 95% of maximum capacity (see vary by up to ±5 percent relative hu- $171.8 of this subchapter) in the case of midity without significant impairment solids and not less than 98% of maxof test reproducibility; or imum in the case of liquids. Bags shall (3) For testing at periodic intervals be filled to the maximum mass at only (i.e., other than initial design which they may be used. The material qualification testing), at ambient conto be transported in the packagings ditions. may be replaced by a non-hazardous (e) Except as otherwise provided, material, except for chemical compateach packaging must be closed in prepibility testing or where this would inaration for testing in the same manner validate the results of the tests. as if prepared for actual shipment. All (c) If the material to be transported closures must be installed using proper is replaced for test purposes by a nontechniques and torques. hazardous material, the material used (f) Bung-type barrels made of natural must be of the same or higher specific wood must be left filled with water for gravity as the material to be carried, at least 24 hours before the tests. and its other physical properties (grain, size, viscosity) which might in- [Amdt. 178-97, 55 FR 52723, Dec. 21, 1990. as fluence the results of the required tests amended at 56 FR 66286, Dec. 20, 1991; Amdt. must correspond as closely as possible 178-106, 59 FR 67522, Dec. 29, 1994; 69 FR 76186, to those of the hazardous material to Dec. 20, 2004] be transported. Water may also be used for the liquid drop test under the con- § 178.603 Drop test. ditions specified in 178.603(e) of this (a) General. The drop test must be subpart. It is permissible to use addiconducted for the qualification of all tives, such as bags of lead shot, to packaging design types and performed achieve the requisite total package periodically as specified in $178.601(e). mass, so long as they are placed so that For other than flat drops, the center of the test results are not affected. gravity of the test packaging must be (d) Paper or fiberboard packagings vertically over the point of impact. must be conditioned for at least 24 Where more than one orientation is hours immediately prior to testing in possible for a given drop test, the orian atmosphere maintainedentation most likely to result in fail- (1) At 50 percent ±2 percent relative ure of the packaging must be used. The humidity, and at a temperature of 23 number of drops required and the pack- °C±2 °C (73 °F+4 °F). Average values ages' orientations are as follows: Packaging No. of tests (samples) Drop orientation of samples Steel drums, Aluminum drums. Metal Six-(three for each First drop (using three samples): The package must strike the drums (other than steel or aludrop). target diagonally on the chime or, if the packaging has no minum), Steel Jerricans, Plywood chime, on a circumferential seam or an edge. Second drop drums, Wooden barrels, Fiber (using the other three samples): The package must strike drums, Plastic drums and Jerricans, the target on the weakest part not tested by the first drop, Composite packagings which are in for example a closure or, for some 7 cylindrical drums, the the shape of a drum. welded longitudinal seam of the drum body. 1031 § 178.603 49 CFR Ch. I (10-1-06 Edition) Packaging No. of tests (samples) Drop orientation of samples Boxes of natural wood, Plywood Five-(one for each First drop: Flat on the bottom (using the first sample). Second boxes, Reconstituted wood boxes, drop). drop: Flat on the top (using the second sample). Third drop: Fiberboard boxes, Plastic boxes, Flat on the long side (using the third sample). Fourth drop: Steel or aluminum boxes, Com- Flat on the short side (using the fourth sample). Fifth drop: posite packagings which are in the On a corner (using the fifth sample). shape of a box. Bags-single-ply with a side seam Three-(three drops First drop: Flat on a wide face (using all three samples). Secper bag). and drop: Flat on a narrow face (using all three samples). Third drop: On an end of the bag (using all three samples). Bags-single-ply without a side seam, Three—(two drops per First drop: Flat on a wide face (using all three samples). Secor multi-ply. bag). and drop: On an end of the bag (using all three samples). (b) Exceptions. For testing of single or be transported or with a non-hazardous composite packagings constructed of material having essentially the same stainless steel, nickel, or monel at physical characteristic, the drop height periodic intervals only (i.e., other than must be determined according to packdesign qualification testing), the drop ing group, as follows: test may be conducted with two sam- (1) Packing Group I: 1.8 m (5.9 feet). ples, one sample each for the two drop (ii) Packing Group II: 1.2 m (3.9 feet). orientations. These samples may have (iii) Packing Group III: 0.8 m (2.6 been previously used for the hydrofeet). static pressure or stacking test. Excep- (2) For liquids in single packagings tions for the number of steel and aluand for inner packagings of combinaminum packaging samples used for tion packagings, if the test is perconducting the drop test are subject to formed with water: the approval of the Associate Adminis- (i) Where the materials to be carried trator. have a specific gravity not exceeding (c) Special preparation of test samples 1.2, drop height must be determined acfor the drop test. (1) Testing of plastic cording to packing group, as follows: drums, plastic jerricans, plastic boxes (A) Packing Group I: 1.8 m (5.9 feet). other than expanded polystyrene boxes, (B) Packing Group II: 1.2 m (3.9 feet). composite packagings (plastic mate- (C) Packing Group III: 0.8 in (2.6 feet). rial), and combination packagings with (ii) Where the materials to be transplastic inner packagings other than ported have a specific gravity exceedplastic bags intended to contain solids ing 1.2, the drop height must be calor articles must be carried out when culated on the basis of the specific the temperature of the test sample and gravity (SG) of the material to be carits contents has been reduced to - 18 °C ried, rounded up to the first decimal, as (0 °F) or lower. Test liquids must be follows: kept in the liquid state, if necessary, (A) Packing Group I: SG X 1.5 m (4.9 feet). by the addition of anti-freeze. Water/ anti-freeze solutions with a minimum (B) Packing Group II: SG 1.0 m (3.3 feet). specific gravity of 0.95 for testing at - 18 °C (0 °F) or lower are considered (C) Packing Group III: SG X 0.67 m (2.2 feet). acceptable test liquids. Test samples (f) Criteria for passing the test. A packprepared in this way are not required age is considered to successfully pass to be conditioned in accordance with the drop tests if for each sample test- $178.602(d). ed- (d) Target. The target must be a rigid, (1) For packagings containing liquid, non-resilient, flat and horizontal sureach packaging does not leak when face. equilibrium has been reached between (e) Drop height. Drop heights, measthe internal and external pressures, exured as the vertical distance from the cept for inner packagings of combinatarget to the lowest point on the packtion packagings when it is not necage, must be equal to or greater than essary that the pressures be equalized; the drop height determined as follows: (2) For removable head drums for sol- (1) For solids and liquids, if the test ids, the entire contents are retained by is performed with the solid or liquid to an inner packaging (e.g., a plastic bag) 1032 Pipeline and Hazardous Materials Safety Admin., DOT § 178.605 even if the closure on the top head of packagings must be tested with clothe drum is no longer sift-proof; sures in place. For production testing, (3) For a bag, neither the outermost packagings need not have their cloply nor an outer packaging exhibits sures in place. Removable heads need any damage likely to adversely affect not be installed during production testsafety during transport; ing. (4) For a composite or combination (2) For testing with closures in place, packaging, there is no damage to the vented closures must either be replaced outer packaging likely to adversely afby similar non-vented closures or the fect safety during transport, and there vent must be sealed. is no leakage of the filling substance (d) Test method. The packaging must from the inner packaging; be restrained under water while an in- (5) Any discharge from a closure is ternal air pressure is applied; the slight and ceases immediately after method of restraint must not affect the impact with no further leakage: and results of the test. The test must be (6) No rupture is permitted in packconducted, for other than production agings for materials in Class 1 which testing, for a minimum time of five would permit spillage of loose explominutes. Other methods, at least sive substances or articles from the equally effective, may be used in acouter packaging. cordance with appendix B of this part. (e) Pressure applied. An internal air [Amdt. 178-97, 55 FR 52723, Dec. 21, 1990, as amended at 56 FR 66286, Dec. 20, 1991; 57 FR pressure (gauge) must be applied to the 45465, Oct. 1, 1992; Amdt. 178-99, 58 FR 51534, packaging as indicated for the fol- Oct. 1, 1993; Amdt. 178-106, 59 FR 67522, Dec. lowing packing groups: 29, 1994; 65 FR 50462, Aug. 18, 2000; 66 FR 45386, (1) Packing Group I: Not less than 30 Aug. 28, 2001; 67 FR 61016, Sept. 27, 2002; 69 FR kPa (4 psi). 76186, Dec. 20, 2004] (2) Packing Group II: Not less than 20 kPa (3 psi). § 178.604 Leakproofness test. (3) Packing Group III: Not less than (a) General. The leakproofness test 20 kPa (3 psi). must be performed with compressed air (f) Criteria for passing the test. A packor other suitable gases on all packaging passes the test if there is no agings intended to contain liquids, exleakage of air from the packaging. cept that: [Amdt. 178-97. 55 FR 52723, Dec. 21, 1990, as (1) The inner receptacle of a comamended at 56 FR 66286, Dec. 20, 1991: Amdt. posite packaging may be tested with- 178-106, 59 FR 67522, Dec. 29, 1994; 66 FR 45386, out the outer packaging provided the Aug. 28, 2001] test results are not affected; and (2) This test is not required for inner § 178.605 Hydrostatic pressure test. packagings of combination packagings. (a) General. The hydrostatic pressure (b) Number of packagings to be testedtest must be conducted for the quali- (1) Production testing. All packagings fication of all metal, plastic, and comsubject to the provisions of this section posite packaging design types intended must be tested and must pass the to contain liquids and be performed peleakproofness test: riodically as specified in $178.601(e). (1) Before they are first used in trans- This test is not required for inner portation: and packagings of combination packagings. (ii) Prior to reuse, when authorized For internal pressure requirements for for reuse by $173.28 of this subchapter. inner packagings of combination pack- (2) Design qualification and periodic agings intended for transportation by testing. Three samples of each different aircraft, see $173.27(c) of this subpackaging must be tested and must chapter. pass the leakproofness test. Exceptions (b) Number of test samples. Three test for the number of samples used in consamples are required for each different ducting the leakproofness test are subpackaging. For packagings constructed ject to the approval of the Associate of stainless steel, monel, or nickel, Administrator. only one sample is required for periodic (c) Special preparation-(1) For design retesting of packagings. Exceptions for qualification and periodic testing, the number of aluminum and steel 1033 § 178.606 49 CFR Ch. I (10-1-06 Edition) sample packagings used in conducting each test sample, there is no leakage of the hydrostatic pressure test are subliquid from the package. ject to the approval of the Associate (Amdt. 178-97, 55 FR 52723, Dec. 21, 1990, as Administrator. amended at 56 FR 66286, Dec. 20, 1991; Amdt. (c) Special preparation of receptacles 178-99, 58 FR 51534. Oct. 1, 1993; Amdt. 178-102, for testings. Vented closures must ei- 59 FR 28494, June 2, 1994; 65 FR 50462, Aug. 18, ther be replaced by similar non-vented 2000; 66 FR 45386, 45390, Aug. 28, 2001] closures or the vent must be sealed. $ 178.606 Stacking test. (d) Test method and pressure to be applied. Metal packagings and composite (a) General. All packaging design packagings other than plastic (e.g., types other than bags must be subglass, porcelain or stoneware), includjected to a stacking test. ing their closures, must be subjected to (b) Number of test samples. Three test the test pressure for 5 minutes. Plastic samples are required for each different packagings and composite packagings packaging. For periodic retesting of (plastic material). including their clopackagings constructed of stainless sures, must be subjected to the test steel, monel, or nickel, only one test pressure for 30 minutes. This pressure sample is required. Exceptions for the is the one to be marked as required in number of aluminum and steel sample § 178.503(a)( of this part. The receppackagings used in conducting the stacking test are subject to the aptacles must be supported in a manner that does not invalidate the test. The proval of the Associate Administrator. Notwithstanding the provisions of test pressure must be applied continu- $178.602(a) of this subpart, combination ously and evenly, and it must be kept packagings may be subjected to the constant throughout the test period. stacking test without their inner pack- The hydraulic pressure (gauge) applied, agings, except where this would invalitaken at the top of the receptacle, and date the results of the test. determined by any one of the following (c) Test method-(1) Design qualificamethods must be: tion testing. The test sample must be (1) Not less than the total gauge pressubjected to a force applied to the top sure measured in the packaging (i.e., surface of the test sample equivalent to the vapor pressure of the filling matethe total weight of identical packages rial and the partial pressure of the air which might be stacked on it during or other inert gas minus 100 kPa (15 transport; where the contents of the psi)) at 55 °C (131 °F). multiplied by a test sample are non-hazardous liquids safety factor of 1.5. This total gauge with specific gravities different from pressure must be determined on the that of the liquid to be transported, the basis of a maximum degree of filling in force must be calculated based on the accordance with § 173.24a(d) of this subspecific gravity that will be marked on chapter and a filling temperature of 15 the packaging. The minimum height of °C (59 °F): the stack, including the test sample, (2) Not less than 1.75 times the vapor must be 3.0 m (10 feet). The duration of pressure at 50 °C (122 °F) of the matethe test must be 24 hours, except that rial to be transported minus 100 kPa (15 plastic drums, jerricans, and composite psi) but with a minimum test pressure packagings 6HH intended for liquids of 100 kPa (15 psig): or shall be subjected to the stacking test (3) Not less than 1.5 times the vapor for a period of 28 days at a temperature pressure at 55 °C (131 °F) of the material of not less than 40°C (104°F). Alterto be transported minus 100 kPa (15 native test methods which yield equivpsi), but with a minimum test pressure alent results may be used if approved of 100 kPa (15 psig). by the Associate Administrator. In guided load tests, stacking stability Packagings intended to contain hazmust be assessed after completion of ardous materials of Packing Group I the test by placing two filled packmust be tested to a minimum test presagings of the same type on the test sure of 250 kPa (36 psig). sample. The stacked packages must (e) Criteria for passing the test. A packmaintain their position for one hour. age passes the hydrostatic test if, for Plastic packagings must be cooled to 1034 Pipeline and Hazardous Materials Safety Admin., DOT § 178.608 ambient temperature before this stacktransportation. For the dynamic coming stability assessment. pression test, a container passes the (2) Periodic retesting. The test sample test if, after application of the required must be tested in accordance with: load, there is no buckling of the side- (i) Section 178.606(c)(1) of this subwalls sufficient to cause damage to its part; or expected contents; in no case may the (ii) The packaging may be tested maximum deflection exceed one inch. using a dynamic compression testing machine. The test must be conducted [Amdt. 178-97, 55 FR 52723, Dec. 21, 1990, as amended at 56 FR 66286, Dec. 20, 1991: 57 FR at room temperature on an empty, un- 45465, Oct. 1, 1992; Amdt. 178-102, 59 FR 28494, sealed packaging. The test sample June 2, 1994; Amdt. 178-106, 59 FR 67522. Dec. must be centered on the bottom platen 29, 1994; 65 FR 58632, Sept. 29, 2000; 66 FR of the testing machine. The top platen 45386, Aug. 28, 2001; 70 FR 34076, June 13, 2005) must be lowered until it comes in contact with the test sample. Compression § 178.607 Cooperage test for bung-type must be applied end to end. The speed wooden barrels. of the compression tester must be onehalf inch plus or minus one-fourth inch (a) Number of samples. One barrel is per minute. An initial preload of 50 required for each different packaging. pounds must be applied to ensure a (b) Method of testing. Remove all definite contact between the test samhoops above the bilge of an empty barple and the platens. The distance berel at least two days old. tween the platens at this time must be (c) Criteria for passing the test. A packrecorded as zero deformation. The force aging passes the cooperage test only if A to then be applied must be calculated the diameter of the cross-section of the using the formula: upper part of the barrel does not increase by more than 10 percent. Liquids: A = (n - 1) [w + (s V 8.3 .98)] X 1.5; § 178.608 Vibration standard. Solids: A = (n - 1) (m (a) Each packaging must be capable Where: of withstanding, without rupture or A - applied load in pounds. leakage, the vibration test procedure m = the certified maximum gross mass for outlined in this section. the container in kilograms: (b) Test method. (1) Three sample n = minimum number of containers that, packagings, selected at random, must when stacked, reach a height of 3 m. be filled and closed as for shipment. S - specific gravity of lading. W = maximum weight of one empty container (2) The three samples must be placed in pounds. on a vibrating platform that has a V = actual capacity of container (rated cavertical or rotary double-amplitude pacity + outage) in gallons. (peak-to-peak displacement) of one And: inch. The packages should be con- 8.3 corresponds to the weight In pounds of 1.0 strained horizontally to prevent them gallon of water. from falling off the platform, but must 1.5 is a compensation factor that converts be left free to move vertically, bounce the static load of the stacking test into a and rotate. load suitable for dynamic compression (3) The test must be performed for testing. one hour at a frequency that causes the (d) Criteria for passing the test. No test package to be raised from the vibrating sample may leak. In composite packplatform to such a degree that a piece agings or combination packagings, of material of approximately 1.6 mm there must be no leakage of the filling (0.063 inch) thickness (such as steel substance from the inner receptacle, or strapping or paperboard) can be passed inner packaging. No test sample may between the bottom of any package show any deterioration which could adand the platform. versely affect transportation safety or (4) Immediately following the period any distortion likely to reduce its of vibration, each package must be restrength, cause instability in stacks of moved from the platform, turned on its packages, or cause damage to inner side and observed for any evidence of packagings likely to reduce safety in leakage. 1035 § 178.609 49 CFR Ch. I (10-1-06 Edition) (5) Other methods, at least equally mary receptacle must be filled to 98 effective, may be used, if approved by percent capacity. Packagings for live the Associate Administrator. animals should be tested with the live (c) Criteria for passing the test. A packanimal being replaced by an approaging passes the vibration test if there priate dummy of similar mass. is no rupture or leakage from any of (c) Packagings prepared as for transthe packages. No test sample should port must be subjected to the tests in show any deterioration which could ad- Table I of this paragraph (c), which, for versely affect transportation safety or test purposes, categorizes packagings any distortion liable to reduce packaccording to their material characteraging strength. istics. For outer packagings, the head- [Amdt. 178-97. 55 FR 52723, Dec. 21, 1990, as ings in Table I relate to fiberboard or amended at 56 FR 66286, Dec. 20. 1991: 66 FR similar materials whose performance 45386, Aug. 28, 2001] may be rapidly affected by moisture; plastics that may embrittle at low § 178.609 Test requirements for packtemperature; and other materials, such agings for infectious substances. as metal, for which performance is not (a) Samples of each packaging must significantly affected by moisture or be prepared for testing as described in temperature. Where a primary recepparagraph (b) of this section and then tacle and a secondary packaging of an subjected to the tests in paragraphs (d) inner packaging are made of different through (i) of this section. materials, the material of the primary (b) Samples of each packaging must receptacle determines the appropriate be prepared as for transport except test. In instances where a primary rethat a liquid or solid infectious subceptacle is made of more than one mastance should be replaced by water or, terial, the material most likely to be where conditioning at - 18 °C (0 °F) is damaged determines the appropriate specified, by water/antifreeze. Each pritest. TABLE I-TESTS REQUIRED Material of Tests required Outer packaging Inner packaging Refer to para. (d) Refer to Fiberboard Plastics Other Plastics Other (d) (e) (f) (g) para. (h) When dry ice is used X (d) Samples must be subjected to (2) Where the samples are in the free-fall drops onto a rigid, nonresilshape of a drum, three samples must be ient, flat, horizontal surface from a dropped, one in each of the following height of 9 m (30 feet). orientations: The drops must be performed as fol- (i) Diagonally on the top chime, with lows: the center of gravity directly above the (1) Where the samples are in the point of impact; shape of a box, five samples must be (ii) Diagonally on the base chime; dropped, one in each of the following and orientation: (iii) Flat on the side. (i) Flat on the base; (3) While the sample should be re- (ii) Flat on the top; leased in the required orientation, it is (iii) Flat on the longest side; accepted that for aerodynamic reasons (iv) Flat on the shortest side; and the impact may not take place in that (v) On a corner. orientation. 1036 Pipeline and Hazardous Materials Safety Admin., DOT § 178.609 (4) Following the appropriate drop semm (1.5 inches) and a radius not exquence, there must be no leakage from ceeding 6 mm (0.2 inches) at the edges the primary receptacle(s) which should of the upper end. The rod must proremain protected by absorbent matetrude from the surface a distance at rial in the secondary packaging. least equal to that between the pri- (e) The samples must be subjected to mary receptacle(s) and the outer sur- a water spray to simulate exposure to face of the outer packaging with a minrainfall of approximately 50 mm (2 imum of 200 mm (7.9 inches). One saminches) per hour for at least one hour. ple must be dropped in a vertical free They must then be subjected to the fall from a height of 1 m (3 feet), meastest described in paragraph (d) of this ured from the top of the steel rod. A section. second sample must be dropped from (f) The sample must be conditioned in the same height in an orientation peran atmosphere of - 18 °C (0 °F) or less pendicular to that used for the first. In for a period of at least 24 hours and each instance, the packaging must be within 15 minutes of removal from that oriented so the steel rod will Impact atmosphere be subjected to the test dethe primary receptacle(s). For a sucscribed in paragraph (d) of this section. cessful test, there must be no leakage Where the sample contains dry ice, the from the primary receptacle(s) folconditioning period may be reduced to lowing each impact. 4 hours. (1) Variations. The following vari- (g) Where packaging is intended to ations in the primary receptacles contain dry ice, a test additional to placed within the secondary packaging that specified in paragraph (d) or (e) or (f) of this section must be carried out. are allowed without additional testing One sample must be stored so that all of the completed package. An equivathe dry ice dissipates and then be sublent level of performance must be maintained. jected to the test described in paragraph (d) of this section. (1) Variation 1. Primary receptacles of (h) Packagings with a gross mass of 7 equivalent or smaller size as compared kg (15 pounds) or less should be subto the tested primary receptacles may jected to the tests described in parabe used provided they meet all of the graph (h)(1) of this section and packfollowing conditions: agings with a gross mass exceeding 7 (i) The primary receptacles are of kg (15 pounds) to the tests in paragraph similar design to the tested primary re- (h) of this section. ceptacle (e.g., shape: round, rectan- (1) Samples must be placed on a gular, etc.). level, hard surface. A cylindrical steel (ii) The material of construction of rod with a mass of at least 7 kg (15 the primary receptacle (glass, plastics, pounds), a diameter not exceeding 38 metal, etc.) offers resistance to impact mm (1.5 inches), and, at the impact end and a stacking force equal to or greater edges, a radius not exceeding 6 mm (0.2 than that of the originally tested priinches). must be dropped in a vertical mary receptacle. free fall from a height of 1 m (3 feet), (iii) The primary receptacles have measured from the impact end of the the same or smaller openings and the sample's impact surface. One sample closure is of similar design (e.g., screw must be placed on its base. A second cap, friction lid, etc.). sample must be placed in an orienta- (iv) Sufficient additional cushioning tion perpendicular to that used for the material is used to fill void spaces and first. In each instance, the steel rod to prevent significant movement of the must be aimed to impact the primary primary receptacles. receptacle(s). For a successful test, (v) Primary receptacles are oriented there must be no leakage from the priwithin the intermediate packaging in mary receptacle(s) following each imthe same manner as in the tested packpact. age. (2) Samples must be dropped onto the (2) Variation 2. A lesser number of the end of a cylindrical steel rod. The rod tested primary receptacles, or of the must be set vertically in a level, hard alternative types of primary recepsurface. It must have a diameter of 38 tacles identified in paragraph (i)(1) of 1037 $ 178.700 49 CFR Ch. I (10-1-06 Edition) this section, may be used provided sufplastic bag. or other equally effective ficient cushioning is added to fill the means of containment. void space(s) and to prevent significant (vii) In addition, the marking removement of the primary receptacles. quired in $178.503(f) of this subchapter (3) Variation 3. Primary receptacles of must be followed by the letter "U". any type may be placed within a secondary packaging and shipped without [Amdt. 178-97, 55 FR 52723. Dec. 21, 1990, as amended by Amdt. 178-111, 60 FR 48787, Sept. testing in the outer packaging provided 20, 1995; 67 FR 53143, Aug. 14, 2002; 69 FR 54046, all of the following conditions are met: Sept. 7, 2004] (i) The secondary and outer packaging combination must be success- Subpart N-IBC Performancefully tested in accordance with para- Oriented Standards graphs (a) through (h) of this section with fragile (e.g., glass) inner recep- § 178.700 Purpose, scope and definitacles. tions. (ii) The total combined gross weight of inner receptacles may not exceed (a) This subpart prescribes requireone-half the gross weight of inner rements applying to IBCs intended for ceptacles used for the drop test in parathe transportation of hazardous mategraph (d) of this section. rials. Standards for these packagings (iii) The thickness of cushioning maare based on the UN Recommendations. terial between inner receptacles and (b) Terms used in this subpart are debetween inner receptacles and the outfined in $171.8 of this subchapter and in side of the secondary packaging may paragraph (c) of this section. not be reduced below the corresponding (c) The following definitions pertain thicknesses in the originally tested to the IBC standards in this subpart. packaging. If a single inner receptacle (1) Body means the receptacle proper was used in the original test, the thick- (including openings and their closures, ness of cushioning between the inner but not including service equipment). receptacles must be no less than the that has a volumetric capacity of not thickness of cushioning between the more than three cubic meters (3,000 L, outside of the secondary packaging and 793 gallons, or 106 cubic feet) and not the inner receptacle in the original less than 0.45 cubic meters (450 L, 119 test. When either fewer or smaller gallons, or 15.9 cubic feet) or a maxinner receptacles are used (as comimum net mass of not less than 400 kg pared to the inner receptacles used in (882) pounds. the drop test), sufficient additional (2) Service equipment means filling and cushioning material must be used to discharge, pressure relief, safety, heatfill the void. ing and heat-insulating devices and (iv) The outer packaging must pass measuring instruments. the stacking test in $178.606 while (3) Structural equipment means the reempty. The total weight of identical inforcing, fastening, handling, protecpackages must be based on the comtive or stabilizing members of the body bined mass of inner receptacles used in or stacking load bearing structural the drop test in paragraph (d) of this members (such as metal cages). section. (4) Maximum permissible gross mass (v) For inner receptacles containing means the mass of the body, its service liquids, an adequate quantity of abequipment, structural equipment and sorbent material must be present to the maximum net mass (see $171.8 of absorb the entire liquid contents of the this subchapter). inner receptacles. [Amdt. 178-103, 59 FR 38068, July 26, 1994, as (vi) If the outer packaging is inamended by Amdt. 178-108, 60 FR 40038. Aug. tended to contain inner receptacles for 4, 1995; 66 FR 45386, 45387, Aug. 28, 2001] liquids and is not leakproof, or is intended to contain inner receptacles for § 178.702 IBC codes. solids and is not sift proof, a means of (a) Intermediate bulk container code containing any liquid or solid contents designations consist of: two numerals in the event of leakage must be prospecified in paragraph (a)(1) of this secvided. This can be a leakproof liner, tion; followed by the capital letter(s) 1038 Pipeline and Hazardous Materials Safety Admin., DOT § 178.703 specified in paragraph (a) (2) of this secformation is required in the sequence tion; followed, when specified in an inpresented: dividual section, by a numeral indi- (i) The United Nations symbol as ilcating the category of intermediate lustrated In $178.503(e)(1). For metal bulk container. IBCs on which the marking is stamped (1) IBC code number designations are or embossed, the capital letters 'UN' as follows: may be applied instead of the symbol. (ii) The code number designating IBC For solids, discharged design type according to $178.702(a). Under pres- The letter "W" must follow the IBC de- Type sure of For liquids by gravity more than sign type identification code on an IBC 10 kPa (1.45 psig) when the IBC differs from the requirements in subpart N of this part, or is Rigid 11 21 31 tested using methods other than those Flexible 13 specified in this subpart, and is approved by the Associate Administrator (2) Intermediate bulk container code in accordance with the provisions in letter designations are as follows: $178.801(i). "A" means steel (all types and surface treat- (iii) A capital letter identifying the ments). performance standard under which the "B" means aluminum. design type has been successfully test- "C" means natural wood. ed, as follows: "D" means plywood. (A) X-for IBCs meeting Packing "F" means reconstituted wood. Group I, II and III tests; "G" means fiberboard. "H" means plastic. (B) Y-for IBCs meeting Packing "L" means textile. Group II and III tests; and "M" means paper, multiwall. (C) Z-for IBCs meeting only Packing "N" means metal (other than steel or alu- Group III tests. minum). (iv) The month (designated numeri- (b) For composite IBCs, two capital cally) and year (last two digits) of manufacture. letters are used in sequence following the numeral indicating IBC design (v) The country authorizing the allocation of the mark. The letters 'USA' type. The first letter indicates the maindicate that the IBC is manufactured terial of the IBC inner receptacle. The and marked in the United States in second letter indicates the material of compliance with the provisions of this the outer IBC. For example, 31HA1 is a subchapter. composite IBC with a plastic inner receptacle and a steel outer packaging. (vi) The name and address or symbol of the manufacturer or the approval [Amdt. 178-103, 59 FR 38068, July 26, 1994, as agency certifying compliance with subamended at 66 FR 45386, Aug. 28, 2001] parts N and 0 of this part. Symbols, if used, must be registered with the Asso- § 178.703 Marking of IBCs. ciate Administrator. (a) The manufacturer shall: (vii) The stacking test load in kilo- (1) Mark every IBC in a durable and grams (kg). For IBCs not designed for clearly visible manner. The marking stacking, the figure "0" must be may be applied in a single line or in shown. multiple lines provided the correct se- (viii) The maximum permissible quence is followed with the informagross mass or, for flexible IBCs, the tion required by this section in letters, maximum net mass, in kg. numerals and symbols of at least 12 (2) The following are examples of mm in height. This minimum marking symbols and required markings: size applies only to IBCs manufactured (i) For a metal IBC containing solids after October 1, 2001). The following indischarged by gravity made from steel: 1039 § 178.703 49 CFR Ch. I (10-1-06 Edition) HE 11A/Y/02 92/USA/ABC/5500/1500 (ii) For a flexible IBC containing solids discharged by gravity and made from woven plastic with a liner: UR 13H3/Z/03 92/USA/ABC/0/1500 (iii) For a rigid plastic IBC constack load and with a manufacturer's taining liquids, made from plastic with symbol in place of the manufacturer's structural equipment withstanding the name and address: H 31H1/Y/04 93/USA/M9399/10800/1200 (iv) For a composite IBC containing with the symbol of a DOT approved liquids, with a rigid plastic inner rethird-party test laboratory: ceptacle and an outer steel body and UR 31HA1/Y/05 93/USA/+ZT1235/10800/1200 (b) Additional marking. In addition to used, the metric unit indicated (e.g., markings required in paragraph (a) of 450 L) must also appear. this section, each IBC must be marked (1) For each rigid plastic and comas follows in a place near the markings posite IBC, the following markings required in paragraph (a) of this secmust be included: tion that is readily accessible for in- (i) Rated capacity in L of water at 20 spection. Where units of measure are °C (68 °F); (ii) Tare mass in kilograms; 1040 Pipeline and Hazardous Materials Safety Admin., DOT § 178.704 (iii) Gauge test pressure in kPa; § 178.704 General IBC standards. (iv) Date of last leakproofness test, if (a) Each IBC must be resistant to, or applicable (month and year); and protected from, deterioration due to (v) Date of last inspection (month exposure to the external environment. and year). IBCs intended for solid hazardous ma- (2) For each metal IBC, the following terials must be sift-proof and water-remarkings must be included on a metal sistant. corrosion-resistant plate: (b) All service equipment must be so (i) Rated capacity in L of water at 20 positioned or protected as to minimize °C (68 °F); potential loss of contents resulting (ii) Tare mass in kilograms; from damage during IBC handling and (iii) Date of last leakproofness test, if transportation. applicable (month and year); (c) Each IBC, including attachments, (iv) Date of last inspection (month and service and structural equipment, and year); must be designed to withstand, without (v) Maximum loading/discharge presloss of hazardous materials, the intersure, in kPa, if applicable; nal pressure of the contents and the (vi) Body material and its minimum stresses of normal handling and transthickness in mm; and port. An IBC intended for stacking (vii) Serial number assigned by the must be designed for stacking. Any manufacturer. lifting or securing features of an IBC (3) Markings required by paragraph must be of sufficient strength to with- (b)(1) or (b)(2) of this section may be stand the normal conditions of hanpreceded by the narrative description dling and transportation without gross of the marking, e.g. "Tare Mass: * distortion or failure and must be posiwhere the * are replaced with the tioned so as to cause no undue stress in tare mass in kilograms of the IBC. any part of the IBC. (4) For each fiberboard and wooden (d) An IBC consisting of a packaging IBC, the tare mass in kg must be within a framework must be so conshown. structed that: (5) Each flexible IBC may be marked (1) The body is not damaged by the with a pictogram displaying recframework; ommended lifting methods. (2) The body is retained within the (6) For each composite IBC, the inner framework at all times; and receptacle must be marked with at (3) The service and structural equipleast the following information: ment are fixed in such a way that they (i) The code number designating the cannot be damaged if the connections IBC design type, the name and address between body and frame allow relative or symbol of the manufacturer, the expansion or motion. date of manufacture and the country (e) Bottom discharge valves must be authorizing the allocation of the mark secured in the closed position and the as specified in paragraph (a) of this secdischarge system suitably protected tion; from damage. Valves having lever clo- (ii) When a composite IBC is designed sures must be secured against acciin such a manner that the outer casing dental opening. The open or closed pois intended to be dismantled for transsition of each valve must be readily apport when empty (such as, for the reparent. For each IBC containing a liqturn of the IBC for reuse to the origiuid, a secondary means of sealing the nal consignor), each of the parts indischarge aperture must also be protended to be detached when so dismanvided, e.g., by a blank flange or equivatled must be marked with the month lent device. and year of manufacture and the name (f) IBC design types must be conor symbol of the manufacturer. structed in such a way as to be bottomlifted or top-lifted as specified in [Amdt. 178-103, 59 FR 38068, July 26, 1994, as §§ 178.811 and 178.812. amended by Amdt. 178-119, 62 FR 24743, May 6, 1997; 64 FR 10782, Mar. 5, 1999; 65 FR 50462, [Amdt. 178-103, 59 FR 38068, July 26, 1994, as Aug. 18, 2000; 65 FR 58632, Sept. 29, 2000; 66 FR amended at 66 FR 45386, Aug. 28, 2001; 68 FR 33451, June 21, 2001; 66 FR 45387, Aug. 28, 2001] 61942, Oct. 30, 2003] 1041 § 178.705 49 CFR Ch. I (10-1-06 Edition) § 178.705 Standards for metal IBCs. (A) For steel, the percentage elon- (a) The provisions in this section gation at fracture must not be less apply to metal IBCs intended to conthan 10,000/Rm with a minimum of 20 tain liquids and solids. Metal IBC types percent; where Rm = minimum tensile are designated: strength of the steel to be used, in N/ (1) 11A, 11B, 11N for solids that are mm²; if U.S. Standard units of psi are loaded or discharged by gravity. used for tensile strength then the ratio (2) 21A, 21B, 21N for solids that are becomes 10,000 X (145/Rm). loaded or discharged at a gauge pres- (B) For aluminum, the percentage sure greater than 10 kPa (1.45 psig). elongation at fracture must not be less (3) 31A, 31B, 31N for liquids or solids. than 10,000/(6Rm) with an absolute min- (b) Definitions for metal IBCs: imum of eight percent; if U.S. Standard (1) Metal IBC means an IBC with a units of psi are used for tensile metal body, together with appropriate service and structural equipment. strength then the ratio becomes 10,000 (2) Protected means providing the IBC 145 / (6Rm). body with additional external protec- (C) Specimens used to determine the tion against impact and abrasion. For elongation at fracture must be taken example, a multi-layer (sandwich) or transversely to the direction of rolling double wall construction or a frame and be so secured that: with a metal lattice-work casing. Lo = 5d (c) Construction requirements for metal IBCs are as follows: or (1) Body. The body must be made of ductile metal materials. Welds must be Lo = 5.65 VA made so as to maintain design type inwhere: tegrity of the receptacle under conditions normally incident to transpor- Lo = gauge length of the specimen before the test tation. d = diameter (i) The use of dissimilar metals must not result in deterioration that could A - cross-sectional area of test specimen. affect the integrity of the body. (iv) Minimum wall thickness: (ii) Aluminum IBCs intended to con- (A) For a reference steel having a tain flammable liquids must have no product of Rm X Ao = 10,000, where Ao movable parts, such as covers and clois the minimum elongation (as a persures, made of unprotected steel liable centage) of the reference steel to be to rust, which might cause a dangerous used on fracture under tensile stress reaction from friction or percussive (Rm X Ao = 10,000 X 145; if tensile contact with the aluminum. strength is in U.S. Standard units of (iii) Metals used in fabricating the body of a metal IBC must meet the folpounds per square inch), the wall thickness must not be less than: lowing requirements: Wall thickness (T) in mm Capacity (C) in liters Types 11A, 118, 11N Types 21A, 21B. 21N, 31A, 31B, 31N Unprotected Protected Unprotected Protected C≤1000 2.0 1.5 2.5 2.0 1000<C>2000 T=C/2000 + 1.5 T=C/2000 + 1.0 T=C/2000 + 2.0 T=C/2000 + 1.5 2000<C<3000 T=C/2000 + 1.5 T=C/2000 + 1.0 T=C/1000 + 1.0 T=C/2000 + 1.5 (B) For metals other than the ref- FORMULA FOR METRIC UNITS erence steel described in paragraph (c)(1)(iii)(A) of this section, the minimum wall thickness is the greater of = 3 1.5 mm (0.059 inches) or as determined by use of the following equivalence formula: 1042 Pipeline and Hazardous Materials Safety Admin., DOT § 178.706 FORMULA FOR U.S. STANDARD devices are the only source of pressure UNITS relief for the IBC. Pressure relief devices must be fitted in the vapor space. [Amdt. 178-103, 59 FR 38068, July 26, 1994, as amended by Amdt. 178-108, 60 FR 40038, Aug. 4. 1995; Amdt. 178-117. 61 FR 50629, Sept. 26. 1996; 66 FR 33452, June 21, 2001; 66 FR 45386, where: 45387, Aug. 28, 2001; 68 FR 45041, July 31, 2003] e, = required equivalent wall thickness of the metal to be used (in mm or if e. is in $178.706 Standards for rigid plastic inches, use formula for U.S. Standard IBCs. units). (a) The provisions in this section e₀ = required minimum wall thickness for the reference steel (in mm or if e. is in apply to rigid plastic IBCs intended to inches, use formula for U.S. Standard contain solids or liquids. Rigid plastic units). IBC types are designated: Rm, = guaranteed minimum tensile strength (1) 11H1 fitted with structural equipof the metal to be used (in N/mm2 or for ment designed to withstand the whole U.S. Standard units, use psi). load when IBCs are stacked, for solids A, = minimum elongation (as a percentage) which are loaded or discharged by gravof the metal to be used on fracture under ity. tensile stress (see paragraph (c)(I) of this section). (2) 11H2 freestanding, for solids which are loaded or discharged by gravity. (C) For purposes of the calculation (3) 21H1 fitted with structural equipdescribed in paragraph (c)(1)(iv)(B) of ment designed to withstand the whole this section, the guaranteed minimum load when IBCs are stacked, for solids tensile strength of the metal to be used which are loaded or discharged under (Rm,) must be the minimum value acpressure. cording to material standards. How- (4) 21H2 freestanding, for solids which ever, for austenitic (stainless) steels, are loaded or discharged under presthe specified minimum value for Rm, sure. according to the material standards, (5) 31H1 fitted with structural equipmay be increased by up to 15% when a ment designed to withstand the whole greater value is provided in the mateload when IBCs are stacked, for liquids. rial inspection certificate. When no (6) 31H2 freestanding, for liquids. material standard exists for the mate- (b) Rigid plastic IBCs consist of a rial in question, the value of Rm must rigid plastic body, which may have be the minimum value indicated in the structural equipment, together with material inspection certificate. appropriate service equipment. (2) Pressure relief. The following pres- (c) Rigid plastic IBCs must be manusure relief requirements apply to IBCs factured from plastic material of intended for liquids: known specifications and be of a (i) IBCs must be capable of releasing strength relative to its capacity and to a sufficient amount of vapor in the the service it is required to perform. In event of fire engulfment to ensure that addition to conformance to $173.24 of no rupture of the body will occur due this subchapter, plastic materials must to pressure build-up. This can be be resistant to aging and to degradaachieved by spring-loaded or non-retion caused by ultraviolet radiation. closing pressure relief devices or by (1) If protection against ultraviolet other means of construction. radiation is necessary. it must be pro- (ii) The start-to-discharge pressure vided by the addition of a pigment or may not be higher than 65 kPa (9 psig) inhibiter such as carbon black. These and no lower than the vapor pressure of additives must be compatible with the the hazardous material plus the partial contents and remain effective throughpressure of the air or other inert gases, out the life of the IBC body. Where use measured in the IBC at 55 °C (131 °F), is made of carbon black, pigments or determined on the basis of a maximum inhibitors, other than those used in the degree of filling as specified in manufacture of the tested design type, 173.35(d) of this subchapter. This does retesting may be omitted if changes in not apply to fusible devices unless such the carbon black content, the pigment 1043 § 178.707 49 CFR Ch. I (10-1-06 Edition) content or the inhibitor content do not (1) A composite IBC is an IBC which adversely affect the physical properties consists of a rigid outer packaging enof the material of construction. closing a plastic inner receptacle to- (2) Additives may be included in the gether with any service or other struccomposition of the plastic material to tural equipment. The outer packaging improve the resistance to aging or to of a composite IBC is designed to bear serve other purposes, provided they do the entire stacking load. The inner renot adversely affect the physical or ceptacle and outer packaging form an chemical properties of the material of integral packaging and are filled, construction. stored, transported, and emptied as a (3) No used material other than prounit. duction residues or regrind from the (2) The term plastic means polymeric same manufacturing process may be materials (i.e., plastic or rubber). used in the manufacture of rigid plastic (3) A "rigid" inner receptacle is an IBCs. inner receptacle which retains its gen- (4) Rigid plastic IBCs intended for the eral shape when empty without clotransportation of liquids must be capasures in place and without benefit of ble of releasing a sufficient amount of the outer casing. Any inner receptacle vapor to prevent the body of the IBC that is not "rigid" is considered to be from rupturing if it is subjected to an "flexible." internal pressure in excess of that for (c) Construction requirements for which it was hydraulically tested. This composite IBCs with plastic inner remay be achieved by spring-loaded or ceptacles are as follows: non-reclosing pressure relief devices or (1) The outer packaging must consist by other means of construction. of rigid material formed so as to pro- [Amdt. 178-103, 59 FR 38068, July 26, 1994. as tect the inner receptacle from physical amended at 66 FR 45386, 45387, Aug. 28, 2001] damage during handling and transportation, but is not required to perform § 178.707 Standards for composite the secondary containment function. It IBCs. includes the base pallet where appro- (a) The provisions in this section priate. The inner receptacle is not inapply to composite IBCs intended to tended to perform a containment funccontain solids and liquids. To complete tion without the outer packaging. the marking codes listed below, the (2) A composite IBC with a fully enletter "Z" must be replaced by a capclosing outer packaging must be deital letter in accordance with signed to permit assessment of the in- § 178.702(a)(2) to indicate the material tegrity of the inner container following used for the outer packaging. Comthe leakproofness and hydraulic tests. posite IBC types are designated: The outer packaging of 31HZ2 com- (1) 11HZ1 Composite IBCs with a rigid posite IBCs must enclose the inner replastic inner receptacle for solids loadceptacles on all sides. ed or discharged by gravity. (3) The inner receptacle must be (2) 11HZ2 Composite IBCs with a manufactured from plastic material of flexible plastic inner receptacle for solknown specifications and be of a ids loaded or discharged by gravity. strength relative to its capacity and to (3) 21HZ1 Composite IBCs with a rigid the service it is required to perform. In plastic inner receptacle for solids loadaddition to conformance with the reed or discharged under pressure. quirements of $173.24 of this sub- (4) 21HZ2 Composite IBCs with a chapter, the material must be resistant flexible plastic inner receptacle for solto aging and to degradation caused by ids loaded or discharged under presultraviolet radiation. The inner recepsure. tacle of 31HZ2 composite IBCs must (5) 31HZ1 Composite IBCs with a rigid consist of at least three plies of film. plastic inner receptacle for liquids. (i) If necessary, protection against (6) 31HZ2 Composite IBCs with a ultraviolet radiation must be provided flexible plastic inner receptacle for liqby the addition of pigments or inhibiuids. tors such as carbon black. These addi- (b) Definitions for composite IBC tives must be compatible with the contypes: tents and remain effective throughout 1044 Pipeline and Hazardous Materials Safety Admin., DOT § 178.707 the life of the inner receptacle. Where equipment of the outer packaging. use is made of carbon black, pigments, Outer packagings must be firmly or inhibitors, other than those used in nailed or secured to corner posts or the manufacture of the tested design ends or be assembled by equally suittype, retesting may be omitted if the able devices. carbon black content, the pigment con- (iii) Outer packagings of reconstitent, or the inhibitor content do not tuted wood must be constructed of adversely affect the physical properties water-resistant reconstituted wood of the material of construction. such as hardboard or particle board. (ii) Additives may be included in the Materials other than reconstituted composition of the plastic material of wood may be used for the construction the inner receptacle to improve resistof structural equipment of reconstiance to aging, provided they do not adtuted wood outer packaging. versely affect the physical or chemical (iv) Fiberboard outer packagings properties of the material. must be constructed of strong, solid, or (iii) No used material other than prodouble-faced corrugated fiberboard duction residues or regrind from the (single or multiwall). same manufacturing process may be (A) Water resistance of the outer surused in the manufacture of inner recepface must be such that the increase in tacles. mass, as determined in a test carried (iv) Composite IBCs intended for the out over a period of 30 minutes by the transportation of liquids must be capa- Cobb method of determining water abble of releasing a sufficient amount of sorption, is not greater than 155 grams vapor to prevent the body of the IBC per square meter (0.0316 pounds per from rupturing if it is subjected to an square foot)-see ISO 535 (E) (IBR, see internal pressure in excess of that for $171.7 of this subchapter). Fiberboard which it was hydraulically tested. This must have proper bending qualities. Fimay be achieved by spring-loaded or berboard must be cut, creased without non-reclosing pressure relief devices or cutting through any thickness of fiberby other means of construction. board, and slotted so as to permit as- (4) The strength of the construction sembly without cracking, surface material comprising the outer packbreaks, or undue bending. The fluting aging and the manner of construction of corrugated fiberboard must be firmmust be appropriate to the capacity of ly glued to the facings. the composite IBC and its intended use. (B) The ends of fiberboard outer The outer packaging must be free of any projection that might damage the packagings may have a wooden frame inner receptacle. or be constructed entirely of wood. (i) Outer packagings of natural wood Wooden battens may be used for reinforcements. must be constructed of well seasoned wood that is commercially dry and free (C) Manufacturers' joints in the bodfrom defects that would materially ies of outer packagings must be taped, lessen the strength of any part of the lapped and glued, or lapped and outer packaging. The tops and bottoms stitched with metal staples. may be made of water-resistant recon- (D) Lapped joints must have an apstituted wood such as hardboard or propriate overlap. particle board. Materials other than (E) Where closing is effected by glunatural wood may be used for construcing or taping, a water-resistant adhetion of structural equipment of the sive must be used. outer packaging. (F) All closures must be sift-proof. (ii) Outer packagings of plywood (v) Outer packagings of plastic matemust be made of well-seasoned, rotary rials must be constructed in accordcut, sliced, or sawn veneer, commerance with the relevant provisions of cially dry and free from defects that paragraph (c)(3) of this section. would materially lessen the strength of (5) Any integral pallet base forming the casing. All adjacent plies must be part of an IBC, or any detachable palglued with water-resistant adhesive. let, must be suitable for the mechan- Materials other than plywood may be ical handling of an IBC filled to its used for construction of structural maximum permissible gross mass. 1045 § 178.708 49 CFR Ch. I (10-1-06 Edition) (i) The pallet or integral base must outer surface must be such that the inbe designed to avoid protrusions that crease in mass, as determined in a test may cause damage to the IBC in hancarried out over a period of 30 minutes dling. by the Cobb method of determining (ii) The outer packaging must be sewater absorption, is not greater than cured to any detachable pallet to en- 155 grams per square meter (0.0316 sure stability in handling and transporpounds per square foot)-see ISO 535 (E) tation. Where a detachable pallet is (IBR, see $171.7 of this subchapter). Fiused, its top surface must be free from berboard must have proper bending sharp protrusions that might damage qualities. Fiberboard must be cut, the IBC. creased without cutting through any (iii) Strengthening devices, such as thickness of fiberboard, and slotted so timber supports to increase stacking as to permit assembly without crackperformance, may be used but must be ing, surface breaks, or undue bending. external to the inner receptacle. The fluting of corrugated fiberboard (iv) The load-bearing surfaces of IBCs must be firmly glued to the facings. intended for stacking must be designed (i) The walls, including top and botto distribute loads in a stable manner. tom, must have a minimum puncture An IBC intended for stacking must be resistance of 15 Joules (11 foot-pounds designed so that loads are not supof energy) measured according to ISO ported by the inner receptacle. 3036 (IBR, see $171.7 of this subchapter). (6) Intermediate IBCs of type 31HZ2 (ii) Manufacturers' joints in the bodmust be limited to a capacity of not ies of IBCs must be made with an apmore than 1,250 L. propriate overlap and be taped, glued, [Amdt. 178-103, 59 FR 38068, July 26, 1994, as stitched with metal staples or fastened amended by Amdt. 178-119, 62 FR 24743, May by other means at least equally effec- 6. 1997; 66 FR 45387, Aug. 28, 2001; 67 FR 61016, tive. Where joints are made by gluing Sept. 27, 2002; 68 FR 75758, Dec. 31, 2003; 69 FR or taping, a water-resistant adhesive 54046, Sept. 7. 2004) must be used. Metal staples must pass completely through all pieces to be fas- § 178.708 Standards for fiberboard tened and be formed or protected so IBCs. that any inner liner cannot be abraded (a) The provisions of this section or punctured by them. apply to fiberboard IBCs intended to (3) The strength of the material used contain solids that are loaded or disand the construction of the liner must charged by gravity. Fiberboard IBCs be appropriate to the capacity of the are designated: 11G. IBC and the intended use. Joints and (b) Definitions for fiberboard IBC closures must be sift-proof and capable types: of withstanding pressures and impacts (1) Fiberboard IBCs consist of a fiberliable to occur under normal conditions board body with or without separate of handling and transport. top and bottom caps, appropriate serv- (4) Any integral pallet base forming ice and structural equipment, and if part of an IBC, or any detachable palnecessary an inner liner (but no inner let, must be suitable for the mechanpackaging). ical handling of an IBC filled to its (2) Liner means a separate tube or maximum permissible gross mass. bag, including the closures of its open- (i) The pallet or integral base must ings, inserted in the body but not formbe designed to avoid protrusions that ing an integral part of it. may cause damage to the IBC in han- (c) Construction requirements for fidling. berboard IBCs are as follows: (ii) The outer packaging must be se- (1) Top lifting devices are prohibited cured to any detachable pallet to enin fiberboard IBCs. sure stability in handling and trans- (2) Fiberboard IBCs must be conport. Where a detachable pallet is used, structed of strong, solid or doubleits top surface must be free from sharp faced corrugated fiberboard (single or protrusions that might damage the multiwall) that is appropriate to the IBC. capacity of the outer packaging and its (iii) Strengthening devices, such as intended use. Water resistance of the timber supports to increase stacking 1046 Pipeline and Hazardous Materials Safety Admin., DOT $ 178.710 performance. may be used but must be cut, sliced or sawn veneer, commerexternal to the inner liner. cially dry, and free from defects that (iv) The load-bearing surfaces of IBCs would materially lessen the strength of intended for stacking must be designed the body. All adjacent plies must be to distribute loads in a stable manner. glued with water-resistant adhesive. [Amdt. 178-103, 59 FR 38068, July 26, 1994, as Materials other than plywood may be amended at 66 FR 45386, Aug. 28, 2001; 68 FR used for the construction of structural 75758, Dec. 31, 2003] equipment of the outer packaging. (iii) Reconstituted wood used in con- § 178.709 Standards for wooden IBCs. struction of bodies must be water re- (a) The provisions in this section sistant reconstituted wood such as apply to wooden IBCs intended to conhardboard or particle board. Materials tain solids that are loaded or disother than reconstituted wood may be charged by gravity. Wooden IBC types used for the construction of structural are designated: equipment of the outer packaging. (1) 11C Natural wood with inner liner. (iv) Wooden IBCs must be firmly (2) 11D Plywood with inner liner. nailed or secured to corner posts or (3) 11F Reconstituted wood with ends or be assembled by similar deinner liner. vices. (b) Definitions for wooden IBCs: (3) The strength of the material used (1) Wooden IBCs consist of a rigid or and the construction of the liner must collapsible wooden body together with be appropriate to the capacity of the an inner liner (but no inner packaging) IBC and its intended use. Joints and and appropriate service and structural closures must be sift-proof and capable equipment. of withstanding pressures and impacts (2) Liner means a separate tube or liable to occur under normal conditions bag, including the closures of its openof handling and transportation. ings, inserted in the body but not form- (4) Any integral pallet base forming ing an integral part of it. part of an IBC, or any detachable pal- (c) Construction requirements for let, must be suitable for the mechanwooden IBCs are as follows: ical handling of an IBC filled to its (1) Top lifting devices are prohibited maximum permissible gross mass. in wooden IBCs. (i) The pallet or integral base must (2) The strength of the materials used be designed to avoid protrusions that and the method of construction must may cause damage to the IBC in hanbe appropriate to the capacity and indling. tended use of the IBC. (ii) The outer packaging must be se- (i) Natural wood used in the concured to any detachable pallet to enstruction of an IBC must be well-seasure stability in handling and transporsoned, commercially dry, and free from tation. Where a detachable pallet is defects that would materially lessen used, its top surface must be free from the strength of any part of the IBC. sharp protrusions that might damage Each IBC part must consist of uncut the IBC. wood or a piece equivalent in strength (iii) Strengthening devices, such as and integrity. IBC parts are equivalent timber supports to increase stacking to one piece when a suitable method of performance, may be used but must be glued assembly is used (i.e., a external to the inner liner. Lindermann joint, tongue and groove (iv) The load-bearing surfaces of IBCs joint, ship lap or rabbet joint, or butt intended for stacking must be designed joint with at least two corrugated to distribute loads in a stable manner. metal fasteners at each joint, or when other methods at least equally effec- [Amdt. 178-103, 59 FR 38068, July 26, 1994, as tive are used). Materials other than amended at 66 FR 45386, Aug. 28, 2001] natural wood may be used for the construction of structural equipment of $ 178.710 Standards for flexible IBCs. the outer packaging. (a) The provisions of this section (ii) Plywood used in construction of apply to flexible IBCs intended to conbodies must be at least 3-ply. Plywood tain solid hazardous materials. Fleximust be made of well-seasoned, rotaryble IBC types are designated: 1047 $ 178.800 49 CFR Ch. I (10-1-06 Edition) (1) 13H1 woven plastic without coatmain effective throughout the life of ing or liner. the container. Where use is made of (2) 13H2 woven plastic, coated. carbon black, pigments, or inhibitors, (3) 13H3 woven plastic with liner. other than those used in the manufac- (4) 13H4 woven plastic, coated and ture of the tested design type, rewith liner. testing may be omitted if the carbon (5) 13H5 plastic film. black content, the pigment content or (6) 13L1 textile without coating or the inhibitor content does not adliner. versely affect the physical properties (7) 13L2 textile, coated. of the material of construction. Addi- (8) 13L3 textile with liner. tives may be included in the composi- (9) 13L4 textile, coated and with tion of the plastic material to improve liner. resistance to aging, provided they do (10) 13M1 paper, multiwall. not adversely affect the physical or (11) 13M2 paper, multiwall, water rechemical properties of the material. sistant. (6) No used material other than pro- (b) Definitions for flexible IBCs: duction residues or regrind from the (1) Flexible IBCs consist of a body consame manufacturing process may be structed of film, woven plastic, woven used in the manufacture of plastic fabric, paper, or combination thereof, flexible IBCs. This does not preclude together with any appropriate service the re-use of component parts such as equipment and handling devices, and if fittings and pallet bases, provided such necessary, an inner coating or liner. components have not in any way been (2) Woven plastic means a material damaged in previous use. made from stretched tapes or (7) When flexible IBCs are filled, the monofilaments. ratio of height to width may not be (3) Handling device means any sling, more than 2:1. loop, eye, or frame attached to the body of the IBC or formed from a con- [Amdt. 178-103, 59 FR 38068, July 26, 1994, as tinuation of the IBC body material. amended by Amdt. 178-108. 60 FR 40038, Aug. 4. 1995; 66 FR 45386. Aug. 28, 2001] (c) Construction requirements for flexible IBCs are as follows: (1) The strength of the material and Subpart O-Testing of IBCs the construction of the flexible IBC $ 178.800 Purpose and scope. must be appropriate to its capacity and its intended use. This subpart prescribes certain test- (2) All materials used in the coning requirements for IBCs identified in struction of flexible IBCs of types 13M1 subpart N of this part. and 13M2 must, after complete immer- [Amdt. 178-103, 59 FR 38074. July 26, 1994, as sion in water for not less than 24 hours, amended by 66 FR 45386, Aug. 28, 2001] retain at least 85 percent of the tensile strength as measured originally on the $ 178.801 General requirements. material conditioned to equilibrium at (a) General. The test procedures pre- 67 percent relative humidity or less. scribed in this subpart are intended to (3) Seams must be stitched or formed ensure that IBCs containing hazardous by heat sealing, gluing or any equivamaterials can withstand normal condilent method. All stitched seam-ends tions of transportation and are considmust be secured. ered minimum requirements. Each (4) In addition to conformance with packaging must be manufactured and the requirements of $173.24 of this subassembled so as to be capable of succhapter, flexible IBCs must be resistant cessfully passing the prescribed tests to aging and degradation caused by uland of conforming to the requirements traviolet radiation. of $173.24 of this subchapter at all (5) For plastic flexible IBCs, if nectimes while in transportation. essary. protection against ultraviolet (b) Responsibility. It is the responsiradiation must be provided by the addibility of the IBC manufacturer to astion of pigments or inhibitors such as sure that each IBC is capable of passing carbon black. These additives must be the prescribed tests. To the extent that compatible with the contents and rean IBC assembly function, including 1048 Pipeline and Hazardous Materials Safety Admin., DOT $ 178.801 final closure, is performed by the per- (iv) A packaging which differs in son who offers a hazardous material for service equipment. transportation, that person is respon- (d) Design qualification testing. The sible for performing the function in acpackaging manufacturer shall achieve cordance with §§ 173.22 and 178.2 of this successful test results for the design subchapter. qualification testing at the start of (c) Definitions. For the purpose of this production of each new or different IBC subpart: design type. The service equipment se- (1) IBC design type refers to IBC lected for this design qualification which does not differ in structural detesting shall be representative of the sign, size, material of construction, type of service equipment that will be wall thickness, manner of construction fitted to any finished IBC body under and representative service equipment. the design. Application of the certifi- (2) Design qualification testing is the cation mark by the manufacturer shall performance of the drop, leakproofness, constitute certification that the IBC hydrostatic pressure, stacking, botdesign type passed the prescribed tests tom-lift or top-lift, tear, topple, rightin this subpart. ing and vibration tests, as applicable, (e) Periodic design requalification testprescribed in this subpart, for each difing. (1) Periodic design requalification ferent IBC design type, at the start of must be conducted on each qualified production of that packaging. IBC design type if the manufacturer is (3) Periodic design requalification test is to maintain authorization for continthe performance of the applicable tests ued production. The IBC manufacturer specified in paragraph (c)(2) of this secshall achieve successful test results for tion on an IBC design type, in order to the periodic design requalification at requalify the design for continued prosufficient frequency to ensure each duction at the frequency specified in packaging produced by the manufacparagraph (e) of this section. turer is capable of passing the design (4) Production inspection is the inspecqualification tests. Design requalification that must initially be conducted tion tests must be conducted at least on each newly manufactured IBC. once every 12 months. (5) Production testing is the perform- (2) Changes in the frequency of design ance of the leakproofness test in acrequalification testing specified in cordance with paragraph (f) of this secparagraph (e)(1) of this section are aution on each IBC intended to contain thorized if approved by the Associate solids discharged by pressure or in- Administrator. These requests must be tended to contain liquids. based on: (6) Periodic retest and inspection is per- (i) Detailed quality assurance proformance of the applicable test and ingrams that assure that proposed despections on each IBC at the frequency creases in test frequency maintain the specified in $180.352 of this subchapter. integrity of originally tested IBC de- (7) Different IBC design type is one sign types: and that differs from a previously qualified (ii) Demonstrations that each IBC IBC design type in structural design, produced is capable of withstanding size, material of construction, wall higher standards (e.g., increased drop thickness, or manner of construction, height, hydrostatic pressure, wall but does not include: thickness, fabric weight). (i) A packaging which differs in sur- (f) Production testing and inspection. face treatment; (1) Production testing consists of the (ii) A rigid plastic IBC or composite leakproofness test prescribed in IBC which differs with regard to addi- § 178.813 of this subpart and must be tives used to comply with $178.706(c), performed on each IBC intended to con- 178.707(c) or 178.710(c); tain solids discharged by pressure or (iii) A packaging which differs only intended to contain liquids. For this in its lesser external dimensions (i.e., test: height, width, length) provided mate- (i) The IBC need not have its closures rials of construction and material fitted. thicknesses or fabric weight remain (ii) The inner receptacle of a comthe same; posite IBC may be tested without the 1049 $ 178.802 49 CFR Ch. I (10-1-06 Edition) outer IBC body, provided the test reignated representative, for testing in sults are not affected. accordance with this subpart. (2) Applicable inspection require- (k) Coatings. If an inner treatment or ments in $180.352 of this subchapter coating of an IBC is required for safety must be performed on each IBC inireasons, the manufacturer shall design tially after production. the IBC so that the treatment or coat- (g) Test samples. The IBC manufacing retains its protective properties turer shall conduct the design qualieven after withstanding the tests prefication and periodic design requaliscribed by this subpart. fication tests prescribed in this subpart (1) Record retention. (1) The person using random samples of IBCs, accordwho certifies an IBC design type shall ing to the appropriate test section. keep records of design qualification (h) Selective testing of IBCs. Variation tests for each IBC design type and for of a tested IBC design type is permitted each periodic design requalification as without further testing, provided selecspecified in this part. These records tive testing demonstrates an equivamust be maintained at each location lent or greater level of safety than the where the IBC is manufactured and at design type tested and which has been each location where design qualificaapproved by the Associate Administion and periodic design requalification trator. testing is performed. These records (i) Approval of equivalent packagings. must be maintained for as long as IBCs An IBC that differs from the standards are manufactured in accordance with in subpart N of this part, or that is each qualified design type and for at tested using methods other than those least 2.5 years thereafter. These specified in this subpart, may be used if records must include the following inapproved by the Associate Adminisformation: name and address of test fatrator. Such IBCs must be shown to be cility; name and address of the person equally effective, and testing methods certifying the IBC; a unique test report used must be equivalent. A large packidentification; date of test report; managing, as defined in $171.8 of this subufacturer of the IBC; description of the chapter, may be used if approved by IBC design type (e.g., dimensions, mathe Associate Administrator. The large terials, closures, thickness, representapackaging must conform to the contive service equipment, etc.); maxstruction standards, performance testimum IBC capacity; characteristics of ing and packaging marking requiretest contents; test descriptions and rements specified in the UN Recsults (including drop heights, hydroommendations (IBR, see $ 171.7 of this static pressures, tear propagation subchapter). length, etc.). Each test report must be (j) Proof of compliance. Notwithsigned with the name of the person standing the periodic design requaliconducting the test, and name of the fication testing intervals specified in person responsible for testing. paragraph (e) of this section, the Asso- (2) The person who certifies each IBC ciate Administrator, or a designated must make all records of design qualirepresentative, may at any time refication tests and periodic design require demonstration of compliance by qualification tests available for inspec- a manufacturer, through testing in action by a representative of the Departcordance with this subpart, that packment upon request. agings meet the requirements of this [Amdt. 178-103, 59 FR 38074, July 26, 1994, as subpart. As required by the Associate amended by Amdt. 178-108, 60 FR 40038, Aug. Administrator, or a designated rep- 4. 1995; 66 FR 45386, Aug. 28, 2001; 66 FR 33452, resentative, the manufacturer shall ei- June 21. 2001; 68 FR 75758, Dec. 31, 2003] ther: (1) Conduct performance tests or § 178.802 Preparation of fiberboard have tests conducted by an inde- IBCs for testing. pendent testing facility, in accordance (a) Fiberboard IBCs and composite with this subpart; or IBCs with fiberboard outer packagings (2) Make a sample IBC available to must be conditioned for at least 24 the Associate Administrator, or a deshours in an atmosphere maintained: 1050 Pipeline and Hazardous Materials Safety Admin., DOT § 178.810 (1) At 50 percent ±2 percent relative (c) For purposes of periodic design rehumidity, and at a temperature of 23° qualification only, fiberboard IBCs or ±2 °C (73 °F ±4 °F); or composite IBCs with fiberboard outer (2) At 65 percent +2 percent relative packagings may be at ambient condihumidity, and at a temperature of 20° tions. +2 °C (68 °F ±4 °F), or 27 °C +2 °C (81 °F [Amdt. 178-103, 59 FR 38074, July 26, 1994, as ±4 °F). amended at 66 FR 45386, Aug. 28, 2001) (b) Average values for temperature and humidity must fall within the lim- $178.803 Testing and certification of IBCs. its in paragraph (a) of this section. Short-term fluctuations and measure- Tests required for the certification of ment limitations may cause individual each IBC design type are specified in measurements to vary by up to ±5 perthe following table. The letter X Indicent relative humidity without significates that one IBC (except where cant impairment of test reproducnoted) of each design type must be subjected to the tests in the order preibility. sented: IBC type Performance test Metal IBCs Rigid plastic Composite Fiber-board Wooden IBCs Flexible IBCs IBCs IBCs IBCs Vibration 6 X X X X 8 X 1.5 X Bottom lift X X X X Top lift X X 2,5 X Stacking X 7 1X 7 X Leakproofness X X Hydrostatic 3X 3X 3X Drop X X X X 4 X Topple X Righting 2,5 X Tear X 1 Flexible IBCs must be capable of withstanding the vibration test. 2 This test must be performed only if IBCs are designed to be handled this way. For metal IBCs. at least one of the bottom lift or top Bft tests must be performed. *The leakproofness and hydrostatic pressure tests are required only for IBCs intended to contain liquids or intended to contain solids loaded or discharged under pressure. 4 Another IBC of the same design type may be used for the drop test set forth in § 178.810 of this subchapter. 5 Another different flexible IBC of the same design type may be used for each test. 6 The vibration test may be performed in another order for IBCs manufactured and tested under provisions of an exemption before October 1, 1994 and for non-DOT specification portable tanks tested before October 1, 1994, intended for export. This test must be performed only if the IBC is designed to be stacked. [Amdt. 178-108, 60 FR 40039, Aug. 4, 1995, as amended at 64 FR 51919, Sept. 27. 1999; 66 FR 45386, 45390, Aug. 28, 2001) $ 178.810 Drop test. rial to not less than 95 percent of their capacity. (a) General. The drop test must be (3) Rigid plastic IBCs and composite conducted for the qualification of all IBCs with plastic inner receptacles IBC design types and performed perimust be conditioned for testing by reodically as specified in $178.801(e) of ducing the temperature of the packthis subpart. aging and its contents to 18 °C (0 °F) (b) Special preparation for the drop test. or lower. Test liquids must be kept in (1) Metal, rigid plastic, and composite the liquid state, if necessary, by the IBCs intended to contain solids must addition of anti-freeze. Water/antibe filled to not less than 95 percent of freeze solutions with a minimum spetheir capacity, or if intended to concific gravity of 0.95 for testing at 18 tain liquids, to not less than 98 percent °C (0 °F) or lower are considered acof their capacity. Pressure relief deceptable test liquids, and may be convices must be removed and their apersidered equivalent to water for test tures plugged or rendered inoperative. purposes. IBCs conditioned in this way (2) Fiberboard, wooden, and flexible are not required to be conditioned in IBCs must be filled with a solid mateaccordance with 178.802. 1051 § 178.811 49 CFR Ch. I (10-1-06 Edition) (c) Test method. Samples of all IBC § 178.811 Bottom lift test. design types must be dropped onto a (a) General. The bottom lift test must rigid, non-resilient, smooth, flat and be conducted for the qualification of horizontal surface. The point of impact all IBC design types designed to be liftmust be the most vulnerable part of ed from the base. the base of the IBC being tested. Fol- (b) Special preparation for the bottom lowing the drop, the IBC must be relift test. The IBC must be loaded to 1.25 stored to the upright position for obtimes its maximum permissible gross servation. mass, the load being evenly distrib- (d) Drop height. (1) For all IBCs, drop uted. heights are specified as follows: (c) Test method. All IBC design types (i) Packing Group I: 1.8 m (5.9 feet). must be raised and lowered twice by a (ii) Packing Group II: 1.2 m (3.9 feet). lift truck with the forks centrally posi- (iii) Packing Group III: 0.8 m (2.6 tioned and spaced at three quarters of feet). the dimension of the side of entry (un- (2) Drop tests are to be performed less the points of entry are fixed). The with the solid or liquid to be transforks must penetrate to three quarters ported or with a non-hazardous mateof the direction of entry. The test must rial having essentially the same physbe repeated from each possible direcical characteristics. tion of entry. (d) Criteria for passing the test. For all (3) The specific gravity and viscosity IBC design types designed to be lifted of a substituted non-hazardous matefrom the base, there may be no permarial used in the drop test for liquids nent deformation which renders the must be similar to the hazardous mate- IBC unsafe for transportation and no rial intended for transportation. Water loss of contents. also may be used for the liquid drop test under the following conditions: [Amdt. 178-103, 59 FR 38074. July 26, 1994, as amended at 66 FR 45386, Aug. 28, 2001] (i) Where the substances to be carried have a specific gravity not exceeding $ 178.812 Top lift test. 1.2, the drop heights must be those (a) General. The top lift test must be specified in paragraph (d)(1) of this secconducted for the qualification of all tion for each IBC design type; and IBC design types designed to be lifted (ii) Where the substances to be carfrom the top or, for flexible IBCs, from ried have a specific gravity exceeding the side. 1.2, the drop heights must be as fol- (b) Special preparation for the top lift lows: test. (1) Metal, rigid plastic, and com- (A) Packing Group I: SG X 1.5 m (4.9 posite IBC design types must be loaded feet). to twice the maximum permissible (B) Packing Group II: SG X 1.0 m (3.3 gross mass with the load being evenly feet). distributed. (C) Packing Group III: SG X 0.67 m (2) Flexible IBC design types must be (2.2 feet). filled to six times the maximum net (e) Criteria for passing the test. For all mass, the load being evenly distrib- IBC design types there may be no loss uted. of contents. A slight discharge from a (c) Test method. (1) A metal or flexible closure upon impact is not considered IBC must be lifted in the manner for to be a failure of the IBC provided that which it is designed until clear of the no further leakage occurs. A slight disfloor and maintained in that position charge (e.g., from closures or stitch for a period of five minutes. holes) upon impact is not considered a (2) Rigid plastic and composite IBC design types must be: failure of the flexible IBC provided that (i) Lifted by each pair of diagonally no further leakage occurs after the IBC opposite lifting devices, so that the has been raised clear of the ground. hoisting forces are applied vertically, [Amdt. 178-103, 59 FR 38074, July 26, 1994, as for a period of five minutes; and amended at 66 FR 45386, Aug. 28, 2001; 69 FR (ii) Lifted by each pair of diagonally 76186. Dec. 20, 2004] opposite lifting devices, so that the 1052 Pipeline and Hazardous Materials Safety Admin., DOT § 178.814 hoisting forces are applied towards the out for a suitable length of time using center at 45° to the vertical, for a peair at a gauge pressure of not less than riod of five minutes. 20 kPa (2.9 psig). Leakproofness of IBC (3) If not tested as indicated in paradesign types must be determined by graph (c)(1) of this section, a flexible coating the seams and joints with a IBC design type must be tested as folheavy oil, a soap solution and water, or lows: other methods suitable for the purpose (i) Fill the flexible IBC to 95% full of detecting leaks. Other methods, if at with a material representative of the least equally effective, may be used in product to be shipped. accordance with appendix B of this (ii) Suspend the flexible IBC by its part, or if approved by the Associate lifting devices. Administrator, as provided in (iii) Apply a constant downward force $178.801(i)). through a specially designed platen. (d) Criterion for passing the test. For The platen will be a minimum of 60% all IBC design types intended to conand a maximum of 80% of the cross sectain solids that are loaded or distional surface area of the flexible IBC. charged under pressure or intended to (iv) The combination of the mass of contain liquids, there may be no leakthe filled flexible IBC and the force apage of air from the IBC. plied through the platen must be a minimum of six times the maximum [Amdt. 178-103, 59 FR 38074, July 26, 1994, as net mass of the flexible IBC. The test amended at 64 FR 10782, Mar. 5, 1999; 66 FR must be conducted for a period of five 45185, 45386, Aug. 28, 2001) minutes. (v) Other equally effective methods § 178.814 Hydrostatic pressure test. of top lift testing and preparation may (a) General. The hydrostatic pressure be used with approval of the Associate test must be conducted for the quali- Administrator. fication of all metal, rigid plastic, and (d) Criteria for passing the test. For all composite IBC design types Intended to IBC design types designed to be lifted contain solids that are loaded or disfrom the top, there may be no permacharged under pressure or intended to nent deformation which renders the contain liquids. IBC, including the base pallets when (b) Special preparation for the hydroapplicable, unsafe for transportation, static pressure test. For metal IBCs, the and no loss of contents. test must be carried out before the fit- [Amdt. 178-103, 59 FR 38074, July 26, 1994, as ting of any thermal insulation equipamended at 66 FR 33452, June 21, 2001: 66 FR ment. For all IBCs, pressure relief de- 45386, Aug. 28, 2001; 68 FR 45042, July 31, 2003] vices and vented closures must be removed and their apertures plugged or § 178.813 Leakproofness test. rendered inoperative. (a) General. The leakproofness test (c) Test method. Hydrostatic gauge must be conducted for the qualification pressure must be measured at the top of all IBC design types and on all proof the IBC. The test must be carried duction units intended to contain solout for a period of at least 10 minutes ids that are loaded or discharged under applying a hydrostatic gauge pressure pressure or intended to contain liquids. not less than that indicated in para- (b) Special preparation for the graph (d) of this section. The IBCs may leakproofness test. Vented closures must not be mechanically restrained during either be replaced by similar non-ventthe test. ed closures or the vent must be sealed. (d) Hydrostatic gauge pressure applied. For metal IBC design types, the initial (1) For metal IBC design types, 31A, test must be carried out before the fit- 31B, 31N: 65 kPa gauge pressure (9.4 ting of any thermal insulation equippsig). ment. The inner receptacle of a com- (2) For metal IBC design types 21A, posite IBC may be tested without the 21B. 21N, 31A, 31B, 31N: 200 kPa (29 outer packaging provided the test repsig). For metal IBC design types 31A, sults are not affected. 31B and 31N, the tests in paragraphs (c) Test method and pressure applied. (d)(1) and (d)(2) of this section must be The leakproofness test must be carried conducted consecutively. 1053 § 178.815 49 CFR Ch. I (10-1-06 Edition) (3) For metal IBCs design types 21A, (3) For rigid plastic IBC types 21H1. 21B, and 21N, for Packing Group I sol- 21H2, 31H1, and 31H2, and composite ids: 250 kPa (36 psig) gauge pressure. IBC types 21HZ1, 21HZ2, 31HZ1, and (4) For rigid plastic IBC design types 31HZ2, there may be no leakage and no 21H1 and 21H2 and composite IBC depermanent deformation which renders sign types 21HZ1 and 21HZ2: 75 kPa (11 the IBC unsafe for transportation. psig). [Amdt. 178-103, 59 FR 38074, July 26, 1994, as (5) For rigid plastic IBC design types amended at 66 FR 45185. 45386, Aug. 28, 2001] 31H1 and 31H2 and composite IBC design types 31HZ1 and 31HZ2: whichever § 178.815 Stacking test. is the greater of: (a) General. The stacking test must (i) The pressure determined by any be conducted for the qualification of one of the following methods: all IBC design types intended to be (A) The gauge pressure (pressure in stacked. the IBC above ambient atmospheric (b) Special preparation for the stacking pressure) measured in the IBC at 55 °C test. (1) All IBCs except flexible IBC de- (131 °F) multiplied by a safety factor of sign types must be loaded to their max- 1.5. This pressure must be determined imum permissible gross mass. on the basis of the IBC being filled and (2) The flexible IBC must be filled to closed to no more than 98 percent canot less than 95 percent of its capacity pacity at 15 °C (60 °F); and to its maximum net mass, with the (B) If absolute pressure (vapor presload being evenly distributed. sure of the hazardous material plus at- (c) Test method. (1) All IBCs must be mospheric pressure) is used, 1.5 multiplaced on their base on level, hard plied by the vapor pressure of the hazground and subjected to a uniformly ardous material at 55 °C (131 °F) minus distributed superimposed test load for 100 kPa (14.5 psi). If this method is cho- a period of at least five minutes (see sen, the hydrostatic test pressure apparagraph (d) of this section). plied must be at least 100 kPa gauge (2) Fiberboard, wooden, and compressure (14.5 psig): or posite IBCs with outer packagings con- (C) If absolute pressure (vapor presstructed of other than plastic matesure of the hazardous material plus atrials must be subjected to the test for mospheric pressure) is used, 1.75 multi- 24 hours. plied by the vapor pressure of the haz- (3) Rigid plastic IBC types and comardous material at 50 °C (122 °F) minus posite IBC types with plastic outer 100 kPa (14.5 psi). If this method is chopackagings (11HH1, 11HH2, 21HH1, sen, the hydrostatic test pressure ap- 21HH2, 31HHI and 31HH2) which bear plied must be at least 100 kPa gauge the stacking load must be subjected to pressure (14.5 psig): or the test for 28 days at 40 °C (104 °F). (ii) Twice the greater of: (A) The (4) For all IBCs, the load must be apstatic pressure of the hazardous mateplied by one of the following methods: rial on the bottom of the IBC filled to (i) One or more IBCs of the same type 98 percent capacity; or loaded to their maximum permissible (B) The static pressure of water on gross mass and stacked on the test the bottom of the IBC filled to 98 per- IBC; cent capacity. (ii) The calculated superimposed test (e) Criteria for passing the test(s). (1) load weight loaded on either a flat For metal IBCs, subjected to the 65 plate or a reproduction of the base of kPa (9.4 psig) test pressure specified in the IBC, which is stacked on the test paragraph (d)(1) of this section, there IBC; or may be no leakage or permanent defor- (iii) The packaging may be tested mation that would make the IBC unusing a dynamic compression testing safe for transportation. machine. The test must be conducted (2) For metal IBCs intended to conat room temperature on an empty, untain liquids, when subjected to the 200 sealed packaging. The test sample kPa (29 psig) and the 250 kPa (36 psig) must be centered on the bottom platen test pressures specified in paragraphs of the testing machine. The top platen (d)(2) and (d)(3) of this section, respecmust be lowered until it comes in contively, there may be no leakage. tact with the test sample. Compression 1054 Pipeline and Hazardous Materials Safety Admin., DOT 178.818 must be applied end to end. The speed 178.816 Topple test. of the compression tester must be onehalf inch plus or minus one-fourth inch (a) General. The topple test must be per minute. An initial preload of 50 conducted for the qualification of all pounds must be applied to ensure a flexible IBC design types. definite contact between the test sam- (b) Special preparation for the topple test. The flexible IBC must be filled to ple and the platens. The distance between the platens at this time must be not less than 95 percent of its capacity recorded as zero deformation. The force and to its maximum net mass, with the "A" to then be applied must be calload being evenly distributed. (c) Test method. A flexible IBC must culated using the applicable formula: be toppled onto any part of its top Liquids: A = (n-1) [w+ (s x v x 8.3 x .98)] upon a rigid, non-resilient, smooth, x1.5; flat, and horizontal surface. or (d) Topple height. For all flexible Solids: A = (n-1) [w+ (s 8.3 IBCs, the topple height is specified as X 1.5 follows: (1) Packing Group I: 1.8 m (5.9 feet). Where: (2) Packing Group II: 1.2 m (3.9 feet). A = applied load in pounds. (3) Packing Group III: 0.8 m (2.6 feet). n = minimum number of containers that, (e) Criteria for passing the test. For all when stacked, reach a height of 3 m. flexible IBCs, there may be no loss of S = specific gravity of lading. W = maximum weight of one empty container contents. A slight discharge (e.g., from in pounds. closures or stitch holes) upon impact is V = actual capacity of container (rated canot considered to be a failure, provided pacity + outage) in gallons. no further leakage occurs. And: [Amdt. 178-103, 59 FR 38074, July 26, 1994, as 8.3 corresponds to the weight in pounds of amended at 66 FR 45386, Aug. 28, 2001] 1.0 gallon of water. 1.5 is a compensation factor that converts § 178.817 Righting test. the static load of the stacking test into a (a) General. The righting test must be load suitable for dynamic compression conducted for the qualification of all testing. flexible IBCs designed to be lifted from (d) Calculation of superimposed test the top or side. load. For all IBCs, the load to be placed (b) Special preparation for the righting on the IBC must be 1.8 times the comtest. The flexible IBC must be filled to bined maximum permissible gross mass not less than 95 percent of its capacity of the number of similar IBCs that may and to its maximum net mass, with the be stacked on top of the IBC during load being evenly distributed. transportation. (c) Test method. The flexible IBC, (e) Criteria for passing the test. (1) For lying on its side, must be lifted at a metal, rigid plastic, and composite speed of at least 0.1 m/second (0.33 ft/s) IBCs there may be no permanent deforto an upright position, clear of the mation which renders the IBC unsafe floor, by one lifting device, or by two for transportation and no loss of conlifting devices when four are provided. tents. (d) Criterion for passing the test. For (2) For fiberboard and wooden IBCs all flexible IBCs, there may be no damthere may be no loss of contents and no age to the IBC or its lifting devices permanent deformation which renders which renders the IBC unsafe for transthe whole IBC, including the base palportation or handling. let, unsafe for transportation. [Amdt. 178-103, 59 FR 38074, July 26, 1994, as (3) For flexible IBCs, there may be no amended at 66 FR 45386, Aug. 28, 2001] deterioration which renders the IBC unsafe for transportation and no loss of $178.818 Tear test. contents. (a) General. The tear test must be [Amdt. 178-103, 59 FR 38074, July 26, 1994, as conducted for the qualification of all amended by Amdt. 178-119, 62 FR 24743, May flexible IBC design types. 6, 1997; 65 FR 50462, 50463, Aug. 18, 2000; 66 FR (b) Special preparation for the tear test. 45386, Aug. 28, 2001] The flexible IBC must be filled to not 1055 § 178.819 49 CFR Ch. I (10-1-06 Edition) less than 95 percent of its capacity and design types must be capable of withto its maximum net mass, the load standing the vibration test. being evenly distributed. (b) Test method. (1) A sample IBC, se- (c) Test method. Once the IBC is lected at random, must be filled and placed on the ground, a 100-mm (4-inch) closed as for shipment. knife score, completely penetrating the (2) The sample IBC must be placed on wall of a wide face, is made at a 45° a vibrating platform that has a vertical angle to the principal axis of the IBC, double-amplitude (peak-to-peak dishalfway between the bottom surface placement) of one inch. The IBC must and the top level of the contents. The be constrained horizontally to prevent IBC must then be subjected to a uniit from falling off the platform, but formly distributed superimposed load must be left free to move vertically equivalent to twice the maximum net and bounce. mass. The load must be applied for at (3) The test must be performed for least five minutes. An IBC which is deone hour at a frequency that causes the signed to be lifted from the top or the package to be raised from the vibrating side must, after removal of the superplatform to such a degree that a piece imposed load, be lifted clear of the of material of approximately 1.6-mm floor and maintained in that position (0.063-inch) thickness (such as steel for a period of five minutes. strapping or paperboard) can be passed (d) Criterion for passing the test. The between the bottom of the IBC and the IBC passes the tear test if the cut does platform. Other methods at least not propagate more than 25 percent of equally effective may be used (see its original length. $178.801(i)). [Amdt. 178-103, 59 FR 38074, July 26, 1994. as (c) Criteria for passing the test. An IBC amended at 66 FR 45386, Aug. 28, 2001] passes the vibration test if there is no rupture or leakage. § 178.819 Vibration test. [Amdt. 178-103, 59 FR 38074, July 26, 1994, as (a) General. The vibration test must amended by Amdt. 178-108, 60 FR 40038, Aug. be conducted for the qualification of 4, 1995; Amdt. 178-110, 60 FR 49111, Sept. 21, all rigid IBC design types. Flexible IBC 1995; 66 FR 45386, Aug. 28, 2001] APPENDIX A TO PART 178-SPECIFICATIONS FOR STEEL TABLE 1 [Open-hearth, basic oxygen, or electric steel of uniform quality. The following chemical composition limits are based on fadle analysis:] Chemical composition, percent-ladle analysis Designation Grade 11 Grade 21.2 Grade 32,4.5 Carbon 0.10/0.20 0.24 maximum 0.22 maximum. Manganese 1.10/1.60 0.50/1.00 1.25 maximum. Phosphorus, maximum 0.04 0.04 0.045. Sulfur, maximum 0.05 0.05 0.05. Silicon 0.15/0.30 0.30 maximum Copper, maximum 0.40 Columbium 0.01/0.04 Heat treatment authorized (3) (3) (3). Maximum stress (p.s.i.) 35,000 35,000 35,000. 1 Addition of other elements to obtain alloying effect is not authorized. 2 Ferritic grain size 6 or finer according to ASTM E 112-96 (IBR, see § 171.7 of this subchapter). 3 Any suitable heat treatment in excess of 1,100 °F., except that liquid quenching is not permitted. 4 Other alloying elements may be added and shall be reported. 5 For compositions with a maximum carbon content of 0.15 percent of fadle analysis, the maximum limit for manganese on ladle analysis may be 1.4D percent. 6 Rephosphorized Grade 3 steels containing no more than 0.15 percent phosphorus are permitted if carbon content does not exceed 0.15 percent and manganese does not exceed 1 percent. 1056 Pipeline and Hazardous Materials Safety Admin., DOT Pt. 178, App. B CHECK ANALYSIS TOLERANCES [A heat of steel made under any of the above grades, the ladle analysis of which is slightly out of the specified range is acceptable If the check analysis is within the following variations:] Tolerance (percent) over the maximum limit or Element Limit or maximum specified (percent) under the minimum limit Under min- Over maximum limit imum limit Carbon To 0.15 inclusive 0.02 0.03 Over 0.15 to 0.40 inclusive 0.03 0.04 Manganese To 0.60 inclusive 0.03 0.03 Over 0.60 to 1.15 inclusive 0.04 0.04 Over 1.15 to 2.50 inclusive 0.05 0.05 Phosphorus? All ranges 0.01 Sulfur All ranges 0.01 Silicon To 0.30 inclusive 0.02 0.03 Over 0.30 to 1.00 inclusive 0.05 0.05 Copper To 1.00 Inclusive 0.03 0.03 Over 1.00 to 2.00 inclusive 0.05 0.05 Nickel To 1.00 inclusive 0.03 0.03 Over 1.00 to 2.00 inclusive 0.05 0.05 Chromium To 0.90 inclusive 0.03 0.03 Over 0.90 to 2.10 inclusive 0.05 0.05 Molybdenum To 0.20 inclusive 0.01 0.01 Over 0.20 to 0.40 inclusive 0.02 0.02 Zirconium All ranges 0.01 0.05 Columbium To 0.04 inclusive 0.005 0.01 Aluminum Over 0.10 to 0.20 inclusive 0.04 0.04 Over 0.20 to 0.30 inclusive 0.05 0.05 Rephosphorized steels not subject to check analysis for phosphorus. [Amdt. 178-3, 34 FR 12283, July 25, 1969; 34 FR 12593, Aug. 1, 1969, as amended by Amdt. 178- 64, 45 FR 81573. Dec. 11, 1980: Amdt. 178-97, 55 FR 52728, Dec. 21, 1990; 68 FR 75758, Dec. 31, 2003] APPENDIX B TO PART 178-ALTERNATIVE test. The test must be conducted for a period LEAKPROOFNESS TEST METHODS of time sufficient to appropriately pressurize or evacuate the interior of the packaging In addition to the method prescribed in and to determine if there is leakage into or $178.604 of this subchapter, the following out of the packaging. A packaging passes the leakproofness test methods are authorized: pressure differential test if there is no (1) Hellum test. The packaging must be change in measured internal pressure. filled with at least 1 L inert helium gas, air (3) Solution over seams. The packaging must tight closed, and placed in a testing chambe restrained while an Internal air pressure ber. The testing chamber must be evacuated is applied; the method of restraint may not down to a pressure of 5 kPa which equals an affect the results of the test. The exterior over-pressure inside the packaging of 95 kPa. surface of all seams and welds must be coat- The air in the testing chamber must be anaed with a solution of soap suds or a water lyzed for traces of helium gas by means of a and oil mixture. The test must be conducted mass spectrograph. The test must be confor a period of time sufficient to pressurize ducted for a period of time sufficient to evacthe interior of the packaging to the specified uate the chamber and to determine if there air pressure and to determine if there is is leakage into or out of the packaging. If heleakage of air from the packaging. A packlium gas is detected, the leaking packaging aging passes the test if there is no leakage of must be automatically separated from nonair from the packaging. leaking drums and the leaking area deter- (4) Solution over partial seams test. For other mined according to the method prescribed in than design qualification testing, the fol- $178.604(d) of this subchapter. A packaging lowing test may be used for metal drums: passes the test if there is no leakage of he- The packaging must be restrained while an lium. internal air pressure of 48 kPa (7.0 psig) is (2) Pressure differential test. The packaging applied: the method of restraint may not afshall be restrained while either pressure or a fect the results of the test. The packaging vacuum is applied internally. The packaging must be coated with a soap solution over the must be pressurized to the pressure required entire side seam and a distance of not less by $178.604(e) of this subchapter for the apthan eight inches on each side of the side propriate packing group. The method of reseam along the chime seam(s). The test must straint must not affect the results of the be conducted for a period of time sufficient 1057 Pt. 178, App. C 49 CFR Ch. I (10-1-06 Edition) to pressurize the interior of the packaging to 179.14 Coupler vertical restraint system. the specified air pressure and to determine if 179.15 Pressure relief devices. there is leakage of air from the packaging. A 179.16 Tank-head puncture-resistance syspackaging passes the test if there is no leaktems. age of air from the packaging. Chime cuts 179.18 Thermal protection systems. must be made on the initial drum at the be- 179.20 Service equipment; protection sysginning of each production run and on the tems. initial drum after any adjustment to the 179.22 Marking. chime seamer. Chime cuts must be maintained on file in date order for not less than Subpart C-Specifications for Pressure six months and be made available to a rep- Tank Car Tanks (Classes DOT-105, 109, resentative of the Department of Transportation on request. 112, 114, and 120) [Amdt. 178-97, 55 FR 52728, Dec. 21, 1990, as 179.100 General specifications applicable to amended at 56 FR 66287, Dec. 20, 1991; 57 FR pressure tank car tanks. 45466, Oct. 1, 1992] 179.100-1 Tanks built under these specifications shall comply with the requirements APPENDIX C TO PART 178-NOMINAL AND of $179.100, 179.101 and when applicable, MINIMUM THICKNESSES OF STEEL $$179.102 and 179.103. DRUMS AND JERRICANS 179.100-3 Type. 179.100-4 Insulation. For each listed packaging capacity, the 179.100-6 Thickness of plates. following table compares the ISO 3574 (IBR, 179.100-7 Materials. see $171.7 of this subchapter) nominal thick- 179.100-8 Tank heads. ness with the corresponding ISO 3574 min- 179.100-9 Welding. imum thickness. 179.100-10 Postweld heat treatment. 179.100-12 Manway nozzle, cover and protec- Cor- ISO nomiresponding tive housing. Maximum capacity (L) ISO minnal (mm) 179.100-13 Venting, loading and unloading imum valves, measuring and sampling devices. (mm) 179.100-14 Bottom outlets. 20 0.7 0.63 179.100-16 Attachments. 30 0.8 0.73 179.100-17 Closures for openings. 40 0.8 0.73 179.100-18 Tests of tanks. 60 1.0 0.92 120 1.0 179.100-19 Tests of safety relief valves. 0.92 220 1.0 0.92 179.100-20 Stamping. 450 1.9 1.77 179.101 Individual specification requirements applicable to pressure tank car tanks. [Amdt. 178-106, 59 FR 67522. Dec. 29, 1994, as 179.101-1 Individual specification requireamended at 68 FR 75758, Dec. 31, 2003] ments. 179.102 Special commodity requirements for PART 179-SPECIFICATIONS FOR pressure tank car tanks. TANK CARS 179.102-1 Carbon dioxide, refrigerated liquid. 179.102-2 Chlorine. Subpart A-Introduction, Approvals and 179.102-4 Vinyl fluoride, stabilized. Reports 179.102-17 Hydrogen chloride, refrigerated liquid. Sec. 179.103 Special requirements for class 114A 179.1 General. *** tank car tanks. 179.2 Definitions and abbreviations. 179.103-1 Type. 179.3 Procedure for securing approval. 179.103-2 Manway cover. 179.4 Changes in specifications for tank 179.103-3 Venting, loading and unloading cars. valves, measuring and sampling devices. 179.5 Certificate of construction. 179.103-4 Safety relief devices and pressure 179.6 Repairs and alterations. regulators. 179.7 Quality assurance program. 179.103-5 Bottom outlets. Subpart B-General Design Requirements Subpart D-Specifications for Nonpressure Tank Car Tanks (Classes DOT-111AW 179.10 Tank mounting. and 115AW) 179.11 Welding certification. 179.12 Interior heater systems. 179.200 General specifications applicable to 179.13 Tank car capacity and gross weight non-pressure tank car tanks (Class DOT limitation. 111). 1058 Pipeline and Hazardous Materials Safety Admin., DOT § 180.2 PART 180-CONTINUING QUALI- Subport F-Qualification and Maintenance FICATION AND MAINTENANCE of Tank Cars OF PACKAGINGS 180.501 Applicability. 180.503 Definitions. Subport A-General 180.505 Quality assurance program. Sec. 180.507 Qualification of tank cars. 180.1 Purpose and scope. 180.509 Requirements for inspection and test 180.2 Applicability. of specification tank cars. 180.3 General requirements. 180.511 Acceptable results of inspections and tests. Subpart B [Reserved] 180.513 Repairs, alterations, conversions, and modifications. Subpart C-Quailfication, Maintenance 180.515 Markings. and Use of Cylinders 180.517 Reporting and record retention requirements. 180.201 Applicability. 180.519 Periodic retest and inspection of 180.203 Definitions. tank cars other than single-unit tank car 180.205 General requirements for requalitanks. fication of specification cylinders. 180.207 Requirements for requalification of Subport G-Quallfication and UN pressure receptacles. Maintenance of Portable Tanks 180.209 Requirements for requalification of specification cylinders. 180.601 Applicability. 180.211 Repair, rebuilding and reheat treat- 180.603 Qualification of portable tanks. ment of DOT-4 series specification cylinders. 180.605 Requirements for periodic testing, 180.212 Repair of seamless DOT 3-series inspection and repair of portable tanks. specification cylinders and seamless UN APPENDIX A TO PART 180-INTERNAL SELFpressure receptacles. CLOSING STOP VALVE EMERGENCY CLO- 180.213 Requalification markings. SURE TEST FOR LIQUEFIED COMPRESSED 180.215 Reporting and record retention re- GASES quirements. APPENDIX B TO PART 180-ACCEPTABLE INTER- 180.217 Requalification requirements for NAL SELF-CLOSING STOP VALVE LEAKAGE MEGCs. TESTS FOR CARGO TANKS TRANSPORTING LIQUEFIED COMPRESSED GASES Subpart D-Qualification and Maintenance APPENDIX C TO PART 180-EDDY CURRENT Exof IBCs AMINATION WITH VISUAL INSPECTION FOR DOT 3AL CYLINDERS MANUFACTURED OF 180.350 Applicability and definitions. ALUMINUM ALLOY 6351-T6 180.351 Qualification of IBCs. 180.352 Requirements for retest and inspec- AUTHORITY: 49 U.S.C. 5101-5127; 49 CFR 1.53. tion of IBCs. SOURCE: Amdt. 180-2, 54 FR 25032, June 12, 1989, unless otherwise noted. Subpart E-Qualification and Maintenance of Cargo Tanks Subpart A--General 180.401 Applicability. 180.403 Definitions. § 180.1 Purpose and scope. 180.405 Qualification of cargo tanks. 180.407 Requirements for test and inspection This part prescribes requirements of specification cargo tanks. pertaining to the maintenance, recon- 180.409 Minimum qualifications for inspecditioning, repair, inspection and testtors and testers. ing of packagings, and any other func- 180.411 Acceptable results of tests and intion having an effect on the continuing spections. qualification and use of a packaging 180.413 Repair, modification, stretching, reunder the requirements of this subbarrelling. or mounting of specification chapter. cargo tanks. 180.415 Test and inspection markings. § 180.2 Applicability. 180.416 Discharge system inspection and maintenance program for cargo tanks (a) Any person who performs a functransporting liquefied compressed gases. tion prescribed in this part shall per- 180.417 Reporting and record retention reform that function in accordance with quirements. this part. 1115 § 180.3 49 CFR Ch. I (10-1-06 Edition) (b) Any person who performs a func- Subpart B [Reserved] tion prescribed in this part is considered subject to the regulations of this Subpart C-Qualification, Maintesubchapter when that person- (1) Makes any representation indinance and Use of Cylinders cating compliance with one or more of the requirements of this part: or SOURCE: 67 FR 51660, Aug. 8, 2002, unless (2) Reintroduces into commerce a otherwise noted. packaging that bears markings indicating compliance with this part. § 180.201 Applicability. [Amdt. 180-2, 54 FR 25032, June 12, 1989, as This subpart prescribes requireamended by Amdt. 180-2, 56 FR 27877, June ments, in addition to those contained 17, 1991) in parts 107, 171, 172, 173, and 178 of this chapter, for the continuing qualifica- § 180.3 General requirements. tion, maintenance, or periodic requali- (a) No person may represent, mark, fication of DOT specification and excertify, sell, or offer a packaging or emption cylinders and UN pressure recontainer as meeting the requirements ceptacles. of this part, or a special permit per- [71 FR 33894, June 12, 2006] taining to this part issued under subchapter A of this chapter, whether or § 180.203 Definitions. not the packaging or container is intended to be used for the transpor- As used in this section, the word tation of a hazardous material, unless "cylinder" includes UN pressure recepit is marked, maintained, reconditacles. In addition to the definitions tioned, repaired, or retested, as approcontained in $ 171.8 of this subchapter, priate, in accordance with this part, an the following definitions apply to this approval issued thereunder, or a special subpart: permit issued under subchapter A of Commercially free of corrosive compothis chapter. nents means a hazardous material hav- (b) The representations, markings, ing a dew point at or below minus 46.7 and certifications subject to the prohi- °C (minus 52 °F) at 101kPa (1 atmosbitions of paragraph (a) of this section phere) and free of components that will include: adversely react with the cylinder (e.g. (1) Identifications that include the chemical stress corrosion). letters "DOT", "MC", "ICC", or "UN"; Condemn means a determination that (2) Special permit, approval, and reg- a cylinder is unserviceable for the conistration numbers that include the lettinued transportation of hazardous maters "DOT"; terials in commerce and that the cyl- (3) Test dates displayed in associainder may not be restored by repair, retion with specification, registration, building. requalification, or any other approval, or exemption markings indiprocedure. cating conformance to a test or retest Defect means an imperfection requirrequirement of this subchapter, an aping removal of a cylinder from service. proval issued thereunder, or a special Elastic expansion means a temporary permit issued under subchapter A of increase in a cylinder's volume, due to this chapter; application of pressure, that is lost (4) Documents indicating conformwhen pressure is released (elastic exance to the testing, inspection, maintepansion = total expansion minus pernance or other continuing qualification manent expansion). requirements of this part; and Filled or charged means an introduc- (5) Sales literature, including advertion or presence of a hazardous matetising, indicating that the packaging rial in a cylinder. or container represented therein con- Non-corrosive service means a hazforms to requirements contained in ardous material that, in the presence subchapter A or C of this chapter. of moisture, is not corrosive to the ma- [Amdt. 180-2, 54 FR 25032, June 12, 1989, as terials of construction of a cylinder amended by Amdt. 180-3, 58 FR 33306, June (including valve, pressure relief device, 16. 1993; 70 FR 73166, Dec. 9, 2005] etc.). 1116 Pipeline and Hazardous Materials Safety Admin., DOT § 180.205 Over-heated means a condition in (2) Direct expansion method means a which the temperature of any portion volumetric expansion test to calculate of an aluminum cylinder has reached a cylinder's total and permanent ex- 176 °C (350 °F) or higher, or in which the pansion by measuring the amount of temperature of any portion of a steel water forced into a cylinder at test or nickel cylinder has reached 343 °C pressure, adjusted for the compress- (650 °F) or higher. ibility of water, as a means of deter- Permanent expansion means a permamining the expansion. nent increase in a cylinder's volume after the test pressure is released. [67 FR 51660, Aug. 8, 2002, as amended at 71 Proof pressure test means a pressure FR 33894, June 12, 2006] test by interior pressurization without the determination of a cylinder's ex- § 180.205 General requirements for requalification of specification cylpansion. inders. Rebuild means the replacement of a pressure part (e.g. a wall, head, or pres- (a) General. Each cylinder used for sure fitting) by welding. the transportation of hazardous mate- Rejected cylinder means a cylinder rials must be an authorized packaging. that cannot be used for the transpor- To qualify as an authorized packaging, tation of a hazardous material in comeach cylinder must conform to this merce without repair, rebuilding, and subpart, the applicable requirements requalification. specified in part 173 of this subchapter, Repair means a procedure for correcand the applicable requirements of subtion of a rejected cylinder that may inpart C of part 178 of this subchapter. volve welding. (b) Persons performing requalification Requalification means the completion functions. No person may represent of a visual inspection and/or the test(s) that a repair or requalification of a required to be performed on a cylinder cylinder has been performed in accordto determine its suitability for continance with the requirements in this subued service. chapter unless that person holds a cur- Requalification identification number or rent approval issued under the proce- RIN means a code assigned by DOT to dural requirements prescribed in subuniquely identify a cylinder requalipart I of part 107 of this chapter. No fication, repair, or rebuilding facility. person may mark a cylinder with a Test pressure means the pressure used RIN and a requalification date or othfor the requalification of a cylinder. Total expansion means the total inerwise represent that a DOT specification or special permit cylinder has crease in a cylinder's volume due to application of the test pressure. been requalified unless all applicable Visual inspection means an internal or requirements of this subpart have been external visual examination, or both, met. A person who requalifies cylinders performed as part of the cylinder remust maintain the records prescribed qualification process. in $180.215 at each location at which it Volumetric expansion test means a inspects, tests, or marks cylinders. pressure test to determine the total (c) Periodic requalification of cylinders. and permanent expansion of a cylinder Each cylinder bearing a DOT specificaat a given pressure. The volumetric extion marking must be requalified and pansion test is conducted using the marked as specified in the Requalificawater jacket or direct expansion methtion Table in this subpart. Each cylods: inder bearing a DOT special permit (1) Water jacket method means a volunumber must be requalified and metric expansion test to determine a marked in conformance with this seccylinder's total and permanent expantion and the terms of the applicable sion by measuring the difference bespecial permit. No cylinder may be tween the volume of water the cylinder filled with a hazardous material and ofexternally displaces at test pressure fered for transportation in commerce and the volume of water the cylinder unless that cylinder has been successexternally displaces at ambient presfully requalified and marked in accordsure. ance with this subpart. A cylinder may 1117 § 180.205 49 CFR Ch. I (10-1-06 Edition) be requalified at any time during or be- (4) The Associate Administrator defore the month and year that the retermines that the cylinder may be in qualification is due. However, a cylan unsafe condition. inder filled before the requalification (e) Cylinders containing Class 8 (corrobecomes due may remain in service sive) liquids. A cylinder previously conuntil it is emptied. A cylinder with a taining a Class 8 (corrosive) liquid may specified service life may not be renot be used to transport a Class 2 mafilled and offered for transportation terial in commerce unless the cylinder after its authorized service life has exis- pired. (1) Visually inspected, internally and (1) Each cylinder that is requalified externally, in accordance with parain accordance with the requirements graph (f) of this section and the inspecspecified in this section must be tion is recorded as prescribed in marked in accordance with $180.213. $180.215; (2) Each cylinder that fails requali- (2) Requalified in accordance with fication must be: this section, regardless of the date of (i) Rejected and may be repaired or the previous requalification; rebuilt in accordance with § 180.211 or (3) Marked in accordance with $ 180.212, as appropriate; or $ 180.213; and (ii) Condemned in accordance with (4) Decontaminated to remove all sigparagraph (i) of this section. nificant residue or impregnation of the (3) For DOT specification cylinders, Class 8 material. the marked service pressure may be (f) Visual inspection. Except as otherchanged upon approval of the Associate wise provided in this subpart, each Administrator and in accordance with time a cylinder is pressure tested, it written procedures specified in the apmust be given an internal and external proval. visual inspection. (4) For a specification 3, 3A, 3AA, (1) The visual inspection must be per- 3AL, 3AX, 3AXX, 3B, 3BN, or 3T cylformed in accordance with the folinder filled with gases in other than Dilowing CGA Pamphlets: C-6 for steel vision 2.2, from the first requalification and nickel cylinders (IBR, see $171.7 of due on or after December 31, 2003, the this subchapter); C-6.1 for seamless burst pressure of a CG-1, CG-4, or CGaluminum cylinders (IBR, see $171.7 of 5 pressure relief device must be at test this subchapter): C-6.2 for fiber reinpressure with a tolerance of plus zero forced composite special permit cylto minus 10%. An additional 5% tolerinders (IBR, see $171.7 of this subance is allowed when a combined rupchapter); C-6.3 for low pressure aluture disc is placed inside a holder. This minum cylinders (IBR, see $171.7 of requirement does not apply if a CG-2, this subchapter): C-8 for DOT 3HT cyl- CG-3 or CG-9 thermally activated relief inders (IBR, see $171.7 of this subdevice or a CG-7 reclosing pressure chapter): and C-13 for DOT 8 series cylvalve is used on the cylinder. inders (IBR, see $171.7 of this sub- (d) Conditions requiring test and inspecchapter). tion of cylinders. Without regard to any (2) For each cylinder with a coating other periodic requalification requireor attachments that would inhibit inments, a cylinder must be tested and spection of the cylinder, the coating or inspected in accordance with this secattachments must be removed before tion prior to further use ifperforming the visual inspection. (1) The cylinder shows evidence of (3) Each cylinder subject to visual indents, corrosion, cracked or abraded spection must be approved, rejected, or areas, leakage, thermal damage, or any condemned according to the criteria in other condition that might render it the applicable CGA pamphlet. unsafe for use in transportation; (4) In addition to other requirements (2) The cylinder has been in an acciprescribed in this paragraph (f), a specdent and has been damaged to an exification or special permit cylinder tent that may adversely affect its ladmade of aluminum alloy 6351-T6 must ing retention capability; be inspected for evidence of sustained (3) The cylinder shows evidence of or load cracking (SLC) in the neck and is known to have been over-heated; or shoulder area. 1118 Pipeline and Hazardous Materials Safety Admin., DOT $ 180.205 (g) Pressure test. (1) Unless otherwise pressure to a value shown on the callprovided, each cylinder required to be bration certificate for the calibrated retested under this subpart must be recylinder used and verifying that the retested by means suitable for measuring sulting total expansion is within +1.0% the expansion of the cylinder under of the total expansion shown on the pressure. Bands and other removable calibration certificate. Alternatively, attachments must be loosened or recalibration may be demonstrated by moved before testing so that the cylbringing the total expansion to a inder is free to expand in all directions. known value on the calibration certifi- (2) The pressure indicating device of cate for the calibrated cylinder used the testing apparatus must permit and verifying that the resulting presreading of pressures to within 1% of sure is within +1.0% of the pressure the minimum prescribed test pressure shown on the calibration certificate. of each cylinder tested, except that for The calibrated cylinder must show no an analog device, interpolation to 1/2 of permanent expansion. The retester the marked gauge divisions is acceptmust demonstrate calibration in conable. The expansion-indicating device formance with this paragraph (g) to an of the testing apparatus must also perauthorized inspector on any day that it mit incremental reading of the cylretests cylinders. A retester must inder expansion to 1% of the total exmaintain calibrated cylinder certifipansion of each cylinder tested or 0.1 cates in conformance with cc, whichever is larger. Midpoint visual $ 180.215(b)(4). interpolation is permitted. (5) Minimum test pressure must be (3) Each day before retesting, the remaintained for at least 30 seconds, and tester shall confirm, by using a callas long as necessary for complete exbrated cylinder or other method aupansion of the cylinder. A system thorized in writing by the Associate check may be performed at or below Administrator, that: 90% of test pressure prior to the retest. (i) The pressure-indicating device, as In the case of a malfunction of the test part of the retest apparatus, is accuequipment, the test may be repeated at rate within ±1.0% of the prescribed test a pressure increased by 10% or 100 psig, pressure of any cylinder tested that whichever is less. This paragraph (g) day. The pressure indicating device, does not authorize retest of a cylinder itself, must be certified as having an otherwise required to be condemned accuracy of +0.5%, or better, of its full under paragraph (i) of this section. range, and must permit readings of (h) Cylinder rejection. A cylinder must pressure from 90%-110% of the minbe rejected when, after a visual inspecimum prescribed test pressure of the tion, it meets a condition for rejection cylinder to be tested. The accuracy of under the visual inspection requirethe pressure indicating device within ments of paragraph (f) of this section. the test system can be demonstrated at (1) Except as provided in paragraphs any point within 500 psig of the actual (h)(3) and (h)(4) of this section, a cyltest pressure for test pressures at or inder that is rejected may not be above 3000 psig. or 10% of the actual marked as meeting the requirements of test pressure for test pressures below this section. 3000 psig. (2) The requalifier must notify the (ii) The expansion-indicating device, cylinder owner, in writing, that the as part of the retest apparatus, gives a cylinder has been rejected. stable reading of expansion and is accu- (3) Unless the cylinder is requalified rate to +1.0% of the total expansion of in conformance with requirements in any cylinder tested or 0.1 CC, whichever $180.211, it may not be filled with a is larger. The expansion-indicating dehazardous material and offered for vice itself must have an accuracy of transportation in commerce where use +0.5%, or better, of its full scale. of a specification packaging is re- (4) The test equipment must be quired. verified to be accurate within ±1.0% of (4) A rejected cylinder with a service the calibrated cylinder's pressure and pressure of less than 900 psig may be corresponding expansion values. This requalified and marked if the cylinder may be accomplished by bringing the is repaired or rebuilt and subsequently 1119 § 180.205, Nt. 49 CFR Ch. 1 (10-1-06 Edition) inspected and tested in conformance (i) Stamp a series of X's over the with- DOT specification number and the (i) The visual inspection requiremarked pressure or stamp "CONments of paragraph (f) of this section; DEMNED" on the shoulder, top head, (ii) Part 178 of this subchapter and or neck using a steel stamp; this part; (ii) For composite cylinders, securely (iii) Any special permit covering the affix to the cylinder a label with the manufacture, requalification, and/or word "CONDEMNED" overcoated with use of that cylinder: and epoxy near, but not obscuring, the (iv) Any approval required under original cylinder manufacturer's label; $180.211. or (i) Cylinder condemnation. (1) A cyl- (iii) As an alternative to the stampinder must be condemned whening or labeling as described in this (i) The cylinder meets a condition for paragraph (i)(2), at the direction of the condemnation under the visual inspecowner, the requalifier may render the tion requirements of paragraph (f) of cylinder incapable of holding pressure. this section. (3) No person may remove or oblit- (ii) The cylinder leaks through its erate the "CONDEMNED" marking. In wall. addition, the requalifier must notify (iii) Evidence of cracking exists to the cylinder owner, in writing. that the the extent that the cylinder is likely to cylinder is condemned and may not be be weakened appreciably. filled with hazardous material and of- (iv) For a DOT specification cylinder, fered for transportation in commerce other than a DOT 4E aluminum cylwhere use of a specification packaging inder or a special permit cylinder, peris required. manent expansion exceeds 10 percent of [67 FR 51660, Aug. 8, 2002, as amended at 68 total expansion. FR 24662, May 8, 2003; 68 FR 75764, Dec. 31, (v) For a DOT 3HT cylinder- 2003; 70 FR 34077, June 13, 2005; 70 FR 73166, (A) The pressure test yields an elas- Dec. 9, 2005] tic expansion exceeding the marked re- EFFECTIVE DATE NOTE: At 71 FR 51128, Aug. jection elastic expansion (REE) value. 29, 2006, § 180.205 was amended by revising (B) The cylinder shows evidence of paragraph (f)(4), effective Jan. 1. 2007. For denting or bulging. the convenience of the user, the revised text (C) The cylinder bears a manufacture is set forth as follows: or an original test date older than $180.205 General requirements for requalitwenty-four years or after 4380 pressurfication of specification cylinders. izations, whichever occurs first. If a cylinder is refilled, on average, more * * than once every other day, an accurate record of the number of rechargings (f) must be maintained by the cylinder (4) In addition to other requirements preowner or the owner's agent. scribed in this paragraph (f), each specifica- (vi) For a DOT 4E aluminum cyltion cylinder manufactured of aluminum inder, permanent expansion exceeds 12 alloy 6351-T6 and used in self-contained unpercent of total expansion. derwater breathing apparatus (SCUBA), selfcontained breathing apparatus (SCBA), or (vii) For a DOT special permit cyloxygen service must be inspected for susinder, permanent expansion exceeds tained load cracking in accordance with Apthe limit in the applicable special perpendix C of this part at the first scheduled 5- mit, or the cylinder meets another criyear requalification period after January 1, terion for condemnation in the applica- 2007, and every five years thereafter. ble special permit. (viii) For an aluminum or an aluminum-lined composite special permit cylinder, the cylinder is known to have § 180.207 Requirements for requalificabeen or shows evidence of having been tion of UN pressure receptacles. over-heated. (a) General. (1) Each UN pressure re- (2) When a cylinder must be conceptacle used for the transportation of demned, the requalifier musthazardous materials must conform to 1120 Pipeline and Hazardous Materials Safety Admin., DOT $ 180.207 the requirements prescribed in paraafter its authorized service life has exgraphs (a), (b) and (d) in § 180.205. pired unless approval has been obtained (2) No pressure receptacle due for rein writing from the Associate Adminisqualification may be filled with a haztrator. ardous material and offered for trans- (b) Periodic requalification of UN presportation in commerce unless that sure receptacles. (1) Each pressure receppressure receptacle has been successtacle that is successfully requalified in fully requalified and marked in accordaccordance with the requirements specance with this subpart. A pressure reified in this section must be marked in ceptacle may be requalified at any time during or before the month and accordance with $180.213. The requalification results must be recorded in acyear that the requalification is due. However, a pressure receptacle filled cordance § 180.215. before the requalification becomes due (2) Each pressure receptacle that fails may remain in service until it is requalification must be rejected or emptied. condemned in accordance with the ap- (3) No person may requalify a UN plicable ISO requalification standard. composite pressure receptacle for con- (c) Requalification interval. Each UN tinued use beyond its 15-years authorpressure receptacle that becomes due ized service life. A pressure receptacle for periodic requalification must be rewith a specified service life may not be qualified at the interval specified in refilled and offered for transportation the following table: TABLE 1.--REQUALIFICATION INTERVALS OF UN PRESSURE RECEPTACLES Interval (years) UN pressure receptacles/hazardous materials 10 Pressure receptacles for all hazardous materials except as noted below (also for dissolved acetylene, see paragraph (d)(3) of this section): 5 Composite pressure receptacles. 5 Pressure receptacles used for: All Division 2.3 materials. UN1013, Carbon dioxide. UN1043, Fertilizer ammoniating solution with free ammonia. UN1051, Hydrogen cyanide, stabilized containing less than 3% water. UN1052, Hydrogen fluoride, anhydrous. UN1745, Bromine pentafluoride. UN1746, Bromine trifluoride. UN2073, Ammonia solution, UN2495, lodine pentafluoride. UN2983, Ethylene Oxide and Propylene oxide mixture, not more than 30% ethylene oxide. (d) Requalification procedures. Each (1) Seamless steel: Each seamless UN pressure receptacle that becomes steel UN pressure receptacle, including due for requalification must be requali- MEGC's pressure receptacles, must be fied at the interval prescribed in pararequalified in accordance with ISO 6406 graph (c) of this section and in accord- (IBR, see $171.7 of this subchapter). ance with the procedures contained in However, UN cylinders with a tensile the following standard, as applicable. strength greater than or equal to 950 When a pressure test is performed on a MPa must be requalified by ultrasonic UN pressure receptacle, the test must examination in accordance with ISO be a water jacket volumetric expansion 6406. test suitable for the determination of (2) Seamless UN aluminum: Each the cylinder expansion or a hydraulic seamless aluminum UN pressure recepproof pressure test. The test equipment tacle must be requalified in accordance must conform to the accuracy requirewith ISO 10461 (IBR, see $171.7 of this ments in $180.205(g). Alternative methsubchapter). ods (e.g., acoustic emission) or requali- (3) Dissolved acetylene UN cylinders: fication procedures may be performed Each dissolved acetylene cylinder must if prior approval has been obtained in be requalified in accordance with ISO writing from the Associate Adminis- 10462 (IBR. see §171.7 of this subtrator. chapter). The porous mass and the 1121 § 180.209 49 CFR Ch. I (10-1-06 Edition) shell must be requalified no sooner § 180.209 Requirements for requalificathan 3 years, 6 months, from the date tion of specification cylinders. of manufacture. Thereafter, subsequent requalifications of the porous mass and (a) Periodic qualification of cylinders. shell must be performed at least once (1) Each specification cylinder that beevery ten years. comes due for periodic requalification. (4) Composite UN cylinders: Each as specified in the following table, composite cylinder must be inspected must be requalified and marked in conand tested in accordance with ISO 11623 formance with the requirements of this (IBR. see § 171.7 of this subchapter). subpart. Requalification records must be maintained in accordance with [71 FR 33894, June 12. 2006, as amended at 71 FR 54397, Sept. 14, 2006] § 180.215. Table 1 follows: TABLE 1-REQUALIFICATION OF CYLINDERS Specification under which cylinder was Minimum test pressure Requalification period made (psig) (years) DOT 3 3000 psig 5 DOT 3A, 3AA 5/3 times service pressure, except non- 5, 10, or 12 (see § 180.209(b), (f), (h), corrosive service (see § 180.209(g)). and (j) DOT 3AL 5/3 times service pressure 5 or 12 (see § 180.209(J)) DOT 3AX, 3AAX 5/3 times service pressure 5 3B, 3BN 2 times service pressure (see 5 or 10 (see $ 180.209(f)) § 180.209(g)). 3E Test not required. 3HT 5/3 times service pressure 3 (see §§ 180.209(k) and 180.213(c)) 3T 5/3 times service pressure 5 4AA480 2 times service pressure (see 5 or 10 (see $ 180.209(h)) $ 180.209(g)). 4B, 4BA, 4BW, 4B-240ET 2 times service pressure, except non- 5, 10, or 12 (see § 180.209(e), (f), and corrosive service (see § 180.209(g)). (I)) 4D, 4DA, 4DS 2 times service 5 DOT 4E 2 times service pressure, except non- 5 corrosive (see $ 180.209(g)). 4L Test not required. 8, 8AL 10 or 20 (see $ 180.209(I)) Exemption or special permit cylinder See current exemption or special permit See current exemption or special permit Foreign cylinder (see $173.301(j) of this As marked on cylinder, but not less than 5 (see §§ 180.209(I) and 180.213(d)(2)) subchapter for restrictions on use). 5/3 of any service or working pressure marking. , Any cylinder not exceeding 2 inches outside diameter and less than 2 feet In length is excepted from volumetric expansion test. 2For cylinders not marked with a service pressure, see § 173.301a(b) of this subchapter. (b) DOT 3A or 3AA cylinders. (1) A cylfrom corroding components; permitted inder conforming to specification DOT mixtures of these gases (see § 173.301(d) 3A or 3AA with a water capacity of 56.7 of this subchapter); and permitted mixkg (125 lb) or less that is removed from tures of these gases with up to 30 perany cluster, bank, group, rack, or vehicent by volume of carbon dioxide, procle each time it is filled, may be revided the gas has a dew point at or qualified every ten years instead of below minus (52 °F) at 1 atmosphere. every five years, provided the cylinder (iii) Before each refill, the cylinder is conforms to all of the following conditions: removed from any cluster, bank, group, (i) The cylinder was manufactured rack or vehicle and passes the hammer after December 31, 1945. test specified in CGA Pamphlet C-6 (ii) The cylinder is used exclusively (IBR, see $171.7 of this subchapter). for air; argon; cyclopropane; ethylene; (iv) The cylinder is dried immehelium; hydrogen; krypton; neon; nidiately after hydrostatic testing to retrogen; nitrous oxide; oxygen; sulfur move all traces of water. hexafluoride; xenon; chlorinated hydro- (v) The cylinder is not used for uncarbons, fluorinated hydrocarbons, liqderwater breathing. uefied hydrocarbons, and mixtures (vi) Each cylinder is stamped with a thereof that are commercially free five-pointed star at least one-fourth of 1122 Pipeline and Hazardous Materials Safety Admin., DOT § 180.209 an inch high immediately following the (e) Proof pressure test A cylinder made test date. in conformance with specifications (2) If, since the last required requali- DOT 4B, 4BA, 4BW, or 4E used exclufication, a cylinder has not been used sively for: liquefied petroleum gas that exclusively for the gases specifically meets the detail requirement limits in identified in paragraph (b)(1)(ii) of this Table I of ASTM D 1835, "Standard section, but currently conforms with Specification for Liquefied Petroleum all other provisions of paragraph (b)(1) (LP) Gases" (IBR see $171.7 of this subof this section, it may be requalified chapter) or an equivalent standard conevery 10 years instead of every five taining the same limits; anhydrous diyears, provided it is first requalified methylamine; anhydrous methylamine; and examined as prescribed by anhydrous trimethylamine; methyl $173.302a(b) (2), (3) and (4) of this subchloride; methylacetylene-propadiene chapter. stabilized; or dichlorodifluoromethane, (3) Except as specified in paragraph difluoroethane, difluorochloroethane, (b)(2) of this section, if a cylinder, chlorodifluoromethane, marked with a star, is filled with a chlorotetrafluoroethane, compressed gas other than as specified trifluorochloroethylene, or mixture in paragraph (b)(1)(ii) of this section, thereof, or mixtures of one or more the star following the most recent test with trichlorofluoromethane; and comdate must be obliterated. The cylinder mercially free from corroding compomust be requalified five years from the nents and protected externally by a marked test date, or prior to the first suitable corrosion-resistant coating filling with a compressed gas, if the re- (such as galvanizing or painting) may quired five-year requalification period be requalified by volumetric expansion has passed. testing every 12 years instead of every (c) DOT 4-series cylinders. A DOT 4-sefive years. As an alternative, the cylries cylinder, except a 4L cylinder, that inder may be subjected to a proof presat any time shows evidence of a leak or sure test at least two times the marked of internal or external corrosion, dentservice pressure, but this latter type of ing, bulging or rough usage to the extest must be repeated every seven tent that it is likely to be weakened years after expiration of the first 12- appreciably, or that has lost five peryear period. When subjected to a proof cent or more of its official tare weight pressure test, the cylinder must be must be requalified before being recarefully examined under test pressure filled and offered for transportation. and removed from service if a leak or (Refer to CGA Pamphlet C-6 or C-6.3, defect is found. as applicable, regarding cylinder weak- (f) Poisonous materials. A cylinder ening.) After testing, the actual tare conforming to specification DOT 3A, weight must be recorded as the new 3AA, 3B, 4BA, or 4BW having a service tare weight. pressure of 300 psig or less and used ex- (d) Cylinders 5.44 kg (12 lb) or less with clusively for methyl bromide, liquid: service pressures of 300 psig or less. A cylmixtures of methyl bromide and ethylinder of 5.44 (12 lb) or less water capacene dibromide, liquid: mixtures of ity authorized for service pressure of methyl bromide and chlorpicrin, liquid; 300 psig or less must be given a commixtures of methyl bromide and petroplete external visual inspection at the leum solvents, liquid; or methyl brotime periodic requalification becomes mide and nonflammable, nonliquefied due. External visual inspection must be compressed gas mixtures, liquid; comin accordance with CGA Pamphlet C-6 mercially free of corroding compoor C-6.1 (IBR, see $171.7 of this subnents, and protected externally by a chapter). The cylinder may be proof suitable corrosion resistant coating pressure tested. The test is successful (such as galvanizing or painting) and if the cylinder, when examined under internally by a suitable corrosion retest pressure, does not display a defect sistant lining (such as galvanizing) described in $180.205(i)(1) (ii) or (iii). may be tested every 10 years instead of Upon successful completion of the test every five years, provided a visual inand inspection, the cylinder must be ternal and external examination of the marked in accordance with § 180.213. cylinder is conducted every five years 1123 § 180.209 49 CFR Ch. I (10-1-06 Edition) in accordance with CGA Pamphlet C-6. a current RIN and the results recorded The cylinder must be examined at each and maintained in accordance with filling, and rejected if a dent, corroded § 180.215. Records must include: date of area, leak or other condition indicates inspection (month and year); DOT specpossible weakness. ification number; cylinder identifica- (g) Visual inspections. A cylinder contion (registered symbol and serial numforming to a specification listed in the ber, date of manufacture, and owner); table in this paragraph and used exclutype of cylinder protective coating (insively in the service indicated may, including statement as to need of refinstead of a periodic hydrostatic test, be ishing or recoating): conditions given a complete external visual inchecked (e.g., leakage, corrosion, gougspection at the time periodic requalies, dents or digs in shell or heads, brofication becomes due. External visual ken or damaged footring or protective inspection must be in accordance with ring or fire damage); disposition of cyl- CGA Pamphlet C-6 or C-6.3, as applicainder (returned to service, returned to ble (IBR, see $171.7 of this subchapter). cylinder manufacturer for repairs or When this inspection is used instead of condemned). A cylinder passing rehydrostatic pressure testing, subsequalification by the external visual inquent inspections are required at fivespection must be marked in accordance year intervals after the first inspecwith $180.213. Specification cylinders tion. After May 31, 2004, inspections must be in exclusive service as shown must be made only by persons holding in the following table: Cylinders conforming to- Used exclusively for- DOT 3A, DOT 3AA, DOT 3A480X, DOT 4AA480 Anhydrous ammonia of at least 99.95% purity. DOT 3A, DOT 3AA, DOT 3A480X, DOT 3B, DOT 4B, DOT Butadiene, inhibited, that is commercially free from corroding 4BA, DOT 4BW. components. DOT 3A, DOT 3A480X, DOT 3AA, DOT 3B, DOT 4AA480, Cyclopropane that is commercially free from corroding compo- DOT 4B, DOT 4BA, DOT 4BW. nents. DOT 3A, DOT 3AA, DOT 3A480X, DOT 4B, DOT 4BA, DOT Chlorinated hydrocarbons and mixtures thereof that are com- 4BW, DOT 4E mercially free from corroding components. DOT 3A, DOT 3AA, DOT 3A480X, DOT 4B, DOT 4BA, DOT Fluorinated hydrocarbons and mixtures thereof that are com- 4BW, DOT 4E mercially free from corroding components, DOT 3A, DOT 3AA, DOT 3A480X, DOT 3B, DOT 4B, DOT Liquefied hydrocarbon gas that is commercially free from cor- 4BA, DOT 4BW, DOT 4E. roding components. DOT 3A, DOT 3AA, DOT 3A480X, DOT 3B, DOT 4B, DOT Liquefied petroleum gas that meets the detail requirements lim- 4BA, DOT 4BW, DOT 4E. its in Table 1 of ASTM 1835, Standard Specification for Liquefied Petroleum (LP) Gases (incorporated by reference; $00 $ 171.7 of this subchapter) or an equivalent standard containing the same limits. DOT 3A, DOT 3AA, DOT 3B, DOT 4B, DOT 4BA, DOT 4BW, Methylacatylene-propadiene, stabilized, that is commercially DOT 4E. free from corroding components. DOT 3A, DOT 3AA, DOT 3B, DOT 4B, DOT 4BA, DOT 4BW Anhydrous mono, di,trimethytamines that are commercially free from corroding components. DOT 4B240, DOT 4BW240 Elhyleneimine, stabilized. (h) Cylinders containing anhydrous am- (i) Requalification of DOT-8 series cylmonia. A cylinder conforming to speciinders. (1) Each owner of a DOT-8 series fication DOT 3A, 3A480X, or 4AA480 cylinder used to transport acetylene used exclusively for anhydrous ammomust have the cylinder shell and the nia, commercially free from corroding porous filler requalified in accordance components, and protected externally with CGA Pamphlet C-13 (IBR, see by a suitable corrosion-resistant coat- $171.7 of this subchapter). Requalificaing (such as paint) may be requalified tion must be performed in accordance every 10 years instead of every five with the following schedule: years. Date of cylinder manu- Shell (visual inspection) requalification Porous filler requalification facture Initial Subsequent Initial Subsequent Before January 1, 1991 Before January 1, 2001 10 years Before January 1, 2011 Not required. 1124 Pipeline and Hazardous Materials Safety Admin., DOT § 180.209, Nt. Date of cylinder manu- Shell (visual inspection) requalification Porous filler requalification facture Initial Subsequent Initial Subsequent On or after January 1, 10 years¹ 10 years 3 to 20 years2 Not required. 1991. 'Years from date of cylinder manufacture. 2 For a cylinder manufactured on or after January 1, 1991, requalification of the porous filler must be performed no sooner than 5 years, and no later than 20 years, from the date of manufacture. (2) Unless requalified and marked in (k) 3HT cylinders. In addition to the accordance with CGA Pamphlet C-13 other requirements of this section, a before October 1, 1994, an acetylene cylcylinder marked DOT-3HT must be re- Inder must be requalified by a person qualified in accordance with CGA C-8 who holds a current RIN. (IBR, see $171.7 of this subchapter). (3) If a cylinder valve is replaced, a (1) Requalification of foreign cylinders cylinder valve of the same weight must filled for export. A cylinder manufacbe used or the tare weight of the cyltured outside the United States, other inder must be adjusted to compensate than as provided in $171.12a of this subfor valve weight differential. chapter, that has not been manufac- (4) The person performing a visual intured, inspected, tested and marked in spection or requalification must record the results as specified in $180.215. accordance with part 178 of this sub- (5) The person performing a visual inchapter may be filled with compressed spection or requalification must mark gas in the United States, and shipped the cylinder as specified in § 180.213. solely for export If it meets the fol- (j) Cylinder used as a fire extinguisher. lowing requirements, in addition to Only a DOT specification cylinder used other requirements of this subchapter: as a fire extinguisher and meeting Spe- (1) It has been inspected, tested and cial Provision 18 in $172.102(c)(1) of this marked (with only the month and year subchapter may be requalified in acof test) in conformance with the procecordance with this paragraph (j). dures and requirements of this subpart (1) A DOT 4B, 4BA, 4B240ET or 4BW or the Associate Administrator has aucylinder may be tested as follows: thorized the filling company to fill for- (1) For a cylinder with a water capaceign cylinders under an alternative ity of 5.44 kg (12 lb) or less, by volumethod of qualification; and metric expansion test using the water (2) It is offered for transportation in jacket method or by proof pressure conformance with the requirements of test. A requalification must be per- § 173.301(1) of this subchapter. formed by the end of 12 years after the original test date and at 12-year inter- [67 FR 51660, Aug. 8, 2002, as amended at 68 vals thereafter. FR 24662, May 8, 2003; 68 FR 55544, Sept. 26, (ii) For a cylinder having a water ca- 2003; 68 FR 48572, Aug. 14, 2003; 68 FR 75764, pacity over 5.44 kg (12 lb)- Dec. 31, 2003; 70 FR 73166, Dec. 9. 2005) (A) By proof pressure test. A requali- EDITORIAL NOTE: The following amendment fication must be performed by the end could not be incorporated into $180.209 beof 12 years after the original test date cause of inaccurate amendatory instruction. and at 7-year intervals; or For the convenience of the user the amend- (B) By volumetric expansion test using atory instruction and text is set forth as folthe water Jacket method. A requalificalows: tion must be performed 12 years after At 71 FR 54397, Sept. 14, 2006, $180.209 was the original test date and at 12-year inamended in paragraph (a)(I), the first and tervals thereafter. third entries in Table 1 were revised to read (2) A DOT 3A, 3AA, or 3AL cylinder as follows: must be requalified by volumetric ex- $180.209 Requirements for requalification pansion test using the water jacket of specification cylinders. method. A requalification must be performed 12 years after the original test (a) (1) date and at 12-year intervals thereafter. 1125 $ 180.209, Nt. 49 CFR Ch. I (10-1-06 Edition) TABLE 1-REQUALIFICATION OF CYLINDERS Specification under which cylinder was Minimum test pressure (psig)² Requalification period (years) made * * * * * 4B, 4BA, 4BW, 4B240ET 2 times service pressure, except non- 5, 7, 10, or 12 (see $ 180.209(e), (f), corrosive (see § 180.209(g)). and (j)). . * * DOT 4E 2 times service pressure, except non- 5 or 7 (see $ 180.209(e)). corrosive (see $ 180.209(g)). EFFECTIVE DATE NOTE: At 71 FR 51128, Aug. $180.209 Requirements for requalification 29. 2006, § 180.209 paragraph (a), in the "Reof specification cylinders. qualification of Cylinders table" the entry "DOT 3AL" was revised, and a new para- * * * * graph (m) was added, effective Jan. 1, 2007. For the convenience of the user, the revised (a) and added text is set forth as follows: TABLE 1.-REQUALIFICATION OF CYLINDERS Specification under which cylinder was made Minimum test pressure (psig.)2 Requalification period (years) * * * * * DOT 3AL 5/3 times service pressure 5 or 12 (see § 180.209(i) and $ 180.209(m)³ * * * . 1Any cylinder not exceeding 2 inches outside diameter and less than 2 feet in length is excepted from volumetric expansion test. 2 For cylinders not marked with a service pressure, see $ 173.301(e)(1) of this subchapter. 3This provision does not apply to cylinders used for carbon dioxide, fire extinguisher or other Industrial gas service. * * fied and inspected for sustained load cracking in accordance with the non-destructive (m) DOT-3AL cylinders manufactured of examination method described in the fol- 6351-T6 aluminum alloy. In addition to the lowing table. Each cylinder with sustained periodic requalification and marking deload cracking that has expanded into the scribed in $180.205. each cylinder manufacneck threads must be condemned in accordtured of aluminum alloy 6351-T6 used in selfance with $180.205(1). This provision does not contained underwater breathing apparatus apply to cylinders used for carbon dioxide, (SCUBA), self-contained breathing apparatus fire extinguisher or other industrial gas serv- (SCBA), or oxygen service must be requaliice. REQUALIFICATION AND INSPECTION OF DOT-3AL CYLINDERS MADE OF ALUMINUM ALLOY 6351-T6 Requalification requirement Sustained Load Cracking Con- Requalifica- Examination procedure 1 demnation Criteria² tion period (years) Eddy current examination combined Eddy current-In accordance with Any crack in the neck or shoulder 5 with visual inspection. Appendix C of this part. of 2 thread lengths or more. Visual inspection-In accordance with CGA Pamphlet C-6.1 (IBR; see $ 171.7 of this subchapter). 1 The requalifier performing eddy current must be familiar with the eddy current equipment and must standardize (calibrate) the system in accordance with the requirements provided in Appendix C to this part. 2The eddy current must be applied from the inside of the cylinder's neck to detect any sustained load cracking that has expanded into the neck threads. 1126 Pipeline and Hazardous Materials Safety Admin., DOT § 180.211 $ 180.211 Repair, rebuilding and remarkings is replaced, all markings heat treatment of DOT-4 series must be transferred to the attachment specification cylinders. on the repaired cylinder. (a) General requirements for repair and (10) Walls, heads or bottoms of cylrebuilding. Any repair or rebuilding of a inders with defects or leaks in base DOT 4-series cylinder must be permetal may not be repaired, but may be formed by a person holding an approval replaced as provided for in paragraph as specified in $107.805 of this chapter. (d) of this section. A person performing a rebuild function (c) Additional repair requirements for is considered a manufacturer subject to 4L cylinders. (1) Repairs to a DOT 4L the requirements of $178.2(a)(2) and cylinder must be performed in accordsubpart C of part 178 of this subchapter. ance with paragraphs (a) and (b) of this The person performing a repair, resection and are limited to the folbuild, or reheat treatment must record lowing: the test results as specified in $180.215. (i) The removal of either end of the Each cylinder that is successfully reinsulation jacket to permit access to paired or rebuilt must be marked in acthe cylinder, piping system, or neck cordance with 180.213. tube. (b) General repair requirements. Each (ii) The replacement of the neck repair of a DOT 4-series cylinder must tube. At least a 13 mm (0.51 inch) piece be made in accordance with the folof the original neck tube must be prolowing conditions: truding above the cylinder's top end. (1) The repair and the inspection of The original weld attaching the neck the work performed must be made in tube to the cylinder must be sound and accordance with the requirements of the replacement neck tube must be the cylinder specification. welded to this remaining piece of the (2) The person performing the repair original neck tube. must use the procedure, equipment, (iii) The replacement of material and filler metal or brazing material as such as, but not limited to, the insuauthorized by the approval issued lating material and the piping system under $107.805 of this chapter. within the insulation space is author- (3) Welding and brazing must be perized. The replacement material must formed on an area free from contamibe equivalent to that used at the time nants. of original manufacture. (4) A weld defect, such as porosity in (iv) Other welding procedures that a pressure retaining seam, must be are permitted by CGA Pamphlet C-3 completely removed before re-welding. (IBR, see § 171.7 of this subchapter), and Puddling may be used to remove a weld not excluded by the definition of "redefect only by the tungsten inert gas build," are authorized. shielded arc process. (5) After removal of a non-pressure (2) After repair, the cylinder must beattachment and before its replacement, the cylinder must be given a visual in- (i) Pressure tested in accordance with spection in accordance with $180.205(f). the specifications under which the cyl- (6) Reheat treatment of DOT 4B, 4BA inder was originally manufactured; or 4BW specification cylinders after re- (ii) Leak tested before and after asplacement of non-pressure attachments sembly of the insulation jacket using a is not required when the total weld mamass spectrometer detection system; terial does not exceed 20.3 cm (8 and inches). Individual welds must be at (iii) Tested for heat conductivity releast 7.6 cm (3 inches) apart. quirements. (7) After repair of a DOT 4B, 4BA or (d) General rebuilding requirements. (1) 4BW cylinder, the weld area must be The rebuilding of a DOT 4-series cylleak tested at the service pressure of Inder must be made in accordance with the cylinder. the following requirements: (8) Repair of weld defects must be (i) The person rebuilding the cylinder free of cracks. must use the procedures and equipment (9) When a non-pressure attachment as authorized by the approval issued with the original cylinder specification under § 107.805 of this chapter. 1127 § 180.211 49 CFR Ch. I (10-1-06 Edition) (ii) After removal of a non-pressure (4) Rebuilding a cylinder with brazed component and before replacement of seams is prohibited. any non-pressure component, the cyl- (5) When an end with the original cylinder must be visually inspected in acinder specification markings is recordance with CGA Pamphlet C-6 (IBR, placed, all markings must be transsee § 171.7 of this subchapter). ferred to the rebuilt cylinder. (iii) The rebuilder may rebuild a DOT 4B, 4BA or 4BW cylinder having a (e) Additional rebuilding requirements water capacity of 9.07 kg (20 lb) or for DOT 4L cylinders. (1) The rebuilding greater by replacing a head of the cylof a DOT 4L cylinder must be perinder using a circumferential joint. formed in accordance with paragraph When this weld joint is located at other (d) of this section. Rebuilding of a DOT than an original welded joint, a nota- 4L cylinder is: tion of this modification must be (i) Substituting or adding material in shown on the Manufacturer's Report of the insulation space not identical to Rebuilding in $ 180.215(c)(2). The weld that used in the original manufacture joint must be on the cylindrical section of that cylinder; of the cylinder. (ii) Making a weld repair not to ex- (iv) Any welding and the inspection ceed 150 mm (5.9 inches) in length on of the rebuilt cylinder must be in acthe longitudinal seam of the cylinder cordance with the requirements of the or 300 mm (11.8 Inches) in length on a applicable cylinder specification and circumferential weld joint of the cylthe following requirements: inder; or (A) Rebuilding of any cylinder in- (iii) Replacing the outer jacket. volving a joint subject to internal pres- (2) Reheat treatment of cylinders is sure may only be performed by fusion prohibited. welding; (B) Welding must be performed on an (3) After rebuilding, each inner conarea free from contaminants; and tainment vessel must be proof pressure (C) A weld defect, such as porosity in tested at 2 times its service pressure. a pressure retaining seam, must be Each completed assembly must be completely removed before re-welding. leak-tested using a mass spectrometer Puddling may be used to remove a weld detection system. defect only by using the tungsten inert (f) Reheat treatment. (1) Prior to regas shielded arc process. heat treatment, each cylinder must be (2) Any rebuilt cylinder must begiven a visual inspection, internally (i) Heat treated in accordance with and externally, in accordance with paragraph (f) of this section; 180.205(f). (ii) Subjected to a volumetric expan- (2) Cylinders must be segregated in sion test on each cylinder. The results lots for reheat treatment. The reheat of the tests must conform to the applitreatment and visual inspection must cable cylinder specification; be performed in accordance with the (iii) Inspected and have test data respecification for the cylinders except viewed to determine conformance with as provided in paragraph (f)(4) of this the applicable cylinder specification; section. and (3) After reheat treatment, each cyl- (iv) Made of material conforming to inder in the lot must be subjected to a the specification. Determination of conformance shall include chemical volumetric expansion test and meet analysis, verification, inspection and the acceptance criteria in the applicatensile testing of the replaced part. ble specification or be scrapped. Tensile tests must be performed on the (4) After all welding and heat treatreplaced part after heat treatment by ment, a test of the new weld must be lots defined in the applicable specificaperformed as required by the original tion. specification. The test results must be (3) For each rebuilt cylinder. an inrecorded in accordance with $ 180.215. spector's report must be prepared to in- [67 FR 51660, Aug. 8, 2002, as amended at 68 clude the information listed in FR 24664, May 8, 2003; 68 FR 75764, Dec. 31, $180.215(c). 2003; 71 FR 54398, Sept. 14, 2006] 1128 Pipeline and Hazardous Materials Safety Admin., DOT $ 180.213 § 180.212 Repair of seamless DOT 3-setaining the same specification limits. ries specification cylinders and The re-threaded cylinder must be seamless UN pressure receptacles. stamped clearly and legibly with the (a) General requirements for repair of words "RETHREAD" on the shoulder, DOT 3-series cylinders and UN pressure top head, or neck. No DOT specificareceptacles. (1) No person may repair a tion cylinder or UN cylinder may be re- DOT 3-series cylinder or a seamless UN threaded more than one time without pressure receptacle unlessapproval of the Associate Adminis- (1) The repair facility holds an aptrator. proval issued under the provisions in [71 FR 33895, June 12. 2006, as amended at 71 $107.805 of this chapter; and FR 54398, Sept. 14, 2006] (ii) Except as provided in paragraph (b) of this section, the repair and the $ 180.213 Requalification markings. inspection is performed under the pro- (a) General. Each cylinder or UN presvisions of an approval issued under subsure receptacle requalified in accordpart H of Part 107 of this chapter and ance with this subpart with acceptable conform to the applicable cylinder results must be marked as specified in specification or ISO standard conthis section. Required specification tained in part 178 of this chapter. (2) The person performing the repair markings may not be altered or removed. must prepare a report containing, at a minimum, the results prescribed in (b) Placement of markings. Each cyl- $ 180.215. inder must be plainly and permanently (b) Repairs not requiring prior apmarked on the metal of the cylinder as proval. Approval is not required for the permitted by the applicable specificafollowing specific repairs: tion. Unless authorized by the cylinder (1) The removal and replacement of a specification, marking on the cylinder neck ring or foot ring on a DOT 3A, sidewall is prohibited. 3AA or 3B cylinder or a UN pressure re- (1) Requalification and required specceptacle that does not affect a pressure ification markings must be legible so part of the cylinder when the repair is as to be readily visible at all times. IIperformed by a repair facility or a cyllegible specification markings may be inder manufacturer of these types of remarked on the cylinder as provided cylinders. The repair may be made by by the original specification. Requaliwelding or brazing in conformance with fication markings may be placed on the original specification. After reany portion of the upper end of the cylmoval and before replacement, the cylinder excluding the sidewall, as proinder must be visually inspected and vided in this section. Requalification any defective cylinder must be reand required specification markings jected. The heat treatment, testing and that are illegible may be reproduced on inspection of the repair must be per- a metal plate and attached as provided formed under the supervision of an inby the original specification. spector and must be performed in ac- (2) Previous requalification markings cordance with the original specificamay not be obliterated, except that, tion. when the space originally provided for (2) External re-threading of DOT requalification dates becomes filled, 3AX, 3AAX or 3T specification cyladditional dates may be added as folinders or a UN pressure receptacle lows: mounted in a MEGC; or the internal re- (i) All preceding requalification dates threading of a DOT-3 series cylinder or may be removed by peening provided a seamless UN pressure receptacle thatwhen performed by the original manu- (A) Permission is obtained from the facturer of the cylinder. The repair cylinder owner; work must be performed under the su- (B) The minimum wall thickness is pervision of an independent inspection maintained in accordance with manuagency. Upon completion of the refacturing specifications for the cylthreading, the threads must be gauged inder; and in accordance with Federal Standard (C) The original manufacturing test H-28 or an equivalent standard condate is not removed. 1129 § 180.213 49 CFR Ch. I (10-1-06 Edition) (ii) When the cylinder is fitted with a "X" represents the symbols described in footring, additional dates may be paragraphs (f)(2) through (f)(7) of this secmarked on the external surface of the tion. footring. (1) Upon a written request, variation (c) Requalification marking method. from the marking requirement may be The depth of requalification markings approved by the Associate Adminismay not be greater than specified in trator. the applicable specification. The mark- (2) Exception. A cylinder subject to ings must be made by stamping, enthe requirements of $173.301(1) of this graving, scribing or other method that subchapter may not be marked with a produces a legible, durable mark. RIN. (1) A cylinder used as a fire extin- (e) Size of markings. The size of the guisher (§ 180.209(j) may be marked by markings must be at least 6.35 mm (1/4 using a pressure sensitive label. in.) high, except RIN characters must (2) For a DOT 3HT cylinder, the test be at least 3.18 mm (1/8 in.) high. date and RIN must be applied by low- (f) Marking Illustrations. Examples of stress steel stamps to a depth no greatrequired requalification markings for er than that prescribed at the time of DOT specification and special permit manufacture. Stamping on the sidewall cylinders are illustrated as follows: is not authorized. (1) For designation of the 5-year volu- (3) For a composite cylinder, the remetric expansion test, 10-year voluqualification markings must be applied metric expansion test for UN cylinders on a pressure sensitive label, securely and cylinders conforming to $180.209(f) affixed in a manner prescribed by the cylinder manufacturer, near the origiand (h), or 12-year volumetric expannal manufacturer's label. Stamping of sion test for fire extinguishers conthe composite surface is not authorforming to $173.309(b) of this subized. chapter and cylinders conforming to (d) Requalification markings. Each cyl- $180.209(e) and 180.209(g). the marking inder that has successfully passed reis as illustrated in paragraph (d) of this section. qualification must be marked with the RIN set in a square pattern, between (2) For designation of the 10-year volthe month and year of the requalificaumetric expansion test for cylinders tion date. The first character of the conforming to $180.209(b). the marking RIN must appear in the upper left coris as illustrated in paragraph (d) of this ner of the square pattern; the second in section, except that the "X" is rethe upper right; the third in the lower placed with a five-point star. right, and the fourth in the lower left. (3) For designation of special filling Example: A cylinder requalified in Seplimits up to 10% in excess of the tember 1998, and approved by a person marked service pressure for cylinders who has been issued RIN "A123", would conforming to $173.302a(b) of this subbe marked plainly and permanently chapter, the marking is as illustrated into the metal of the cylinder in acin paragraph (d) of this section, except cordance with location requirements of that the "X" is replaced with a plus the cylinder specification or on a metal sign "+". plate permanently secured to the cyl- (4) For designation of the proof presinder in accordance with paragraph (b) sure test, the marking is as illustrated of this section. An example of the in paragraph (d) of this section, except markings prescribed in this paragraph that the "X" is replaced with the letter (d) is as follows: "S". (5) For designation of the 5-year ex- Al ternal visual inspection for cylinders 9 98 X conforming to $180.209(g). the marking is as illustrated in paragraph (d) of this 32 section, except that the "X" is replaced with the letter "E". Where: "9" is the month of requalification, (6) For designation of DOT 8 series "A123" is the RIN, cylinder shell requalification only, the "98" is the year of requalification. and marking is as illustrated in paragraph 1130 Pipeline and Hazardous Materials Safety Admin., DOT $ 180.215 (d) of this section, except that the "X" "X" represents the symbols described in is replaced with the letter "S". paragraphs (f)(2) through (f)(9) of this section. (7) For designation of DOT 8 series and UN cylinder shell and porous filler requalification, the marking is as illustrated in paragraph (d) of this section, (f) * except that the "X" is replaced with (9) For designation of the eddy current exthe letters "FS." amination combined with a visual inspection, the marking is as illustrated in para- (8) For designation of a nongraph (d) of this section, except the "X" is destructive examination combined replaced with the letters "VE." with a visual inspection, the marking is as illustrated in paragraph (d) of this $ 180.215 Reporting and record retensection, except that the "X" is retion requirements. placed with the type of test performed, (a) Facility records. A person who refor example the letters "AE" for acousqualifies, repairs or rebuilds cylinders tic emission or "UE" for ultrasonic exmust maintain the following records amination. where the requalification is performed: (1) Current RIN Issuance letter; [67 FR 51660, Aug. 8, 2002, as amended at 70 (2) If the RIN has expired and renewal FR 73166, Dec. 9, 2005; 71 FR 33896, June 12, is pending. a copy of the renewal re- 2006] quest; EFFECTIVE DATE NOTE: At 71 FR 51128, Aug. (3) Copies of notifications to Asso- 29, 2006, $180.213 was amended by revising ciate Administrator required under paragraph (d) and adding paragraph (f)(9). ef- $107.805 of this chapter; fective Jan. 1, 2007. For the convenience of (4) Current copies of those portions of the user, the revised and added text is set this subchapter applicable to its cylforth as follows: inder requalification and marking activities at that location; $ 180.213 Requalification markings. (5) Current copies of all special permits governing exemption cylinders re- * * * * qualified or marked by the requalifier at that location; and (d) Requalification markings. Each cylinder (6) The information contained in each successfully passing requalification must be marked with the RIN set in a square pattern, applicable CGA or ASTM standard inbetween the month and year of the requalicorporated by reference in §171.7 of this fication date. The first character of the RIN subchapter applicable to the requalimust appear in the upper left corner of the fier's activities. This information must square pattern; the second in the upper be the same as contained in the edition right; the third in the lower right: and the incorporated by reference in $171.7 of fourth in the lower left. Example: A cylinder this subchapter. requalified in September 2006, and approved (b) Requalification records. Daily by a person who has been Issued RIN "A123", records of visual inspection, pressure would be marked plainly and permanently test, and ultrasonic examination if perinto the metal of the cylinder in accordance mitted under a special permit, as appliwith location requirements of the cylinder cable, must be maintained by the perspecification or on a metal plate permason who performs the requalification nently secured to the cylinder in accordance until either the expiration of the rewith paragraph (b) of this section. An examqualification period or until the cylple of the markings prescribed in this parainder is again requalified, whichever graph (d) is as follows: occurs first. A single date may be used A1 for each test sheet, provided each test 9 06 X on the sheet was conducted on that 32 date. Ditto marks or a solid vertical line may be used to indicate repetition Where: of the preceding entry for the following "9" is the month of requalification entries only: date; actual dimensions; "A123" is the RIN manufacturer's name or symbol; owner's name or symbol, if present; and "06" is the year of requalification, and test operator. Blank spaces may not be 1131 § 180.215 49 CFR Ch. I (10-1-06 Edition) used to indicate repetition of a prior (i) Name and address of test facility, entry. The records must include the date of test report, and name of origifollowing information: nal manufacturer; (1) Calibration test records. For each (ii) Marks stamped on cylinder to intest to demonstrate calibration, the clude specification number, service date; serial number of the calibrated pressure, serial number, symbol of cylinder; calibration test pressure; manufacturer, inspector's mark, and total, elastic and permanent expanother marks, if any; sions; and legible identification of test (iii) Cylinder outside diameter and operator. The test operator must be able to demonstrate that the results of length in inches; the daily calibration verification cor- (iv) Rebuild process (welded. brazed, respond to the hydrostatic tests pertype seams, etc.); formed on that day. The daily (v) Description of assembly and any verification of calibration(s) may be reattachments replaced (e.g., neckrings, corded on the same sheets as, and with, footrings): test records for that date. (vi) Chemical analysis of material for (2) Pressure test and visual inspection the cylinder, including seat and Code records. The date of requalification; se- No., type of analysis (ladle, check), rial number; DOT specification or spechemical components (Carbon (C), cial permit number; marked pressure; Phosphorous (P), Sulfur (S), Silicon actual dimensions; manufacturer's (Si), Manganese (Mn), Nickel (NI), name or symbol; owner's name or sym- Chromium (Cr). Molybdenum (Mo), bol, if present; result of visual inspec- Copper (Cu), Aluminum (Al), Zinc tion; actual test pressure; total, elastic (Zn)), material manufacturer, name of and permanent expansions; percent person performing the analysis, results permanent expansion; disposition, with of physical tests of material for cylreason for any repeated test, rejection inder (yield strength (psi), tensile or condemnation; and legible identistrength (psi), elongation percentage fication of test operator. For each cylinder marked pursuant (inches). reduction in area percentage, to weld bend, tensile bend, name of in- §173.302a(b)(5) of this subchapter, the test sheet must indicate the method by spector): which any average or maximum wall (vii) Results of proof pressure test on stress was computed. Records must be cylinder, including test method, test kept for all completed, as well as unpressure, total expansion, permanent successful tests. The entry for a second expansion, elastic expansion, percent test after a failure to hold test pressure permanent expansion (permanent exmust indicate the date of the earlier pansion may not exceed ten percent test. (10%) of total expansion), and volu- (3) Wall stress. Calculations of avermetric capacity (volumetric capacity age and maximum wall stress pursuant of a rebuilt cylinder must be within to §173.302a(b)(3) of this subchapter, if +3% of the calculated capacity): performed. (viii) Each report must include the (4) Calibration certificates. The most following certification statement: "I recent certificate of calibration must certify that this rebuilt cylinder is acbe maintained for each calibrated cylcurately represented by the data above inder. and conforms to all of the require- (c) Repair, rebuilding or reheat treatments in Subchapter C of Chapter I of ment records. (1) Records covering weld- Title 49 of the Code of Federal Regulaing or brazing repairs, rebuilding or retions.". The certification must be heat treating shall be retained for a minimum of fifteen years by the apsigned by the rebuild technician and proved facility. principal, officer, or partner of the re- (2) A record of rebuilding, in accordbuild facility. ance with $180.211(d), must be com- [67 FR 51660, Aug. 8, 2002, as amended at 68 pleted for each cylinder rebuilt. The FR 24664, May 8, 2003; 70 FR 73166, Dec. 9, record must be clear, legible, and con- 2005; 71 FR 54398, Sept. 14, 2006] tain the following information: 1132 Pipeline and Hazardous Materials Safety Admin., DOT § 180.217 § 180.217 Requalification requirements As a minimum, an exceptional inspecfor MEGCs. tion of a MEGC must include inspec- (a) Periodic inspections. Each MEGC tion as specified in paragraph (a)(1) of must be given an initial visual inspecthis section. tion and test in accordance with (c) Correction of unsafe condition. $178.75(i) of this subchapter before When evidence of any unsafe condition being put into service for the first is discovered, the MEGC may not be retime. After the initial inspection, a turned to service until the unsafe con- MEGC must be inspected at least once dition has been corrected and the every five years. MEGC has been requalified in accord- (1) The 5-year periodic inspection ance with the applicable tests and inmust include an external examination spection. of the structure, the pressure recep- (d) Repairs and modifications to tacles and the service equipment, as MEGCs. No person may perform a follows: modification to an approved MEGC (i) The pressure receptacles are inthat may affect conformance to the apspected externally for pitting, corroplicable ISO standard or safe use, and sion, abrasions, dents, distortions, dethat involve a change to the design fects in welds or any other conditions, type or affect its ability to retain the including leakage, that might render hazardous material in transportation. the MEGC unsafe for transport. Before making any modification (ii) The piping, valves, and gaskets changes to an approved MEGC, the are inspected for corroded areas, deowner must obtain approval from the fects, and other conditions, including Associate Administrator as prescribed leakage, that might render the MEGC in $178.74 of this subchapter. The repair unsafe for filling, discharge or transof a MEGC's structural equipment is port. authorized provided such repairs are (iii) Missing or loose bolts or nuts on made in accordance with the requireany flanged connection or blank flange ments prescribed for its approved deare replaced or tightened. sign and construction. Any repair to (iv) All emergency devices and valves the pressure receptacles of a MEGC are free from corrosion, distortion and must meet the requirements of any damage or defect that could pre- $180.212. vent their normal operation. Remote (e) Requalification markings. Each closure devices and self-closing stop MEGC must be durably and legibly valves must be operated to demmarked in English, with the year and onstrate proper operation. month, and the type of the most recent (v) Required markings on the MEGC periodic requalification performed (e.g., are legible in accordance with the ap- 2004-05 AE/UE, where "AE" represents plicable requirements. acoustic emission and "UE" represents (vi) The framework, the supports and ultrasonic examination) followed by the arrangements for lifting the MEGC the stamp of the approval agency who are in satisfactory condition. performed or witnessed the most recent (2) The MEGC's pressure receptacles test. and piping must be periodically re- (f) Records. The owner of each MEGC qualified as prescribed in $ 180.207(c), at or the owner's authorized agent must the interval specified in Table 1 in retain a written record of the date and $ 180.207. results of all repairs and required in- (b) Exceptional Inspection and test. If a spections and tests. The report must MEGC shows evidence of damaged or contain the name and address of the corroded areas, leakage. or other condiperson performing the inspection or tions that indicate a deficiency that test. The periodic test and inspection could affect the integrity of the MEGC, records must be retained until the next an exceptional inspection and test inspection or test is completed. Repair must be performed, regardless of the records and the initial exceptional inlast periodic inspection and test. The spection and test records must be reextent of the exceptional inspection tained during the period the MEGC is and test will depend on the amount of in service and for one year thereafter. damage or deterioration of the MEGC. These records must be made available 1133 § 180.350 49 CFR Ch. I (10-1-06 Edition) for inspection by a representative of (iii) Restoration of structural equipthe Department on request. ment not directly performing a hazardous material containment or dis- [71 FR 33896, June 12, 2006] charge pressure retention function so as to conform to the design type (for Subpart D-Qualification and example, the straightening of legs or Maintenance of IBCs lifting attachments), provided the containment function of the IBC is not af- § 180.350 Applicability and definitions. fected. This subpart prescribes require- (2) Plastics or textile flexible IBCs of ments, in addition to those contained operations. such as: in parts 107, 171, 172, 173 and 178 of this (i) Cleaning: or subchapter, applicable to any person (ii) Replacement of non-integral comresponsible for the continuing qualiponents, such as non-integral liners fication, maintenance, or periodic reand closure ties, with components contesting of an IBC. The following definiforming to the original manufacturer's tions apply: specification; provided that these oper- (a) Remanufactured IBCs are metal, ations do not adversely affect the containment function of the flexible IBC rigid plastic or composite IBCs produced as a UN type from a non-UN or alter the design type. type, or are converted from one UN de- [68 FR 45042, July 31, 2003, as amended at 69 sign type to another UN design type. FR 76186, Dec. 20, 2004] Remanufactured IBCs are subject to the same requirements of this sub- § 180.351 Qualification of IBCs. chapter that apply to new IBCs of the (a) General. Each IBC used for the same type (also see $178.801 (c) (1) of this transportation of hazardous materials subchapter for design type definition). must be an authorized packaging. (b) Repaired IBCs are metal, rigid (b) IBC specifications. To qualify as an plastic or composite IBCs that, as a reauthorized packaging, each IBC must sult of impact or for any other cause conform to this subpart, the applicable (such as corrosion, embrittlement or requirements specified in part 173 of other evidence of reduced strength as this subchapter, and the applicable recompared to the design type), are requirements of subparts N and 0 of part stored so as to conform to the design 178 of this subchapter. type and to be able to withstand the [Amdt. 180-5, 59 FR 38079, July 26, 1994, as design type tests. For the purposes of amended at 66 FR 45391, Aug. 28, 2001] this subchapter, the replacement of the rigid inner receptacle of a composite § 180.352 Requirements for retest and IBC with a receptacle conforming to inspection of IBCs. the original manufacturer's specifica- (a) General. Each IBC constructed in tion is considered repair. Routine accordance with a UN standard for maintenance of IBCs (see definition in which a test or inspection specified in paragraph (c) of this section) is not paragraphs (b)(1), (b)(2) and (b)(3) of considered repair. The bodies of rigid this section is required may not be plastic IBCs and the inner receptacles filled and offered for transportation or of composite IBCs are not repairable. transported until the test or inspection (c) Routine maintenance of IBCs is has been successfully completed. This the routine performance on: paragraph does not apply to any IBC (1) Metal, rigid plastic or composite filled prior to the test or inspection IBCs of operations such as: due date. The requirements in this sec- (i) Cleaning: tion do not apply to DOT 56 and 57 (ii) Removal and reinstallation or reportable tanks. placement of body closures (including (b) Test and inspections for metal, rigid associated gaskets), or of service equipplastic, and composite IBCs. Each IBC is ment conforming to the original manusubject to the following test and infacturer's specifications provided that spections: the leaktightness of the IBC is verified; (1) Each IBC intended to contain solor ids that are loaded or discharged under 1134 Pipeline and Hazardous Materials Safety Admin., DOT § 180.352 pressure or intended to contain liquids (i) The IBC must be internally inmust be tested in accordance with the spected for cracks, warpage, and corroleakproofness test prescribed in sion or any other defect that might $178.813 of this subchapter every 2.5 render the IBC unsafe for transporyears, starting from the date of manutation. An IBC found with such defects facture or the date of a repair conmust be removed from hazardous mateforming to paragraph (d)(1) of this secrials service until restored to the origition. nal design type of the IBC. (2) An external visual inspection (ii) Metal IBCs must be inspected to must be conducted initially after proensure the minimum wall thickness reduction and every 2.5 years starting quirements in §178.705(c)(1)(iv) of this from the date of manufacture or the subchapter are met. Metal IBCs not date of a repair conforming to paraconforming to minimum wall thickness graph (d)(1) of this section to ensure requirements must be removed from that: hazardous materials service. (i) The IBC is marked in accordance (c) Visual inspection for flexible, fiberwith requirements in $178.703 of this board, or wooden IBCs. Each IBC must subchapter. Missing or damaged markbe visually inspected prior to first use ings, or markings difficult to read and permitted reuse, by the person who must be restored or returned to origiplaces hazardous materials in the IBC, nal condition. to ensure that: (ii) Service equipment is fully func- (1) The IBC is marked in accordance tional and free from damage which with requirements in $178.703 of this may cause failure. Missing, broken, or subchapter. Additional marking aldamaged parts must be repaired or relowed for each design type may be placed. present. Required markings that are (iii) The IBC is capable of withmissing, damaged or difficult to read standing the applicable design qualimust be restored or returned to origification tests. The IBC must be external condition. nally inspected for cracks, warpage, (2) Proper construction and design corrosion or any other damage which specifications have been met. might render the IBC unsafe for trans- (1) Each flexible IBC must be inportation. An IBC found with such defects must be removed from service or spected to ensure that: repaired in accordance with paragraph (A) Lifting straps if used, are se- (d) of this section. The inner receptacle curely fastened to the IBC in accordof a composite IBC must be removed ance with the design type. from the outer IBC body for inspection (B) Seams are free from defects in unless the inner receptacle is bonded to stitching, heat sealing or gluing which the outer body or unless the outer body would render the IBC unsafe for transis constructed in such a way (e.g., a portation of hazardous materials. All welded or riveted cage) that removal of stitched seam-ends must be secure. the inner receptacle is not possible (C) Fabric used to construct the IBC without impairing the integrity of the is free from cuts, tears and punctures. outer body. Defective inner receptacles Additionally, fabric must be free from must be replaced in accordance with scoring which may render the IBC unparagraph (d) of this section or the ensafe for transport. tire IBC must be removed from service. (ii) Each fiberboard IBC must be in- For metal IBCs, thermal insulation spected to ensure that: must be removed to the extent nec- (A) Fluting or corrugated fiberboard essary for proper examination of the is firmly glued to facings. IBC body. (B) Seams are creased and free from (3) Each metal, rigid plastic and comscoring, cuts, and scratches. posite IBC must be internally inspected (C) Joints are appropriately overat least every five years to ensure that lapped and glued, stitched. taped or the IBC is free from damage and to enstapled as prescribed by the design. sure that the IBC is capable of with- Where staples are used, the joints must standing the applicable design qualibe inspected for protruding staple-ends fication tests. which could puncture or abrade the 1135 § 180.352 49 CFR Ch. I (10-1-06 Edition) inner liner. All such ends must be pro- (i) The repaired IBC conforms to the tected before the IBC is authorized for original design type and is capable of hazardous materials service. withstanding the applicable design (iii) Each wooden IBC must be inqualification tests; and spected to ensure that: (ii) The IBC is subjected to the inter- (A) End joints are secured in the nal and external inspection requiremanner prescribed by the design. ments as specified in paragraph (b) of (B) IBC walls are free from defects in this section. wood. Inner protrusions which could (3) Service equipment may be repuncture or abrade the liner must be placed provided: covered. (i) The repaired IBC conforms to the (d) Requirements applicable to repair of original design type and is capable of IBCs. (1) Except for flexible and fiberwithstanding the applicable design board IBCs and the bodies of rigid plasqualification tests; tic and composite IBCs, damaged IBCs (ii) The IBC is subjected to the extermay be repaired and the inner recepnal visual inspection requirements as tacles of composite packagings may be specified in paragraph (b) of this secreplaced and returned to service protion; and vided: (111) The proper functioning and leak (i) The repaired IBC conforms to the tightness of the service equipment, if original design type, is capable of withapplicable, is verified. standing the applicable design quali- (e) Requirements applicable to routine fication tests, and is retested and inmaintenance of IBCs. Except for routine spected in accordance with the applicamaintenance of metal, rigid plastics ble requirements of this section; and composite IBCs performed by the (ii) An IBC intended to contain liqowner of the IBC, whose State and uids or solids that are loaded or disname or authorized symbol is durably charged under pressure is subjected to marked on the IBC, the party per- a leakproofness test as specified in forming the routine maintenance shall $178.813 of this subchapter and is durably mark the IBC near the manumarked with the date of the test; and facturer's UN design type marking to (iii) The IBC is subjected to the intershow the following: nal and external inspection require- (1) The country in which the routine ments as specified in paragraph (b) of maintenance was carried out; and this section. (2) The name or authorized symbol of (iv) The person performing the tests the party performing the routine maintenance. and inspections after the repair must (f) Retest date. The date of the most durably mark the IBC near the recent periodic retest must be marked manfacturer's UN design type marking as provided in $178.703(b) of this subto show the following: chapter. (A) The country in which the tests (g) Record retention. The owner or lesand inspections were performed; see of the IBC must keep records of (B) The name or authorized symbol of periodic retests, initial and periodic inthe person performing the tests and inspections, and test performed on the spections; and IBC if it has been repaired. Records (C) The date (month, year) of the must include design types and packtests and inspections. aging specifications, test and inspec- (v) Retests and inspections performed tion dates, name and address of test in accordance with paragraphs (d)(1)(i) and inspection facilities, names or and (ii) of this section may be used to name of any persons conducting tests satisfy the requirements for the 2.5 and or inspections, and test or inspection five year periodic tests and inspections specifics and results. Records must be required by paragraph (b) of this seckept for each packaging at each location, as applicable. tion where periodic tests are con- (2) Except for flexible and fiberboard ducted, until such tests are success- IBCs, the structural equipment of an fully performed again or at least 2.5 IBC may be repaired and returned to years from the date of the last test. service provided: The owner or lessee must make these 1136 Pipeline and Hazardous Materials Safety Admin., DOT § 180.403 records available for inspection by a "Repair" as defined in this section. Exrepresentative of the Department on cluded from this category are the folrequest. lowing: [Amdt. 180-5, 59 FR 38079, July 26, 1994, as (1) A change to motor vehicle equipamended at 64 FR 10782, Mar. 5, 1999; 65 FR ment such as lights, truck or tractor 58632, Sept. 29, 2000; 66 FR 45186, 45391, Aug. power train components, steering and 28, 2001; 68 FR 45042, July 31, 2003; 69 FR 76186, brake systems, and suspension parts, Dec. 20, 2004; 70 FR 34399, June 14, 2005; 70 FR and changes to appurtenances, such as 56099, Sept. 23, 2005] fender attachments, lighting brackets, ladder brackets; and Subpart E-Qualification and (2) Replacement of components such Maintenance of Cargo Tanks as valves, vents, and fittings with a component of a similar design and of § 180.401 Applicability. the same size. This subpart prescribes require- Owner means the person who owns a ments, in addition to those contained cargo tank motor vehicle used for the in parts 107, 171, 172, 173 and 178 of this transportation of hazardous materials, subchapter, applicable to any person or that person's authorized agent. responsible for the continuing quali- Piping system means any component fication, maintenance or periodic testof a cargo tank delivery system, other ing of a cargo tank. than a delivery hose assembly, that [Amdt. 180-2, 54 FR 25032, June 12, 1989, as contains product during loading or unamended at 55 FR 37065, Sept. 7. 1990] loading. Rebarrelling means replacing more § 180.403 Definitions. than 50 percent of the combined shell In addition to the definitions conand head material of a cargo tank. tained in $$171.8, 178.320(a) and 178.345- Repair means any welding on a cargo 1 of this subchapter, the following defitank wall done to return a cargo tank nitions apply to this subpart: or a cargo tank motor vehicle to its Corroded or abraded means any visible original design and construction specireduction in the material thickness of fication, or to a condition prescribed the cargo tank wall or valve due to pitfor a later equivalent specification in ting, flaking, gouging, or chemical reeffect at the time of the repair. Exaction to the material surface that efcluded from this category are the folfects the safety or serviceability of the lowing: cargo tank. The term does not include (1) A change to motor vehicle equipcosmetic or minor surface degradation ment such as lights, truck or tractor that does not effect the safety or servpower train components, steering and iceability of the cargo tank brake systems, and suspension parts, Corrosive to the tank or valve means and changes to appurtenances, such as that the lading has been shown through fender attachments, lighting brackets, experience or test data to reduce the ladder brackets; and thickness of the material of construc- (2) Replacement of components such tion of the tank wall or valve. as valves, vents, and fittings with a Delivery hose assembly means a liquid component of a similar design and of delivery hose and its attached couthe same size. plings. (3) Replacement of an appurtenance Modification means any change to the by welding to a mounting pad. original design and construction of a Replacement of a barrel means to recargo tank or a cargo tank motor vehiplace the existing tank on a motor vecle that affects its structural integrity hicle chassis with an unused (new) or lading retention capability includtank. For the definition of tank, see ing changes to equipment certified as $178.320, $178.345, or $178.338-1 of this part of an emergency discharge control subchapter, as applicable. system required by § 173.315(n)(2) of this Stretching means any change in subchapter. Any modification that inlength, width or diameter of the cargo volves welding on the cargo tank wall tank, or any change to a cargo tank must also meet all requirements for motor vehicle's undercarriage that 1137 § 180.405 49 CFR Ch. I (10-1-06 Edition) may affect the cargo tank's structural conforms to the original structural deintegrity. sign requirements in effect at the time the tank was originally constructed; [Amdt. 180-2, 54 FR 25032, June 12, 1989. as amended at 55 FR 37065, Sept. 7, 1990; Amdt. (iv) The cargo tank meets all applica- 180-3, 57 FR 45466, Oct. 1. 1992; Amdt. 180-7, 59 ble tests and inspections required by FR 55177, Nov. 3, 1994; 60 FR 17402, Apr. 5, § 180.407(c); and 1995; Amdt. 180-10, 61 FR 51342. Oct. 1. 1996; 63 (v) The cargo tank is recertified to FR 52850, Oct. 1, 1998; 64 FR 28050, May 24, the original specification in accordance 1999: 68 FR 19286, Apr. 18, 2003; 69 FR 54047, with the reporting and record retention Sept. 7. 2004] provisions of $180.417. The certification § 180.405 Qualification of cargo tanks. documents required by $180.417(a)(3) must include both the date the cargo (a) General. Unless otherwise protank was originally certified to the vided in this subpart, each cargo tank specification and the date it was recerused for the transportation of haztified. The specification plate on the ardous material must be an authorized cargo tank or the cargo tank motor vepackaging. hicle must display the date the cargo (b) Cargo tank specifications. (1) To tank was originally certified to the qualify as an authorized packaging, specification. each cargo tank must conform to this (c) Cargo tank specifications no longer subpart, the applicable requirements authorized for construction. (1) A cargo specified in part 173 of this subchapter tank made to a specification listed in for the specific lading, and where a column 1 of table 1 or table 2 of this DOT specification cargo tank is reparagraph (c)(1) may be used when auquired, an applicable specification in thorized in this part, providedeffect on the date initial construction (i) The cargo tank initial construcbegan: MC 300, MC 301, MC 302, MC 303, tion began on or before the date listed MC 304, MC 305, MC 306, MC 307, MC 310, in table 1, column 2, as follows: MC 311, MC 312, MC 330, MC 331, MC 338, DOT 406, DOT 407, or DOT 412 (§§ 178.337, TABLE 1 178.338, 178.345, 178.346, 178.347, 178.348 of Column 1 Column 2 this subchapter). However, except as provided in paragraphs (b)(2). (d), (e), MC 300 Sept. 2, 1967 (f)(5). and (f)(6) of this section, no cargo MC 3D1 June 12, 1961 tank may be marked or certified after MC 302, MC 303, MC 304, MC 305, MC Sept. 2, 1967 310, MC 311. August 31, 1995, to the applicable MC MC 330 May 15, 1967 306, MC 307, MC 312, MC 331, or MC 338 specification in effect on December 30, (ii) The cargo tank was marked or 1990. certified before the date listed in table (2) Exception. A cargo tank originally 2, column 2, as follows: manufactured to the MC 306, MC 307, or MC 312 specification may be recertified TABLE 2 to the original specification provided: Column 1 Column 2 (i) Records are available verifying the cargo tank was originally manufac- MC 306, MC 307, MC 312 Sept. 1, 1995 tured to the specification; (11) If the cargo tank was stretched, (2) A cargo tank of a specification rebarrelled, or modified, records are listed in paragraph (c)(1) of this section available verifying that the stretching. may have its pressure relief devices rebarrelling, or modification was perand outlets modified as follows: formed in accordance with the Na- (i) A Specification MC 300, MC 301, tional Board Inspection Code and this MC 302, MC 303, or MC 305 cargo tank, part: to conform with a Specification MC 306 (iii) A Design Certifying Engineer or or DOT 406 cargo tank (See $$ 178.346-3 Registered Inspector verifies the cargo and 178.346-4 of this subchapter). tank conforms to all applicable re- (ii) A Specification MC 306 cargo quirements of the original specificatank to conform to a Specification tion and furnishes to the owner written DOT 406 cargo tank (See $§ 178.346-3 and documentation that verifies the tank 178.346-4 of this subchapter). 1138 Pipeline and Hazardous Materials Safety Admin., DOT § 180.405 (iii) A Specification MC 304 cargo (2) The holding time determined by tank, to conform with a Specification test for one authorized cryogenic liquid MC 307 or DOT 407 cargo tank (See may be used as the basis for estab- §§ 178.347-4 and 178.345-11 of this sublishing the holding time for other auchapter). thorized cryogenic liquids. (iv) A Specification MC 307 cargo (e) MC 331 cargo tanks. The owner of tank, to conform with a Specification a MC 331 ($178.337 of this subchapter) DOT 407 cargo tank (See §§ 178.347-4 and cargo tank that conforms to and was 178.345-11 of this subchapter). used under an exemption issued before (v) A Specification MC 310 or MC 311 October 1, 1984, that authorizes the cargo tank, to conform with a Specitransportation of ethane, refrigerated fication MC 312 or DOT 412 cargo tank liquid; ethane-propane mixture, refrig- (See $178.348-4 and 178.345-11 of this erated liquid; or hydrogen chloride, resubchapter). frigerated liquid shall remove the ex- (vi) A Specification MC 312 cargo emption number stenciled on the cargo tank, to conform with a Specification tank and stamp the exemption number DOT 412 cargo tank (See 178.348-4 and on the specification plate (or a plate 178.345-11 of this subchapter). placed adjacent to the specification (vii) A Specification MC 330 cargo plate), immediately after the DOT tank, to conform with a Specification Specification, for example, "DOT MC MC 331 cargo tank, except as specifi- 331-E (Asterisks to be replaced cally required by $173.315 of this subby the exemption number.) The cargo chapter (see 178.337-8 and 178.337-9 of tank must be remarked prior to the exthis subchapter). piration date of the exemption. During (d) MC 338 cargo tank. The owner of a the period the cargo tank is in service, cargo tank that conforms to and was the owner of a cargo tank that is reused under the terms of an exemption marked in this manner must retain at issued before October 1, 1984, that authe owner's principal place of business thorizes the transportation of a cryo- a copy of the last exemption in effect. genic liquid shall remove the exemp- (f) MC 306, MC 307, MC 312 cargo tanks. tion number stenciled on the cargo Either a Registered Inspector or a Detank and stamp the specification plate sign Certifying Engineer and the owner (or a plate placed adjacent to the speciof a MC 306, MC 307 or MC 312 cargo fication plate) "DOT MC 338" followed tank motor vehicle constructed in acby the exemption number, for example, cordance with and used under an ex- "DOT MC 338-E * (Asterisks to emption issued before December 31, be replaced by the exemption number). 1990, that authorizes a condition speci- The cargo tank must be remarked prior fied in this paragraph shall examine to the expiration date of the exempthe cargo tank motor vehicle and its tion. During the period the cargo tank design to determine if it meets the reis in service, the owner of a cargo tank quirements of the applicable MC 306, that is remarked in this manner must MC 307 or MC 312 specification in effect retain at its principal place of business at the time of manufacture, except as a copy of the last exemption in effect. specified herein. No new construction of cargo tanks (1) A cargo tank motor vehicle conpursuant to such exemption is authorstructed after August 1, 1981, or the ized. date specified in the applicable exemp- (1) The holding time must be detertion, in conformance with the folmined. as required in $178.338-9 of this lowing conditions that apply, may be subchapter, on each cargo tank or on remarked and certified in accordance at least one cargo tank of each design. with paragraphs (f) (5) and (6) of this Any subsequent cargo tank manufacsection: tured to the same design type (see (i) A vacuum-loaded cargo tank must $178.320), if not individually tested, have an ASME Code stamped specificamust have the optional test regimen tion plate marked with a minimum inperformed during the first shipment ternal design pressure of 25 psig, and be (see $178.338-9 (b) and (c) of this subdesigned for a minimum external dechapter). sign pressure of 15 psig. 1139 $ 180.405 49 CFR Ch. I (10-1-06 Edition) (ii) An outlet equipped with a self- (6) of this section after the cargo tank closing system which includes an exmotor vehicle has been equipped with ternal stop-valve must have the stop the self-closing system. valve and associated piping protected (3) A vacuum-loaded cargo tank conwithin the vehicle's rear-end tank prostructed prior to August 1, 1981, in contection device, vehicle frame or an formance with paragraph (f)(1) of this equally adequate accident damage prosection, except for paragraph (f)(1)(i), tection device (See § 178.345-8 of this may be remarked and certified in acsubchapter.) The self-closing system cordance with paragraphs (f) (5) and (6) (See $178.345-11 of this subchapter) of this section. must be equipped with a remotely ac- (4) A vacuum-loaded cargo tank contuated means of closure as follows: structed prior to August 1, 1981, in con- (A) For a cargo tank used in other formance with paragraph (f)(1) of this than corrosive service, the remote section, except for paragraph (f)(1)(i) of means of closure must be activated for this section, and except that an outlet closure by manual or mechanical is equipped with an external valve means and, in case of fire, by an autowhich is not part of a self-closing sysmatic heat activated means. tem: (B) For a cargo tank used in corro- (i) Must be equipped with a self-clossive service, the remote means of cloing system prior to September 1, 1993. sure may be actuated by manual or me- (ii) May be remarked and certified in chanical means only. accordance with paragraphs (f)(5) and (iii) A cargo tank having an (6) of this section after the cargo tank unreinforced portion of the shell exmotor vehicle has been equipped with ceeding 60 inches must have the cirthe self-closing system. cumferential reinforcement located so (5) The owner of a cargo tank for that the thickness and tensile strength which a determination has been made of shell material in combination with that the cargo tank is in conformance the frame and circumferential reinwith paragraph (f) (1), (2), (3), or (4) of forcement produces a structural integthis section shall complete a written rity at least equal to that prescribed in certification, in English, signed by the $178.345-3 of this subchapter or the owner and containing at least the folspecification in effect at time of manulowing information: facture. (i) A statement certifying that each (iv) A cargo tank having a projection cargo tank conforms to $ 180.405 (f) (1), from the tank shell or head that may (2), (3), or (4): contain lading in any tank position is (ii) The applicable DOT exemption authorized, provided such projection is number, the applicable specification as strong as the tank shell or head and number and the owner's and manufacis located within the motor vehicle's turer's serial number for the cargo rear-end tank protection or other aptank; propriate accident damage protection (iii) A statement setting forth any device. modifications made to bring the cargo (v) A cargo tank may be constructed tank into conformance with $180.405(f) of nickel, titanium, or other ASME (1), (2), (3), or (4), or the applicable sheet or plate materials in accordance specification; with an exemption. (iv) A statement identifying the per- (2) A vacuum-loaded cargo tank conson certifying the cargo tank and the structed after August 1, 1981, or the date of certification. date specified in the applicable exemp- (6) The owner of a certified cargo tion, in conformance with paragraph tank shall remove the exemption num- (f)(1) of this section, except that an ber stenciled on the cargo tank and outlet equipped with an external valve shall durably mark the specification which is not part of a self-closing sysplate (or a plate placed adjacent to the tem: specification plate) "MC +++E (i) Must be equipped with a self-clos- ****####" (where "+++" is to be reing system prior to September 1, 1993. placed by the applicable specification (ii) May be remarked and certified in number, by the exemption accordance with paragraphs (f)(5) and number and "# # # #" by the alloy.) 1140 Pipeline and Hazardous Materials Safety Admin., DOT § 180.405 (7) A cargo tank remarked and cer- (1) Until August 31, 1998, the owner of tifled in conformance with this para- a cargo tank may replace a reclosing graph (f) is excepted from the provipressure relief device with a device sions of $180.405(c). which is in compliance with the re- (8) During the period the cargo tank quirements for pressure relief devices is in service, and for one year therein effect at the time the cargo tank after, the owner of a cargo tank that is specification became superseded. If the certified and remarked in this manner pressure relief device is installed as an must retain on file at its principal integral part of a manhole cover asplace of business a copy of the certifisembly, the manhole cover must comcate and the last exemption in effect. ply with the requirements of paragraph (g) Cargo tank manhole assemblies. (1) (g) of this section. MC 306, MC 307. and MC 312 cargo tanks (2) After August 31, 1998, replacement marked or certified after December 30, for any reclosing pressure relief valve 1990, and DOT 406, DOT 407, and DOT must be capable of reseating to a leak- 412 cargo tank motor vehicles must be tight condition after a pressure surge, equipped with manhole assemblies conand the volume of lading released may forming with $178.345-5 of this subnot exceed 1 L. Specific performance chapter. requirements for these pressure relief (2) On or before August 31, 1995, each valves are set forth in §178.345-10(b)(3) owner of a cargo tank marked or certified before December 31, 1990, authorof this subchapter. ized for the transportation of a haz- (3) As provided in paragraph (c) of ardous material, must have the cargo this section, the owner of a cargo tank tank equipped with manhole assemmay elect to modify reclosing pressure blies conforming with § 178.345-5, except relief devices to more recent cargo for the dimensional requirements in tank specifications. However, replace- $178.345-5(a), the hydrostatic testing ment devices constructed to the rerequirements in $178.345-5(b), and the quirements of 178.345-10 of this submarking requirements in $178.345-5(e) chapter must provide the minimum of this subchapter. A manhole assemventing capacity required by the origibly meeting one of the following provinal specification to which the cargo sions is considered to be in compliance tank was designed and constructed. with this paragraph: (i) Flammable cryogenic liquids. Each (i) Manhole assemblies on MC 300, MC cargo tank used to transport a flam- 301, MC 302, MC 303, MC 305, MC 306, MC mable cryogenic liquid must be exam- 310, MC 311, and MC 312 cargo tanks ined after each shipment to determine that are marked or certified in writing its actual holding time (See as conforming to $178.345-5 of this sub- $173.318(g)(3) of this subchapter.) chapter or TTMA RP No. 61-98 (incor- (j) Withdrawal of certification. A speciporated by reference; see $171.7 of this fication cargo tank that for any reason subchapter). or are tested and certified no longer meets the applicable speciin accordance with TTMA TB No. 107 fication may not be used to transport (incorporated by reference; see $171.7 of hazardous materials unless the cargo this subchapter). tank is repaired and retested in accord- (11) Manhole assemblies on MC 304 ance with $$180.413 and 180.407 prior to and MC 307 cargo tanks. being returned to hazardous materials (iii) Manhole assemblies on MC 310, service. If the cargo tank is not in con- MC 311, and MC 312 cargo tanks with a formance with the applicable specificatest pressure of 36 psig or greater. tion requirements, the specification (3) [Reserved] plate on the cargo tank must be re- (h) Pressure relief system. Properly moved, obliterated or securely covered. functioning reclosing pressure relief The details of the conditions necessivalves and frangible or fusible vents tating withdrawal of the certification need not be replaced. However, replacemust be recorded and signed on the ment of reclosing pressure relief valves written certificate for that cargo tank. on MC-specification cargo tanks is au- The vehicle owner shall retain the certhorized subject to the following retificate for at least 1 year after withquirements: drawal of the certification. 1141 § 180.405 49 CFR Ch. I (10-1-06 Edition) (k) DOT-specification cargo tank with $173.315(k) of this subchapter, intended no marked design pressure or a marked for use in the transportation of liquefied design pressure of less than 3 psig. The compressed gases. (1) No later than the owner of an MC 300, MC 301, MC 302, MC date of its first scheduled pressure test 303, MC 305, MC 306, or MC 312 cargo after July 1, 2001, each specification tank with a pressure relief system set MC 330 and MC 331 cargo tank motor at 3 psig, must mark or remark the vehicle, and each nonspecification cargo tank with an MAWP or design cargo tank motor vehicle conforming pressure of not less than 3 psig. to $173.315(k) of this subchapter, (1) MC 300, MC 301, MC 302, MC 303, marked and certified before July 1, MC 305, MC 306 cargo tank-Rear acci- 2001, that is used to transport a Divident damage protection. (1) Notwithsion 2.1 material, a Division 2.2 matestanding the requirements in rial with a subsidiary hazard, a Divi- $180.405(b), the applicable specification sion 2.3 material, or anhydrous ammorequirement for a rear bumper or rearnia must have an emergency discharge end tank protection device on MC 300, control capability as specified in MC 301, MC 302, MC 303, MC 305, and MC $173.315(n) of this subchapter. Each 306 cargo tanks does not apply to a passive shut-off system installed prior cargo tank truck (power unit) until to July 1. 2001, must be certified by a July 1, 1992, if the cargo tank truck- Design Certifying Engineer that it (i) Was manufactured before July 1, meets the requirements of § 173.315(n) (2) 1989; of this subchapter. (ii) Is used to transport gasoline or (2) The requirement in paragraph any other petroleum distillate product; (m)(1) of this section does not apply to and a cargo tank equal to or less than (iii) Is operated in combination with 13,247.5 L (3,500 gallons) water capacity a cargo tank full trailer. However, an transporting in metered delivery servempty cargo tank truck, without a ice a Division 2.1 material, a Division cargo tank full trailer attached, may 2.2 material with a subsidiary hazard, be operated without the required rear bumper or rear-end tank protection deor anhydrous ammonia equipped with an off-truck remote shut-off device vice on a one-time basis while being transported to a repair facility for inthat was installed prior to July 1. 2000. The device must be capable of stopping stallation of a rear bumper or rear-end the transfer of lading by operation of a protection device. (2) Each cargo tank shall be provided transmitter carried by a qualified perwith a rear accident damage protection son attending unloading of the cargo device to protect the tank and piping tank. The device is subject to the rein the event of a rear-end collision and quirement in $177.840(o) of this subreduce the likelihood of damage which chapter for a daily test at 45.72 meters could result in the loss of lading. The (150 feet). rear-end protection device must be in (3) Each specification MC 330 and MC the form of a rear-end tank protection 331 cargo tank in metered delivery device meeting the requirements of service of greater than 13,247.5 L (3,500 § 178.345-8(d) or a rear bumper meeting gallons) water capacity transporting a the following: Division 2.1 material, a Division 2.2 (i) The bumper shall be located at material with a subsidiary hazard, or least 6 inches to the rear of any vehicle anhydrous ammonia, marked and cercomponent used for loading or unloadtified before July 1, 1999, must have an ing or that may contain lading while emergency discharge control capability the vehicle is in transit. as specified in $$173.315(n) and 177.840 of (ii) The dimensions of the bumper this subchapter no later than the date shall conform to $393.86 of this title. of its first scheduled pressure test after (iii) The structure of the bumper July 1, 2001, or July 1, 2003, whichever must be designed in accordance with is earlier. $178.345-8(d)(3) of this subchapter. (n) Thermal activation. No later than (m) Specification MC 330, MC 331 cargo the date of its first scheduled leakage tank motor vehicles, and nonspectfication test after July 1, 1999, each specificacargo tank motor vehicles conforming to tion MC 330 or MC 331 cargo tank 1142 Pipeline and Hazardous Materials Safety Admin., DOT § 180.407 motor vehicle and each nonspecificanot apply to any cargo tank filled prior tion cargo tank motor vehicle conto the test or inspection due date. forming to $173.315(k) of this sub- (2) Except during a pressure test, a chapter, marked and certified before cargo tank may not be subjected to a July 1, 1999, that is used to transport a pressure greater than its design presliquefied compressed gas, other than sure or MAWP. carbon dioxide and chlorine, that has a (3) A person witnessing or performing water capacity of 13,247.5 L (3,500 gal- a test or inspection specified in this lons) or less must be equipped with a section must meet the minimum qualimeans of thermal activation for the infications prescribed in $180.409. ternal self-closing stop valve as speci- (4) Each cargo tank must be evalufied in § 178.337-8(a)(4) of this subated in accordance with the acceptable chapter. results of tests and inspections pre- (o) On-truck remote control of self-closscribed in $ 180.411. ing stop valves-MC 330, MC 331, and MC (5) Each cargo tank which has suc- 338. On or before October 2, 2006- cessfully passed a test or inspection (1) Each owner of an MC 330 or MC 331 specified in this section must be cargo tank motor vehicle marked or marked in accordance with § 180.415. certified before January 1, 1995, must (6) A cargo tank which fails a preequip the cargo tank with an on-vehiscribed test or inspection must: cle remote means of closure of the in- (i) Be repaired and retested in accordternal self-closing stop valve in conance with § 180.413; or formance with $178.337-8(a)(4) of this (ii) Be removed from hazardous matesubchapter. This requirement does not rials service and the specification plate apply to cargo tanks used only for carremoved, obliterated or covered in a sebon dioxide and marked "For carbon cure manner. dioxide only" or intended for use in chlorine service only. (b) Conditions requiring test and inspection of cargo tanks. Without regard to (2) Each owner of an MC 338 cargo any other test or inspection requiretank motor vehicle marked or certified ments, a specification cargo tank must before January 1, 1995. must equip each be tested and inspected in accordance remotely controlled shutoff valve with with this section prior to further use if: an on-vehicle remote means of automatic closure in conformance with (1) The cargo tank shows evidence of $178.338-11(c) of this subchapter. This dents, cuts, gouges, corroded or abrequirement does not apply to cargo raded areas, leakage, or any other contanks used for the transportation of dition that might render it unsafe for hazardous materials service. At a minargon, carbon dioxide, helium, krypton, neon, nitrogen, or xenon, or miximum, any area of a cargo tank showtures thereof. ing evidence of dents, cuts, digs, gouges, or corroded or abraded areas must |Amdt. 180-2, 54 FR 25032, June 12, 1989 be thickness tested in accordance with EDITORIAL NOTE: For FEDERAL REGISTER clthe procedures set forth in paragraphs tations affecting 180.405, see the List of CFR (i)(2), (i)(3), (i)(5), and (i)(6) of this sec- Sections Affected which appears in the Findtion and evaluated in accordance with ing Aids section of the printed volume and the criteria prescribed in § 180.411. Any on GPO Access. signs of leakage must be repaired in accordance with $180.413. The suitability § 180.407 Requirements for test and inof any repair affecting the structural spection of specification cargo integrity of the cargo tank must be detanks. termined either by the testing required (a) General. (1) A cargo tank conin the applicable manufacturing specistructed in accordance with a DOT fication or in paragraph (g)(1)(iv) of specification for which a test or inspecthis section. tion specified in this section has be- (2) The cargo tank has sustained come due, may not be filled and offered damage to an extent that may adfor transportation or transported until versely affect its lading retention capathe test or inspection has been successbility. A damaged cargo tank must be fully completed. This paragraph does pressure tested in accordance with the 1143 § 180.407 49 CFR Ch. I (10-1-06 Edition) procedures set forth in paragraph (g) of the cargo tank is in an unsafe operthis section. ating condition. (3) The cargo tank has been out of (c) Periodic test and inspection. Each hazardous materials transportation specification cargo tank must be tested service for a period of one year or and inspected as specified in the folmore. Each cargo tank that has been out of hazardous materials transporlowing table by an inspector meeting tation service for a period of one year the qualifications in $180.409. The retest date shall be determined from or more must be pressure tested in accordance with § 180.407(g) prior to furthe specified interval identified in the ther use. following table from the most recent (4) [Reserved] inspection or the CTMV certification (5) The Department so requires based date. on the existence of probable cause that COMPLIANCE DATES-INSPECTIONS AND TEST UNDER § 180.407(C) Test or inspection (cargo tank specification, configuration, and service) Date by which first test must be Interval period after first completed (see note 1) test External Visual Inspection: All cargo tanks designed to be loaded by vacuum with full open- September 1, 1991 6 months. ing rear heads. All other cargo tanks September 1, 1991 1 year. Internal Visual Inspection: All insulated cargo tanks, except MC 330, MC 331, MC 338 (see September 1, 1991 1 year. Note 4). All cargo tanks transporting lading corrosive to the tank September 1, 1991 1 year. All other cargo tanks, except MC 338 September 1, 1995 5 years. Lining Inspection: All lined cargo tanks transporting lading corrosive to the tank September 1, 1991 1 year. Leakage Test: MC 330 and MC 331 cargo tanks in chlorine service September 1, 1991 2 years. All other cargo tanks except MC 338 September 1, 1991 1 year. Pressure Test: (Hydrostatic or pneumatic) (See Notes 2 and 3) All cargo tanks which are insulated with no manhole or insulated September 1. 1991 1 year. and lined, except MC 338. All cargo tanks designed to be loaded by vacuum with full open- September 1, 1992 2 years. ing rear heads. MC 330 and MC 331 cargo tanks in chlorine service September 1, 1992 2 years. All other cargo tanks September 1, 1995 5 years. Thickness Test: All unlined cargo tanks transporting material corrosive to the September 1, 1992 2 years. tank, except MC 338. NOTE 1: If a cargo tank is subject to an applicable inspection or test requirement under the regulations in effect on December 30, 1990, and the due date (as specified by a requirement in effect on December 30, 1990) for completing the required inspection or test occurs before the compliance date listed in table I, the earlier date applies. NOTE 2: Pressure testing la not required for MC 330 and MC 331 cargo tanks in dedicated sodium metal service. NOTE 3: Pressure testing is not required for uninsulated lined cargo tanks, with a design pressure or MAWP 15 psig or less, which receive an external visual inspection and lining inspection at least once each year. NOTE 4: Insulated cargo tanks equipped with manholes or inspection openings may perform either an internal visual inspection in conjunction with the external visual inspection or a hydrostatic or pneumatic pressure-test of the cargo tank. (d) External visual inspection and testany part of the cargo tank wall is exing. The following applies to the exterternally lined, coated, or designed to nal visual inspection and testing of prevent an external visual inspection, cargo tanks: those areas of the cargo tank must be (1) Where insulation precludes a cominternally inspected. If internal visual plete external visual inspection as reinspection is precluded because the quired by paragraphs (d)(2) through cargo tank is lined, coated, or designed (d)(6) of this section, the cargo tank so as to prevent access for internal inalso must be given an internal visual spection, the tank must be inspection in accordance with parahydrostatically or pneumatically testgraph (e) of this section. If external ed in accordance with paragraph visual inspection is precluded because (g)(1)(iv) of this section. Those items 1144 Pipeline and Hazardous Materials Safety Admin., DOT § 180.407 able to be externally inspected must be upper coupler (fifth wheel) assembly externally inspected and noted in the must be removed from the cargo tank inspection report. for this inspection. (2) The external visual inspection and (3) All reclosing pressure relief valves testing must include as a minimum the must be externally inspected for any following: corrosion or damage which might pre- (i) The tank shell and heads must be vent safe operation. All reclosing presinspected for corroded or abraded sure relief valves on cargo tanks carareas, dents, distortions, defects in rying lading corrosive to the valve welds and any other conditions, includmust be removed from the cargo tank ing leakage, that might render the for inspection and testing. Each retank unsafe for transportation service; closing pressure relief valve required to (ii) The piping, valves, and gaskets be removed and tested must open at must be carefully inspected for corthe required set pressure and reseat to roded areas, defects in welds, and other a leak-tight condition at 90 percent of conditions, including leakage, that the set-to-discharge pressure or the might render the tank unsafe for transpressure prescribed for the applicable portation service; cargo tank specification. (iii) All devices for tightening man- (4) Ring stiffeners or other appurhole covers must be operative and tenances, installed on cargo tanks conthere must be no evidence of leakage at structed of mild steel or high-strength, manhole covers or gaskets; low-alloy steel, that create air cavities (iv) All emergency devices and valves adjacent to the tank shell that do not including self-closing stop valves, exallow for external visual inspection cess flow valves and remote closure demust be thickness tested in accordance vices must be free from corrosion, diswith paragraphs (i)(2) and (i)(3) of this tortion, erosion and any external damsection, at least once every 2 years. At age that will prevent safe operation. least four symmetrically distributed Remote closure devices and self-closing readings must be taken to establish an stop valves must be functioned to demaverage thickness for the ring stiffener onstrate proper operation: or appurtenance. If any thickness read- (v) Missing bolts, nuts and fusible links or elements must be replaced, ing is less than the average thickness by more than 10%, thickness testing in and loose bolts and nuts must be tightaccordance with paragraphs (i)(2) and ened; (i)(3) of this section must be conducted (vi) All markings on the cargo tank from the inside of the cargo tank on required by parts 172, 178 and 180 of this the area of the tank wall covered by subchapter must be legible; (vii) [Reserved] the appurtenance or ring stiffener. (viii) All major appurtenances and (5) Corroded or abraded areas of the structural attachments on the cargo cargo tank wall must be thickness tank including, but not limited to, sustested in accordance with the procepension system attachments, condures set forth in paragraphs (i)(2), necting structures, and those elements (i)(3), (i)(5) and (1)(6) of this section. of the upper coupler (fifth wheel) as- (6) The gaskets on any full opening sembly that can be inspected without rear head must be: dismantling the upper coupler (fifth (i) Visually inspected for cracks or wheel) assembly must be inspected for splits caused by weather or wear; and any corrosion or damage which might (ii) Replaced if cuts or cracks which prevent safe operation; are likely to cause leakage, or are of a (ix) For cargo tanks transporting laddepth one-half inch or more, are found. ing corrosive to the tank, areas cov- (7) The inspector must record the reered by the upper coupler (fifth wheel) sults of the external visual examinaassembly must be inspected at least tion as specified in $180.417(b). once in each two year period for cor- (e) Internal visual inspection. (1) When roded and abraded areas, dents, distorthe cargo tank is not equipped with a tions, defects in welds, and any other manhole or inspection opening, or the condition that might render the tank cargo tank design precludes an internal unsafe for transportation service. The inspection, the tank shall be 1145 § 180.407 49 CFR Ch. I (10-1-06 Edition) hydrostatically or pneumatically testbrated periodically using the test calied in accordance with 180.407(c) and (g). bration coupon, and the same power (2) The internal visual inspection source, probe, and cable length. must include as a minimum the fol- (iii) After calibration, the probe must lowing: be passed over the lining in an uninter- (i) The tank shell and heads must be rupted stroke. inspected for corroded and abraded (iv) Holes that are found must be reareas, dents, distortions, defects in paired using equipment and procedures welds, and any other condition that prescribed by the lining manufacturer might render the tank unsafe for transor lining installer. portation service. (2) Linings made of other than rubber (ii) Tank liners must be inspected as (elastomeric material) must be tested specified in § 180.407(f). using equipment and procedures pre- (3) Corroded or abraded areas of the scribed by the lining manufacturer or cargo tank wall must be thickness lining installer. tested in accordance with paragraphs (i)(2). (i)(3), (i)(5) and (1)(6) of this sec- (3) Degraded or defective areas of the tion. cargo tank liner must be removed and (4) The inspector must record the rethe cargo tank wall below the defect sults of the internal visual inspection must be inspected. Corroded areas of the tank wall must be thickness tested as specified in $180.417(b). (f) Lining inspection. The integrity of in accordance with paragraphs (i)(2), (i)(3), (1)(5) and (i)(6) of this section. the lining on all lined cargo tanks, when lining is required by this sub- (4) The inspector must record the rechapter, must be verified at least once sults of the lining inspection as specieach year as follows: fied in $180.417(b). (1) Rubber (elastomeric) lining must (g) Pressure test. All components of be tested for holes as follows: the cargo tank wall, as defined in (i) Equipment must consist of: $178.320(a) of this subchapter, must be (A) A high frequency spark tester capressure tested as prescribed by this pable of producing sufficient voltage to paragraph. ensure proper calibration; (1) Test Procedure-(i) As part of the (B) A probe with an "L" shaped 2.4 pressure test, the inspector must permm (0.09 inch) diameter wire with up form an external and internal visual to a 30.5 cm (12-inch) bottom leg (end inspection, except that on an MC 338 bent to a 12.7 mm (0.5 inch) radius), or cargo tank, or a cargo tank not equally sensitive probe; and equipped with a manhole or inspection (C) A steel calibration coupon 30.5 cm opening, an internal inspection is not X 30.5 cm (12 inches X 12 inches) covered required. with the same material and thickness (ii) All self-closing pressure relief as that to be tested. The material on valves, including emergency relief the coupon shall have a test hole to the vents and normal vents, must be remetal substrate made by puncturing moved from the cargo tank for inspecthe material with a 22 gauge hypotion and testing. dermic needle or comparable piercing (A) Each self-closing pressure relief tool. valve that is an emergency relief vent (ii) The probe must be passed over must open at the required set pressure the surface of the calibration coupon in and seat to a leak-tight condition at 90 a constant uninterrupted manner until percent of the set-to-discharge pressure the hole is found. The hole is detected or the pressure prescribed for the appliby the white or light blue spark cable cargo tank specification. formed. (A sound lining causes a dark (B) Normal vents (1 psig vents) must blue or purple spark.) The voltage must be tested according to the testing cribe adjusted to the lowest setting that teria established by the valve manufacwill produce a minimum 12.7 mm (0.5 turer. inch) spark measured from the top of (C) Self-closing pressure relief dethe lining to the probe. To assure that vices not tested or failing the tests in the setting on the probe has not this paragraph (g)(1)(ii) must be rechanged, the spark tester must be calipaired or replaced. 1146 Pipeline and Hazardous Materials Safety Admin., DOT § 180.407 (iii) Except for cargo tanks carrying ing similar viscosity, at a temperature lading corrosive to the tank, areas COVnot exceeding 100 °F. The cargo tank ered by the upper coupler (fifth wheel) must then be pressurized to not less assembly must be inspected for corthan the pressure specified in pararoded and abraded areas, dents, distorgraph (g)(1)(iv) of this section. The tions, defects in welds, and any other cargo tank, including its closures, condition that might render the tank must hold the prescribed test pressure unsafe for transportation service. The for at least 10 minutes during which upper coupler (fifth wheel) assembly time it shall be inspected for leakage, must be removed from the cargo tank bulging or any other defect. for this inspection. (ix) Pneumatic test method. Pneumatic (iv) Each cargo tank must be tested testing may involve higher risk than hydrostatically or pneumatically to hydrostatic testing. Therefore, suitable the internal pressure specified in the safeguards must be provided to protect following table. At no time during the personnel and facilities should failure pressure test may a cargo tank be suboccur during the test. The cargo tank ject to pressures that exceed those must be pressurized with air or an identified in the following table: inert gas. The pneumatic test pressure Specification Test pressure in the cargo tank must be reached by gradually increasing the pressure to MC 300, 301, 302, 303, 305, 20.7 kPa (3 psig) or design one-half of the test pressure. There- 306. pressure, whichever is after, the pressure must be increased in greater. MC 304, 307 275.8 kPa (40 psig) or 1.5 steps of approximately one-tenth of the times the design pressure, test pressure until the required test whichever is greater. pressure has been reached. The test MC 310, 311, 312 20.7 kPa (3 psig) or 1.5 times the design pressure, whichpressure must be held for at least 5 ever is greater. minutes. The pressure must then be re- MC 330, 331 1.5 times either the MAWP or duced to the MAWP, which must be the re-rated pressure, whichever is applicable. maintained during the time the entire MC 338 1.25 times either the MAWP cargo tank surface is inspected. During or the re-rated pressure, the inspection, a suitable method must whichever is applicable. DOT 406 34.5 kPa (5 psig) or 1.5 times be used for detecting the existence of the MAWP, whichever is leaks. This method must consist either greater. of coating the entire surface of all DOT 407 275.8 kPa (40 psig) or 1.5 joints under pressure with a solution of times the MAWP, whichever is greater. soap and water, or using other equally DOT 412 1.5 times the MAWP, sensitive methods. (2) When testing an insulated cargo (v) [Reserved] tank, the insulation and jacketing need (vi) Each cargo tank of a multi-tank not be removed unless it is otherwise cargo tank motor vehicle must be testimpossible to reach test pressure and ed with the adjacent cargo tanks maintain a condition of pressure equiempty and at atmospheric pressure. librium after test pressure is reached, (vii) All closures except pressure reor the vacuum integrity cannot be lief devices must be in place during the maintained in the insulation space. If test. All prescribed loading and unloadan MC 338 cargo tank used for the ing venting devices rated at less than transportation of a flammable gas or test pressure may be removed during oxygen, refrigerated liquid is opened the test. If retained, the devices must for any reason, the cleanliness must be be rendered inoperative by clamps, verified prior to closure using the proplugs, or other equally effective recedures contained in § 178.338-15 of this straining devices. Restraining devices subchapter. may not prevent detection of leaks or (3) Each MC 330 and MC 331 cargo damage the venting devices and must tank constructed of quenched and tembe removed immediately after the test pered steel in accordance with Part is completed. UHT in Section VIII of the ASME Code (viii) Hydrostatic test method. Each (IBR, see $171.7 of this subchapter), or cargo tank, including its domes, must constructed of other than quenched be filled with water or other liquid havand tempered steel but without 1147 $ 180.407 49 CFR Ch. I (10-1-06 Edition) postweld heat treatment, used for the follows: A cargo tank with a heating transportation of anhydrous ammonia system which does not hold pressure or any other hazardous materials that may remain in service as an unheated may cause corrosion stress cracking, cargo tank if: must be internally inspected by the (i) The heating system remains in wet fluorescent magnetic particle place and is structurally sound and no method immediately prior to and in lading may leak into the heating sysconjunction with the performance of tem, and the pressure test prescribed in this sec- (11) The specification plate heating tion. Each MC 330 and MC 331 cargo system information is changed to inditank constructed of quenched and temcate that the cargo tank has no workpered steel in accordance with Part ing heating system. UHT in Section VIII of the ASME Code (7) The inspector must record the reand used for the transportation of liqsults of the pressure test as specified in uefied petroleum gas must be inter- $ 180.417(b). nally inspected by the wet fluorescent (h) Leakage test. The following remagnetic particle method immediately quirements apply to cargo tanks reprior to and in conjunction with the quiring a leakage test: performance of the pressure test pre- (1) Each cargo tank must be tested scribed in this section. The wet fluoresfor leaks in accordance with paragraph cent magnetic particle inspection must (c) of this section. The leakage test be in accordance with Section V of the must include testing product piping ASME Code and CGA Technical Bulwith all valves and accessories in place letin TB-2 (IBR, see $171.7 of this suband operative. except that any venting chapter). This paragraph does not devices set to discharge at less than apply to cargo tanks that do not have the leakage test pressure must be remanholes. (See $180.417(c) for reporting moved or rendered inoperative during requirements.) the test. All internal or external self- (4) All pressure bearing portions of a closing stop valves must be tested for cargo tank heating system employing a leak tightness. Each cargo tank of a medium such as, but not limited to, multi-cargo tank motor vehicle must steam or hot water for heating the ladbe tested with adjacent cargo tanks ing must be hydrostatically pressure empty and at atmospheric pressure. tested at least once every 5 years. The Test pressure must be maintained for test pressure must be at least the maxat least 5 minutes. Cargo tanks in liqimum system design operating pressure uefied compressed gas service must be and must be maintained for five minexternally inspected for leaks during utes. A heating system employing flues the leakage test. Suitable safeguards for heating the lading must be tested must be provided to protect personnel to ensure against lading leakage into should a failure occur. Cargo tanks the flues or into the atmosphere. may be leakage tested with hazardous (5) Exceptions. (i) Pressure testing is materials contained in the cargo tank not required for MC 330 and MC 331 during the test. Leakage test pressure cargo tanks in dedicated sodium metal must be no less than 80% of MAWP service. marked on the specification plate ex- (ii) Pressure testing is not required cept as follows: for uninsulated lined cargo tanks, with (i) A cargo tank with an MAWP of 690 a design pressure or MAWP of 15 psig kPa (100 psig) or more may be leakage or less, which receive an external vistested at its maximum normal operual inspection and a lining inspection ating pressure provided it is in dediat least once each year. cated service or services; or (6) Acceptance criteria. A cargo tank (ii) An MC 330 or MC 331 cargo tank that leaks, fails to retain test pressure in dedicated liquified petroleum gas or pneumatic inspection pressure, service may be leakage tested at not shows distortion, excessive permanent less than 414 kPa (60 psig). expansion, or other evidence of weak- (iii) An operator of a specification ness that might render the cargo tank MC 330 or MC 331 cargo tank, and a unsafe for transportation service, may nonspecification cargo tank authorized not be returned to service, except as under $ 173.315(k) of this subchapter, 1148 Pipeline and Hazardous Materials Safety Admin., DOT § 180.407 equipped with a meter may check leak of the hose assembly and piping system tightness of the internal self-closing tested. stop valve by conducting a meter creep (5) The inspector must record the retest. (See appendix B to this part.) sults of the leakage test as specified in (iv) An MC 330 or MC 331 cargo tank $180.417(b). in dedicated service for anhydrous am- (i) Thickness testing. (1) The shell and monia may be leakage tested at not head thickness of all unlined cargo less than 414 kPa (60 psig). tanks used for the transportation of (v) A non-specification cargo tank rematerials corrosive to the tank must quired by $173.8(d) of this subchapter to be measured at least once every 2 be leakage tested, must be leakage years, except that cargo tanks meastested at not less than 16.6 kPa (2.4 uring less than the sum of the minpsig), or as specified in paragraph (h)(2) imum prescribed thickness, plus oneof this section. fifth of the original corrosion allow- (2) Cargo tanks used to transport peance, must be tested annually. troleum distillate fuels that are (2) Measurements must be made equipped with vapor collection equipusing a device capable of accurately ment may be leak tested in accordance measuring thickness to within ±0.002 of with the Environmental Protection an inch. Agency's "Method 27-Determination (3) Any person performing thickness of Vapor Tightness of Gasoline Delivtesting must be trained in the proper ery Tank Using Pressure-Vacuum use of the thickness testing device used Test," as set forth in Appendix A to 40 in accordance with the manufacturer's CFR part 60. Test methods and proceinstruction. dures and maximum allowable pressure (4) Thickness testing must be perand vacuum changes are in 40 CFR formed in the following areas of the 63.425(e)(1). The hydrostatic test altercargo tank wall, as a minimum: native, using liquid in Environmental (i) Areas of the tank shell and heads Protection Agency's "Method 27-Deand shell and head area around any termination of Vapor Tightness of Gaspiping that retains lading: oline Delivery Tank Using Pressure- (ii) Areas of high shell stress such as Vacuum Test," may not be used to satthe bottom center of the tank; isfy the leak testing requirements of (iii) Areas near openings; this paragraph. The test must be conducted using air. (iv) Areas around weld joints; (3) A cargo tank that fails to retain (v) Areas around shell reinforceleakage test pressure may not be rements; turned to service as a specification (vi) Areas around appurtenance atcargo tank, except under conditions tachments; specified in $180.411(d). (vii) Areas near upper coupler (fifth (4) After July 1, 2000, Registered Inwheel) assembly attachments; spectors of specification MC 330 and MC (viii) Areas near suspension system 331 cargo tanks, and nonspecification attachments and connecting struccargo tanks authorized under tures; $173.315(k) of this subchapter must vis- (ix) Known thin areas in the tank ually inspect the delivery hose assemshell and nominal liquid level lines; bly and piping system while the assemand bly is under leakage test pressure uti- (x) Connecting structures joining lizing the rejection criteria listed in multiple cargo tanks of carbon steel in $180.416(g). Delivery hose assemblies a self-supporting cargo tank motor venot permanently attached to the cargo hicle. tank motor vehicle may be inspected (5) Minimum thicknesses for MC 300, separately from the cargo tank motor MC 301, MC 302, MC 303, MC 304, MC 305, vehicle. In addition to a written record MC 306, MC 307, MC 310, MC 311, and MC of the inspection prepared in accord- 312 cargo tanks are determined based ance with $180.417(b), the Registered on the definition of minimum thick- Inspector conducting the test must ness found in $178.320(a) of this subnote the hose identification number, chapter. The following Tables I and II the date of the test, and the condition identify the "In-Service Minimum 1149 § 180.407 49 CFR Ch. I (10-1-06 Edition) Thickness" values to be used to deter- TABLE II-IN-SERVICE MINIMUM THICKmine the minimum thickness for the NESS FOR MC 301, MC 302, MC 304, MC referenced cargo tanks. The column 305, MC 306, MC 307, MC 311, AND MC headed "Minimum Manufactured 312 SPECIFICATION CARGO TANKS Thickness" indicates the minimum CONSTRUCTED OF ALUMINUM AND values required for new construction of ALUMINUM ALLOYS-Continued DOT 400 series cargo tanks, found in Tables I and II of SS 178.346-2. 178.347-2, In-service and 178.348-2 of this subchapter. In- Minimum manufactured thickness minimum thickness Service Minimum Thicknesses for MC (inches) 300, MC 301, MC 302, MC 303, MC 304, MC 0.194 0.175 305, MC 306, MC 307, MC 310, MC 311, and 0.216 0.194 MC 312 cargo tanks are based on 90 per- 0.237 0.213 0.270 0.243 cent of the manufactured thickness 0.360 0.324 specified in the DOT specification, 0.450 0.405 rounded to three places. 0.540 0.486 TABLE I-IN-SERVICE MINIMUM THICK- (6) An owner of a cargo tank that no NESS FOR MC 300, MC 303, MC 304, MC longer conforms to the minimum 306, MC 307, MC 310, MC 311, AND MC thickness prescribed for the design as 312 SPECIFICATION CARGO TANKS manufactured may use the cargo tank CONSTRUCTED OF STEEL AND STEEL to transport authorized materials at ALLOYS reduced maximum weight of lading or reduced maximum working pressure, or Nominal In-service combinations thereof, provided the fol- Minimum manufactured thickness decimal minimum (US gauge or inches) equivathickness lowing conditions are met: lent for reference (i) A Design Certifying Engineer (inches) (inches) must certify that the cargo tank de- 19 0.0418 0.038 sign and thickness are appropriate for 18 0.0478 0.043 17 the reduced loading conditions by 0.0538 0.048 16 0.0598 0.054 issuance of a revised manufacturer's 15 0.0673 0.061 certificate, and 14 0.0747 0.067 (ii) The cargo tank motor vehicle's 13 0.0897 0.081 12 0.1046 0.094 nameplate must reflect the revised 11 0.1196 0.108 service limits. 10 0.1345 0.121 (7) An owner of a cargo tank that no 9 0.1495 0.135 8 longer conforms with the minimum 0.1644 0.148 7 0.1793 0.161 thickness prescribed for the specifica- 3/16 0.1875 0.169 tion may not return the cargo tank to 1/4 0.2500 0.225 hazardous materials service. The 5/16 0.3125 0.281 3/8 0.3750 0.338 tank's specification plate must be removed, obliterated or covered in a se- TABLE II-IN-SERVICE MINIMUM THICKcure manner. (8) The inspector must record the re- NESS FOR MC 301, MC 302, MC 304, MC 305, MC 306, MC 307, MC 311, AND MC sults of the thickness test as specified in § 180.417(b). 312 SPECIFICATION CARGO TANKS CONSTRUCTED OF ALUMINUM AND (9) For MC 331 cargo tanks constructed before October 1, 2003, min- ALUMINUM ALLOYS Imum thickness shall be determined by In-service the thickness indicated on the U1A Minimum manufactured thickness minimum form minus any corrosion allowance. thickness (inches) For MC 331 cargo tanks constructed after October 1. 2003, the minimum 0.078 0.070 thickness will be the value indicated 0.087 0.078 0.096 0.086 on the specification plate. If no corro- 0.109 0.098 sion allowance is indicated on the U1A 0.130 0.117 form then the thickness of the tank 0.141 0.127 0.151 shall be the thickness of the material 0.136 0.172 0.155 of construction indicated on the UIA 0.173 0.156 form with no corrosion allowance. 1150 Pipeline and Hazardous Materials Safety Admin., DOT § 180.411 (10) For 400-series cargo tanks, minby that person, for petroleum products imum thickness is calculated accordas authorized by $173.8(c) of this subing to tables in each applicable section chapter, is not required to be regof this subchapter for that specificaistered in accordance with subpart F of tion: $ 178.346-2 for DOT 406 cargo part 107 of this chapter. In addition the tanks, § 178.347-2 for DOT 407 cargo person who signs the inspection report tanks, and 178.348-2 for DOT 412 cargo required by $180.417(b) of this subpart tanks. for such non-bulk tanks is not required [Amdt. 180-2, 54 FR 25032, June 12, 1989) to be registered. Although not required EDITORIAL NOTE: For FEDERAL REGISTER cito register, a person who performs vistations affecting § 180.407, see the List of CFR ual inspections or leakage tests or Sections Affected which appears in the Findsigns the inspection reports must have ing Aids section of the printed volume and the knowledge and ability to perform on GPO Access. such inspections and tests and must perform them as required by this sub- § 180.409 Minimum qualifications for chapter. inspectors and testers. (d) A motor carrier or cargo tank (a) Except as otherwise provided in owner who meets the requirements of this section, any person performing or paragraph (a) of this section may use witnessing the inspections and tests an employee who is not a Registered specified in $ 180.407 must- Inspector to perform a portion of the (1) Be registered with the Federal pressure retest required by $180.407(g). Motor Carrier Safety Administration External and internal visual inspecin accordance with part 107, subpart F tions must be accomplished by a Regof this chapter, istered Inspector, but the hydrostatic (2) Be familiar with DOT-specificaor pneumatic pressure test, as set forth tion cargo tanks and trained and expein $180.407(g)(1)(viii) and (ix), respecrienced in use of the inspection and tively, may be done by an employee testing equipment needed, and (3) Have the training and experience who is not a Registered Inspector provided thatrequired to meet the definition of "Registered Inspector" in $171.8 of this (1) The employee is familiar with the chapter. cargo tank and is trained and experi- (b) A person who only performs anenced in the use of the inspection and nual external visual inspections and testing equipment used; leakage tests on a cargo tank motor (2) The employer submits certifivehicle, owned or operated by that percation that such employee meets the son, with a capacity of less than 13,250 qualification requirements to the Asso- L (3,500 gallons) used exclusively for ciate Administrator, Attn: (PHH-32), flammable liquid petroleum fuels, is Pipeline and Hazardous Materials Safenot required to meet the educational ty Administration, Department of and years of experience requirements Transportation, 400 Seventh Street, set forth in the definition of "Reg- SW., Washington, DC 20590; and istered Inspector" in $171.8 of this sub- (3) The employer retains a copy of chapter. Although not required to meet the tester's qualifications with the docthe educational and years of experience uments required by § 180.417(b). requirements, a person who performs [Amdt. 180-2, 55 FR 37069, Sept. 7, 1990, as visual inspections or leakage tests or amended by Amdt. 180-3, 56 FR 66287, Dec. 20, signs the inspection reports must have 1991; 57 FR 45466, Oct. 1, 1992; Amdt. 180-11, 62 the knowledge and ability to perform FR 1217, Jan. 8, 1997; 66 FR 45391, Aug. 28, such inspections and tests and must 2001: 68 FR 19288, Apr. 18, 2003; 70 FR 56100, perform them as required by this sub- Sept. 23, 2005] chapter, and must register with the Department as required by subpart F of $ 180.411 Acceptable results of tests part 107 of this chapter. and inspections. (c) A person who performs only an- (a) Corroded or abraded areas. The nual external visual inspections and minimum thickness may not be less leakage tests on a permanently mountthan that prescribed in the applicable ed non-bulk tank, owned or operated specification. 1151 $ 180.413 49 CFR Ch. I (10-1-06 Edition) (b) Dents, cuts, digs and gouges. For fication cargo tanks may be performed evaluation procedures, see CGA C-6 by: (IBR, see $171.7 of this subchapter). (A) A cargo tank manufacturer hold- (1) For dents at welds or that include ing a valid ASME Certificate of Au- a weld, the maximum allowable depth thorization for the use of the ASME is 1/2 inch. For dents away from welds, "U" stamp using the quality control the maximum allowable depth is 1/10 of procedures used to obtain the Certifithe greatest dimension of the dent. but cate of Authorization; or in no case may the depth exceed one inch. (B) A repair facility holding a valid National Board Certificate of Author- (2) The minimum thickness remainization for use of the National Board ing beneath a cut, dig, or gouge may not be less than that prescribed in the "R" stamp using the quality control applicable specification. procedures used to obtain the Certificate of Authorization. (c) Weld or structural defects. Any cargo tank with a weld defect such as (ii) A repair, modification, stretch- a crack, pinhole, or incomplete fusion, ing, or rebarrelling of a non-ASME or a structural defect must be taken stamped cargo tank may be done without of hazardous materials service out certification by an Authorized Inuntil repaired. spector, completion of the R-1 form, or (d) Leakage. All sources of leakage being stamped with the "R" stamp. must be properly repaired prior to re- (2) Prior to each repair, modification, turning a tank to hazardous materials stretching, rebarrelling. or mounting, service. the cargo tank motor vehicle must be (e) Relief valves. Any pressure relief emptied of any hazardous material ladvalve that fails to open and reclose at ing. In addition, cargo tank motor vethe prescribed pressure must be rehicles used to transport flammable or paired or replaced. toxic lading must be sufficiently (f) Liner integrity. Any defect shown cleaned of residue and purged of vapors by the test must be properly repaired. so any potential hazard is removed, in- (g) Pressure test. Any tank that fails cluding void spaces between double to meet the acceptance criteria found bulkheads, piping and vapor recovery in the individual specification that apsystems. plies must be properly repaired. (3) Each person performing a repair, [Amdt. 180-2, 54 FR 25032, June 12, 1989, as modification, stretching, rebarrelling amended at 68 FR 75764, Dec. 31, 2003] or mounting of a DOT specification cargo tank must be registered in ac- § 180.413 Repair, modification, stretchcordance with subpart F of part 107 of ing, rebarrelling, or mounting of this chapter. specification cargo tanks. (b) Repair. The suitability of each re- (a) General. Any repair, modification, pair affecting the structural integrity stretching, rebarrelling. or mounting or lading retention capability of the of a cargo tank must be performed in cargo tank must be determined by the conformance with the requirements of testing required either in the applicathis section. ble manufacturing specification or in (1) Except as otherwise provided in $180.407(g)(1)(iv). Each repair of a cargo this section, each repair. modification, tank involving welding on the shell or stretching, or rebarrelling of a specihead must be certified by a Registered fication cargo tank must be performed Inspector. The following provisions by a repair facility holding a valid Naapply to specific cargo tank repairs: tional Board Certificate of Authoriza- (1) DOT 406, DOT 407, and DOT 412 tion for use of the National Board "R" cargo tanks must be repaired in acstamp and must be made in accordance cordance with the specification rewith the edition of the National Board quirements in effect at the time of re- Inspection Code in effect at the time pair; the work is performed. (2) MC 300, MC 301, MC 302, MC 303, (i) Repairs, modifications, MC 305, and MC 306 cargo tanks must stretchings, and rebarrellings perbe repaired in accordance with either formed on non-ASME stamped specithe most recent revision of the original 1152 Pipeline and Hazardous Materials Safety Admin., DOT § 180.413 specification or with the DOT 406 speci- A hose may be tested before or after infication in effect at the time of repair; stallation on the cargo tank. (3) MC 304 and MC 307 cargo tanks (2) After repair or replacement of pipmust be repaired in accordance with eiing, valves, or fittings that involves ther the most recent revision of the welding on the cargo tank wall, the original specification or with the DOT cargo tank must be pressure tested in 407 specification in effect at the time of accordance with the applicable manurepair; facturing specification or (4) MC 310, MC 311, and MC 312 cargo §180.407(g)(1)(iv). In addition, the aftanks must be repaired in accordance fected piping, valve, or fitting must be with either the most recent revision of tested in accordance with paragraph the original specification or with the (c)(1) of this section. DOT 412 specification in effect at the (3) Hoses on cargo tanks in dedicated time of repair; liquefied compressed gas, except car- (5) MC 338 cargo tanks must be rebon dioxide, service are excepted from paired in accordance with the specithese testing requirements, but must fication requirements in effect at the be tested in accordance with § 180.416(f). time of repair; and (d) Modification, stretching, or rebarrel- (6) MC 330 and MC 331 cargo tanks ling. Modification, stretching or remust be repaired in accordance with barrelling of a cargo tank motor vehithe repair procedures described in CGA cle must conform to the following pro- Technical Bulletin TB-2 (IBR, see visions: 171.7 of this subchapter) and the Na- (1) The design of the modified, tional Board Inspection Code (IBR, see stretched, or rebarrelled cargo tank § 171.7 of this subchapter). Each cargo motor vehicle must be certified in tank having cracks or other defects rewriting by a Design Certifying Engiquiring welded repairs must meet all neer as meeting the structural integinspection, test, and heat treatment rerity and accident damage protection quirements in $178.337-16 of this subrequirements of the applicable specichapter in effect at the time of the refication. pair, except that postweld heat treat- (2) Except as provided in paragraph ment after minor weld repairs is not (d) of this section, all new materequired. When a repair is made of derial and equipment affected by modifects revealed by the wet fluorescent fication, stretching, or rebarrelling magnetic particle inspection, including must meet the requirements of the those repaired by grinding, the affected specification in effect at the time such area of the cargo tank must again be work is performed, and all applicable examined by the wet fluorescent magstructural integrity requirements netic particle method after hydrostatic ($178.337-3. $178.338-3, or $178.345-3 of testing to assure that all defects have this subchapter). The work must conbeen removed. form to the requirements of the appli- (c) Maintenance or replacement of pipcable specification as follows: ing, valves, hoses, or fittings. After each (i) For specification MC 300, MC 301, repair, maintenance or replacement of MC 302, MC 303, MC 305 and MC 306 a pipe, valve, hose, or fitting on a cargo cargo tanks, the provisions of either tank, that component must be inspecification MC 306 or DOT 406 until stalled in accordance with the provi- August 31, 1995 and, thereafter to specisions of the applicable specification befication DOT 406 only; fore the cargo tank is returned to serv- (ii) For specification MC 304 and MC ice. 307 cargo tanks, the provisions of ei- (1) After maintenance or replacement ther specification MC 307 or DOT 407 that does not involve welding on the until August 31, 1995 and, thereafter to cargo tank wall, the repaired or respecification DOT 407 only; placed piping, valve, hose, or fitting (iii) For specification MC 310, MC 311, must be tested for leaks. This requireand MC 312 cargo tanks, the provisions ment is met when the piping, valve, of either specification MC 312 or DOT hose, or fitting is tested after installa- 412 until August 31, 1995 and, thereafter tion in accordance with $180.407(h)(1). to specification DOT 412 only; 1153 § 180.415 49 CFR Ch. I (10-1-06 Edition) (iv) For specification MC 330 cargo rebarrelled cargo tank conforms to the tanks, the provisions of specification requirements of this section and the MC 331; and applicable specification by issuing a (v) For specification MC 338 cargo supplemental certificate of compliance. tanks, the provisions of specification The registration number of the Reg- MC 338. However, structural modificaistered Inspector must be entered on tions to MC 338 cargo tanks authorized the certificate. under $180.405(d) may conform to appli- (e) Mounting of cargo tanks. Mounting cable provisions of the ASME Code in- a cargo tank on a cargo tank motor vestead of specification MC 338, provided hicle must be: the structural integrity of the modified (1) Performed as required by paracargo tank is at least equivalent to graph (d)(2) of this section and certified that of the original cargo tank. by a Design Certifying Engineer if the (3) The person performing the modimounting of a cargo tank on a motor fication, stretching, or rebarrelling vehicle chassis involves welding on the must: cargo tank head or shell or any change (i) Have knowledge of the original deor modification of the methods of atsign concept, particularly with respect tachment; or to structural design analysis, material (2) In accordance with the original and welding procedures. specification for attachment to the (ii) Assure compliance of the rebuilt chassis or the specification for attachcargo tank's structural integrity, ventment to the chassis in effect at the ing, and accident damage protection time of the mounting, and performed with the applicable specification reunder the supervision of a Registered quirements. Inspector if the mounting of a cargo (iii) Assure compliance with all aptank on a motor vehicle chassis does plicable Federal Motor Carrier Safety not involve welding on the cargo tank Regulations for all newly installed head or shell or a change or modificasafety equipment. tion of the methods of attachment. (iv) Assure the suitability of each (f) Records. Each owner of a cargo modification, stretching and rebarreltank motor vehicle must retain at the ling that affects the lading retention owner's principal place of business all capability of the cargo tank by perrecords of repair, modification, forming the tests required in the applistretching, or rebarrelling, including cable specification or $180.407(g)(1)(iv). notation of any tests conducted to (v) Any modification that changes inverify the suitability of the repair, formation displayed on the specificamodification, stretching, or rebarreltion plate requires the installation of a ling made to each cargo tank during supplemental specification plate, the time the cargo tank motor vehicle nameplate, or both containing the inis in service and for one year thereformation that reflects the cargo tank after. Copies of these records must be as modified, stretched or rebarrelled. retained by a motor carrier, if not the The plate must include the name of the owner of the cargo tank motor vehicle, person or facility doing the work, DOT at its principal place of business during registration number, date work is comthe period the cargo tank motor vehipleted, retest information, and any cle is in the carrier's service. other information that differs from the [68 FR 19288, Apr. 18, 2003; 68 FR 52372, Sept. original plate. The supplemental plates 3. 2003, as amended at 68 FR 75764, Dec. 31, must be installed immediately adja- 2003] cent to the existing plate or plates. (vi) On a variable specification cargo $ 180.415 Test and inspection marktank, install a supplemental or new ings. variable specification plate, and re- (a) Each cargo tank successfully place the specification listed on the completing the test and inspection reoriginal specification plate with the quirements contained in $180.407 must words "see variable specification be marked as specified in this section. plate." (b) Each cargo tank must be durably (4) A Registered Inspector must cerand legibly marked, in English, with tify that the modified, stretched, or the date (month and year) and the type 1154 Pipeline and Hazardous Materials Safety Admin., DOT § 180.416 of test or inspection performed, subject § 180.416 Discharge system inspection to the following provisions: and maintenance program for cargo (1) The date must be readily identifitanks transporting liquefied comable with the applicable test or inspecpressed gases. tion. (a) Applicability. This section is appli- (2) The markings must be in letters cable to an operator using specification and numbers at least 32 mm (1.25 MC 330, MC 331, and nonspecification inches) high, near the specification cargo tanks authorized under plate or anywhere on the front head. § 173.315(k) of this subchapter for trans- (3) The type of test or inspection may portation of liquefied compressed gases be abbreviated as follows: other than carbon dioxide. Paragraphs (i) V for external visual inspection (b), (c), (d)(1), (d)(5), (e), (f), and (g)(1) of and test; this section, applicable to delivery (ii) I for internal visual inspection; hose assemblies, apply only to hose assemblies installed or carried on the (iii) P for pressure test; cargo tank. (iv) L for lining inspection; (b) Hose identification. By July 1, 2000, (v) T for thickness test; and the operator must assure that each de- (vi) K for leakage test for a cargo livery hose assembly is permanently tank tested under § 180.407, except marked with a unique identification $180.407(h)(2): and number and maximum working pres- (vii) K-EPA27 for a cargo tank tested sure. under $ 180.407(h)(2) after October 1, (c) Post-delivery hose check. After each 2004. unloading. the operator must visually Examples to paragraph (b). The markings check that portion of the delivery hose "10-99 P, V, L" represent that in October 1999 assembly deployed during the unload- a cargo tank passed the prescribed pressure ing. test, external visual inspection and test, and (d) Monthly inspections and tests. (1) the lining inspection. The markings "2-00 K- The operator must visually inspect EPA27" represent that in February 2000 a each delivery hose assembly at least cargo tank passed the leakage test under once each calendar month the delivery $ 180.407(h)(2). The markings "2-00 K, K- hose assembly is in service. EPA27" represent that in February 2000 a (2) The operator must visually incargo tank passed the leakage test under spect the piping system at least once both $180.407(h)(1) and under EPA Method 27 in 180.407(h)(2). each calendar month the cargo tank is in service. The inspection must include (c) For a cargo tank motor vehicle fusible elements and all components of composed of multiple cargo tanks conthe piping system, including bolts, constructed to the same specification. nections, and seals. which are tested and inspected at the (3) At least once each calendar month same time, one set of test and inspec- a cargo tank is in service, the operator tion markings may be used to satisfy must actuate all emergency discharge the requirements of this section. For a control devices designed to close the cargo tank motor vehicle composed of internal self-closing stop valve to asmultiple cargo tanks constructed to sure that all linkages operate as dedifferent specifications, which are testsigned. appendix A to this part outlines ed and inspected at different intervals, acceptable procedures that may be the test and inspection markings must used for this test. appear in the order of the cargo tank's (4) The operator of a cargo tank must corresponding location, from front to check the internal self-closing stop rear. valve in the liquid discharge opening for leakage through the valve at least [Amdt. 180-2, 56 FR 27879. June 17, 1991, as once each calendar month the cargo amended by Amdt. 180-3. 56 FR 66287, Dec. 20, 1991; 57 FR 45466, Oct. 1. 1992; Amdt. 180-6, 59 tank is in service. On cargo tanks FR 49135, Sept. 26, 1994; Amdt. 180-10, 61 FR equipped with a meter, the meter creep 51343, Oct. 1, 1996; 68 FR 19290, Apr. 18, 2003; 68 test as outlined in appendix B to this FR 52372, Sept. 3, 2003] part or a test providing equivalent accuracy is acceptable. For cargo tanks 1155 § 180.417 49 CFR Ch. I (10-1-06 Edition) that are not equipped with a meter, ap- (g) Rejection criteria. (1) No operator pendix B to this part outlines one acmay use a delivery hose assembly deceptable method that may be used to termined to have any condition identicheck internal self-closing stop valves fied below for unloading liquefied comfor closure. pressed gases. An operator may remove (5) After July 1, 2000, the operator and replace damaged sections or cormust note each inspection in a record. rect defects discovered. Repaired hose That record must include the inspecassemblies may be placed back in servtion date, the name of the person perice if retested successfully in accordforming the inspection, the hose asance with paragraph (f) of this section. sembly identification number, the (i) Damage to the hose cover that excompany name, the date the hose was poses the reinforcement. assembled and tested, and an indica- (1i) Wire braid reinforcement that tion that the delivery hose assembly has been kinked or flattened so as to and piping system passed or failed the permanently deform the wire braid. tests and inspections. A copy of each (iii) Soft spots when not under prestest and inspection record must be resure, bulging under pressure, or loose tained by the operator at its principal outer covering. (iv) Damaged, slipping, or excessively place of business or where the vehicle is housed or maintained until the next worn hose couplings. (v) Loose or missing bolts or fastest of the same type is successfully tenings on bolted hose coupling assemcompleted. blies. (e) Annual hose leakage test. The (2) No operator may use a cargo tank owner of a delivery hose assembly that with a piping system found to have any is not permanently attached to a cargo condition identified in this paragraph tank motor vehicle must ensure that (g)(2) for unloading liquefied comthe hose assembly is annually tested in pressed gases. accordance with § 180.407(h)(4). (i) Any external leak identifiable (f) New or repaired delivery hose assemwithout the use of instruments. blies. Each operator of a cargo tank (ii) Bolts that are loose, missing, or must ensure each new and repaired deseverely corroded. livery hose assembly is tested at a min- (iii) Manual stop valves that will not imum of 120 percent of the hose maxactuate. imum working pressure. (iv) Rubber hose flexible connectors (1) The operator must visually examwith any condition outlined in paraine the delivery hose assembly while it graph (g)(1) (g) of this section. is under pressure. (v) Stainless steel flexible connectors (2) Upon successful completion of the with damaged reinforcement braid. pressure test and inspection, the oper- (vi) Internal self-closing stop valves ator must assure that the delivery hose that fail to close or that permit leakassembly is permanently marked with age through the valve detectable withthe month and year of the test. out the use of instruments. (3) After July 1, 2000, the operator (vii) Pipes or joints that are severely must complete a record documenting corroded. the test and inspection, including the [64 FR 28051, May 24, 1999] date, the signature of the inspector, the hose owner, the hose identification § 180.417 Reporting and record retennumber, the date of original delivery tion requirements. hose assembly and test, notes of any (a) Vehicle certification. (1) Each defects observed and repairs made, and owner of a specification cargo tank an indication that the delivery hose asmust retain the manufacturer's certifisembly passed or failed the tests and cate, the manufacturer's ASME U1A inspections. A copy of each test and indata report, where applicable, and respection record must be retained by lated papers certifying that the specithe operator at its principal place of fication cargo tank identified in the business or where the vehicle is housed documents was manufactured and testor maintained until the next test of the ed in accordance with the applicable same type is successfully completed. specification. This would include any 1156 Pipeline and Hazardous Materials Safety Admin., DOT $ 180.417 certification of emergency discharge plates. Additionally, both the owner control systems required by $173.315(n) and the Registered Inspector must cerof this subchapter or $180.405(m). The tify that the cargo tank fully conforms owner must retain the documents to the specification. The owner must throughout his ownership of the speciretain such documents, as specified in fication cargo tank and for one year this section. thereafter. In the event of a change in (b) Test or inspection reporting. Each ownership, the prior owner must retain person performing a test or inspection non-fading photo copies of these docuas specified in § 180.407 must prepare a ments for one year. written report, in English, in accord- (2) Each motor carrier who uses a ance with this paragraph. specification cargo tank motor vehicle (1) Each test or inspection report must obtain a copy of the manufacturmust include the following informaer's certificate and related papers or tion: the alternative report authorized by (i) Owner's and manufacturer's paragraph (a)(3)(i) or (ii) of this section and retain the documents as specified unique serial number for the cargo in this paragraph (a)(2). A motor cartank; rier who is not the owner of a cargo (ii) Name of cargo tank manufactank motor vehicle must also retain a turer; copy of the vehicle certification report (iii) Cargo tank DOT or MC specificafor as long as the cargo tank motor vetion number; hicle is used by that carrier and for one (iv) MAWP of the cargo tank; year thereafter. The information re- (v) Minimum thickness of the cargo quired by this section must be maintank shell and heads when the cargo tained at the company's principal place tank is thickness tested in accordance of business or at the location where the with § 180.407(d)(4). § 180.407(e)(3), vehicle is housed or maintained. The $ 180.407(f)(3). or $180.407(i): provisions of this section do not apply (vi) Indication of whether the cargo to a motor carrier who leases a cargo tank is lined, insulated, or both; and tank for less than 30 days. (vii) Indication of special service of (3) DOT Specification cargo tanks manthe cargo tank (e.g., transports mateufactured before September 1, 1995-(i) rial corrosive to the tank, dedicated Non-ASME Code stamped cargo tanks-If service, etc.) an owner does not have a manufactur- (2) Each test or inspection report er's certificate for a cargo tank and he must include the following specific inwishes to certify it as a specification formation as appropriate for each indicargo tank, the owner must perform vidual type of test or inspection: appropriate tests and inspections, under the direct supervision of a Reg- (1) Type of test or inspection peristered Inspector, to determine if the formed; cargo tank conforms with the applica- (1i) Date of test or inspection (month ble specification. Both the owner and and year); the Registered Inspector must certify (iii) Listing of all items tested or inthat the cargo tank fully conforms to spected, including information about the applicable specification. The owner pressure relief devices that are remust retain the certificate, as specified moved, inspected and tested or rein this section. placed, when applicable (type of device, (ii) ASME Code Stamped cargo tanks. If set to discharge pressure, pressure at the owner does not have the manufacwhich device opened, pressure at which turer's certificate required by the specdevice re-seated, and a statement of ification and the manufacturer's data disposition of the device (e.g., rereport required by the ASME, the installed, repaired, or replaced)); inforowner may contact the National Board mation regarding the inspection of for a copy of the manufacturer's data upper coupler assemblies, when applireport, if the cargo tank was registered cable (visually examined in place. or with the National Board, or copy the removed for examination); and, inforinformation contained on the cargo mation regarding leakage and pressure tank's identification and ASME Code testing, when applicable (pneumatic or 1157 $ 180.417 49 CFR Ch. I (10-1-06 Edition) hydrostatic testing method, identificato indicate the location of defects detion of the fluid used for the test, test tected, such as in weld, heat-affected pressure, and holding time of test); zone, the liquid phase, the vapor phase, (iv) Location of defects found and or the head-to-shell seam. If no defect method of repair; or damage was discovered, that fact (v) ASME or National Board Certifimust be reported; cate of Authorization number of facility performing repairs, if applicable; (vii) A statement indicating the (vi) Name and address of person permethods employed to make repairs, forming test; who made the repairs, and the date (vii) Registration number of the fathey were completed. Also, a statement cility or person performing the test; of whether or not the tank was stress (viii) Continued qualification staterelieved after repairs and, if SO, whethment, such as "cargo tank meets the er full or local stress relieving was perrequirements of the DOT specification formed; identified on this report" or "cargo (viii) A statement of the disposition tank fails to meet the requirements of of the cargo tank, such as "cargo tank the DOT specification identified on scrapped" or "cargo tank returned to this report"; service"; and (ix) DOT registration number of the (ix) A statement of whether or not registered inspector; and the cargo tank is used in anhydrous (x) Dated signature of the registered ammonia, liquefied petroleum gas, or inspector and the cargo tank owner. any other service that may cause (3) The owner and the motor carrier, stress corrosion cracking. Also, if the if not the owner, must each retain a cargo tank has been used in anhydrous copy of the test and inspection reports ammonia service since the last report, until the next test or inspection of the a statement indicating whether each same type is successfully completed. This requirement does not apply to a shipment of ammonia was certified by motor carrier leasing a cargo tank for its shipper as containing 0.2 percent fewer than 30 days. water by weight. (c) Additional requirements for Speci- (2) A copy of the report must be refication MC 330 and MC 331 cargo tanks. tained by the carrier at its principal (1) After completion of the pressure place of business during the period the test specified in § 180.407(g)(3). each cargo tank is in the carrier's service motor carrier operating a Specification and for one year thereafter. Upon a MC 330 or MC 331 cargo tank in anhywritten request to, and with the apdrous ammonia, liquefied petroleum proval of, the Field Administrator, Regas, or any other service that may gional Service Center, Federal Motor cause stress corrosion cracking, must Carrier Safety Administration for the make a written report containing the region in which a motor carrier has its following information: principal place of business, the carrier (i) Carrier's name, address of prinmay maintain the reports at a regional cipal place of business, and telephone or terminal office. number; (3) The requirement in paragraph (ii) Complete identification plate (c)(1) of this section does not apply to data required by Specification MC 330 a motor carrier leasing a cargo tank or MC 331, including data required by for less than 30 days. ASME Code; (iii) Carrier's equipment number; (d) Supplying certificates and reports. (iv) A statement indicating whether Each person offering a DOT-specificaor not the tank was stress relieved tion cargo tank for sale or lease must after fabrication; provide the purchaser or lessee a copy (v) Name and address of the person of the cargo tank certificate of compliperforming the test and the date of the ance, records of repair, modification, test; stretching, or rebarrelling: and the (vi) A statement of the nature and semost recent inspection and test reports verity of any defects found. In parmade under this section. Copies of such ticular, Information must be furnished reports must be provided to the lessee 1158 Pipeline and Hazardous Materials Safety Admin., DOT § 180.507 if the cargo tank is leased for more Specification prescribed in the current Other specifications perthan 30 days. Notes mitted regulations [Amdt. 180-2, 54 FR 25032, June 12, 1989, as amended at 55 FR 21038, May 22. 1990; 55 FR 105A200W 105A100W 1 105A200ALW 105A100ALW 1 37069, Sept. 7, 1990; 56 FR 27879, June 17, 1991: 105A300W 58 FR 12905, Mar. 8, 1993; Amdt. 180-2, 59 FR ICC-105, 105A300. 105A400W 105A400. 1786, Jan. 12, 1994: Amdt. 180-10, 61 FR 51343, 105A500W 105A500. Oct. 1, 1996; 63 FR 52850, Oct. 1, 1998; 64 FR 105A600W 105A600. 28052, May 24, 1999; 65 FR 50463, Aug. 18, 2000; 106A500X 67 FR 61016, Sept. 27, 2002: 68 FR 19290, Apr. ICC-27, BE-27, 106A500. 106A800X 106A800. 18, 2003; 68 FR 52372, Sept. 3, 2003; 69 FR 54047, 107A 2 Sept. 7, 2004; 70 FR 34077, June 13, 2005] NOTE 1: Tanks bulli as Specification DOT 105A100W or DOT 105A100ALW may be altered and converted to DOT Subpart F-Qualification and 105A200W and DOT 105A200ALW, respectively. Maintenance of Tank Cars NOTE 2: The test pressures of tanks built in the United States between January 1, 1941 and December 31, 1955, may be increased to conform to Specification 107A. Original and revised test pressure markings must be indicated and SOURCE: Amdt. 180-8, 60 FR 49079, Sept. 21, may be shown on the tank or on a plate attached to the bulk- 1995, unless otherwise noted. head of the car. Tanks built before 1941 are not authorized. § 180.501 Applicability. (2) For each tank car conforming to and used under an exemption issued be- (a) This subpart prescribes requirefore October 1, 1984, which authorized ments, in addition to those contained in parts 107, 171, 172, 173, and 179 of this the transportation of a cryogenic liqsubchapter, applicable to any person uid in a tank car, the owner or operwho manufactures, fabricates, marks, ator shall remove the exemption nummaintains, repairs, inspects, or services ber stenciled on the tank car and tank cars to ensure continuing qualistamp the tank car with the approfication. priate Class DOT-113 specification fol- (b) Any person who performs a funclowed by the applicable exemption tion prescribed in this part shall pernumber. For example: DOT-113D60W-E form that function in accordance with (asterisks to be replaced by the this part. exemption number). The owner or oper- [Amdt. 180-8, 60 FR 49079, Sept. 21, 1995, as ator marking a tank car in this manamended by Amdt. 179-50. 61 FR 33256, June ner shall retain on file a copy of the 26, 1996] last exemption in effect during the period the tank car is in service. No per- § 180.503 Definitions. son may modify a tank car marked The definitions contained in §§ 171.8 under this paragraph unless the modiand 179.2 of this subchapter apply. fication is in compliance with an applicable requirement or provision of this $ 180.505 Quality assurance program. subchapter. The quality assurance program re- (3) Specification DOT-113A175W, quirements of $179.7 of this subchapter DOT-113C60W, DOT-113D60W, and DOTapply. 113D120W tank cars may continue in use, but new construction is not au- $ 180.507 Qualification of tank cars. thorized. (a) Each tank car marked as meeting (4) Class DOT 105A and 105S tank cars a "DOT" specification or any other used to transport hydrogen chloride, tank car used for the transportation of refrigerated liquid under the terms of a hazardous material must meet the re- DOT-E 3992 may continue in service, quirements of this subchapter or the but new construction is not authorized. applicable specification to which the (5) Specification DOT-103A-ALW, tank was constructed. 103AW, 103ALW, 103ANW, 103BW, (b) Tank car specifications no longer 103CW, 103DW, 103EW. and 104W tank authorized for construction. (1) Tank cars prescribed in the following table cars may continue in use, but new construction is not authorized. are authorized for service provided they conform to all applicable safety [Amdt. 180-8, 60 FR 49079, Sept. 21. 1995, as requirements of this subchapter: amended at 68 FR 48572, Aug. 14, 2003] 1159 § 180.509 49 CFR Ch. I (10-1-06 Edition) § 180.509 Requirements for inspection ment (i.e., filling and discharge, ventand test of specification tank cars. ing, safety, heating, and measuring de- (a) General. (1) Each tank car facility vices). shall evaluate a tank car according to (ii) For non-lined or non-coated tank the requirements specified in $ 180.511. cars transporting materials corrosive (2) Each tank car that successfully to the tank, an interval based on the passes a periodic inspection and test following formula, but in no case shall must be marked as prescribed in the interval exceed 10 years for the $180.515. tank and 5 years for service equipment: (3) A written report as specified in $180.517(b) must be prepared for each / = 4-12 tank car that is inspected and tested r under this section. Where: (b) Conditions requiring inspection and i is the inspection and test interval. test of tank cars. Without regard to any t₁ is the actual thickness. other periodic inspection and test re- t₂ is the allowable minimum thickness under quirements, a tank car must have an paragraph (g) of this section. appropriate inspection and test accord- I is the corrosion rate per year. ing to the type of defect and the type of maintenance or repair performed if: (iii) For lined or coated tank cars (1) The tank car shows evidence of transporting a material corrosive to abrasion, corrosion, cracks, dents, disthe tank, every 10 years for the tank, 5 tortions, defects in welds, or any other years for the service equipment. condition that makes the tank car un- (A) When a lining or coating is apsafe for transportation. An example is plied to protect the tank shell from the if maintenance is performed to replace lading, the owner of the lining or coat- a fitting, then only a leakage pressure ing shall determine the periodic inspectest needs to be performed. tion interval, test technique, and ac- (2) The tank car was in an accident ceptance criteria for the lining or coatand damaged to an extent that may ading. The owner must maintain at its versely affect its capability to retain principal place of business all supits contents. porting documentation used to make (3) The tank bears evidence of damsuch a determination, such as the linage caused by fire. ing or coating manufacturer's rec- (4) The Associate Administrator for ommended inspection interval, test Safety, FRA, requires it based on the technique, and acceptance criteria. The existence of probable cause that a tank supporting documentation must be car or a class or design of tank cars made available to FRA upon request. may be in an unsafe operating condi- (B) The owner of the lining or coattion. ing shall provide the periodic inspec- (c) Frequency of inspection and tests. tion interval, test technique, and ac- Each tank car shall have an inspection ceptance criteria for the lining or coatand test according to the requirements ing to the person responsible for qualiof this paragraph. fying the lining and coating. (1) For Class 107 tank cars and tank (d) Visual inspection. At a minimum, cars of riveted construction, the tank each tank car facility must visually incar must have a hydrostatic pressure spect the tank externally and intertest and visual inspection conforming nally as follows: to the requirements in effect prior to (1) An internal inspection of the tank July 1, 1996, for the tank specification. shell and heads for abrasion, corrosion, (2) For Class DOT 113 tank cars, see cracks, dents, distortions, defects in $173.319(e) of this subchapter. welds, or any other condition that (3) For fusion welded tank cars, each makes the tank car unsafe for transtank car must have an inspection and portation, and except in the areas test in accordance with paragraphs (d) where insulation or a thermal protecthrough (k) of this section. tion system precludes it, an external (1) For cars transporting materials inspection of the tank shell and heads not corrosive to the tank, every 10 for abrasion, corrosion, cracks, dents, years for the tank and service equipdistortions, defects in welds, or any 1160 Pipeline and Hazardous Materials Safety Admin., DOT § 180.509 other condition that makes the tank (1) Dye penetrant test; car unsafe for transportation: (2) Radiography test; (2) An inspection of the piping, (3) Magnetic particle test; valves, fittings, and gaskets for indica- (4) Ultrasonic test; or tions of corrosion and other conditions (5) Optically-aided visual inspection that make the tank car unsafe for (e.g., magnifiers, fiberscopes, transportation; borescopes, and machine vision tech- (3) An inspection for missing or loose nology). bolts, nuts, or elements that make the (f) Thickness tests. (1) Each tank car tank car unsafe for transportation; facility shall measure the thickness of (4) An inspection of all closures on the tank car shell, heads, sumps, the tank car for proper securement in a domes, and nozzles on each tank car by tool tight condition and an inspection using a device capable of accurately of the protective housings for proper measuring the thickness to within +0.05 securement; mm (±0.002 inch). (5) An inspection of excess flow (2) After repairs, alterations, convervalves having threaded seats for tightsions or modifications of a tank car ness; and that result in a reduction to the tank (6) An inspection of the required car shell thickness, the tank car facilmarkings on the tank car for legibility. ity shall measure the thickness of the (e) Structural integrity inspections and tank car shell in the area of reduced tests. At a minimum, each tank car fashell thickness to ensure that the shell cility shall inspect the tank car for thickness conforms to paragraph (g) of structural integrity as specified in this this section. section. The structural integrity in- (g) Service life shell thickness allowspection and test shall include all ance. (1) A tank car found with a shell transverse fillet welds greater than 0.64 thickness below the required minimum cm (0.25 inch) within 121.92 cm (4 feet) thickness after forming for its speciof the bottom longitudinal center line; fication, as stated in part 179 of this the termination of longitudinal fillet subchapter. may continue in service if: welds greater than 0.64 cm (0.25 inch) (i) Construction of the tank car shell within 121.92 cm (4 feet) of the bottom and heads is from carbon steel, stainlongitudinal center line; and all tank less steel, aluminum, nickel, or manshell butt welds within 60.96 cm (2 feet) ganese-molybdenum steel; and of the bottom longitudinal center line (ii) Any reduction in the required by one or more of the following inspecminimum thickness of the tank shell tion and test methods to determine or head is not more than that provided that the welds are in proper condition: in the following table: ALLOWABLE SHELL THICKNESS REDUCTIONS Class DOT 103, 104, 111, and 115 tank cars Class DOT 105, 109, 112, and 114 tank cars Damage type Top shell and tank Bottom shell Top shell and tank Bottom shell head head Corrosion 3.17 mm (0.125 inch) 1.58 mm (0.063 inch) 0.79 mm (0.031 inch) 0.79 mm (0.031 inch). Corrosion and mechanical 3.17 mm (0.125 inch) 1.58 mm (0.063 inch) 0.79 mm (0.031 inch) 0.79 mm (0.031 inch). Corrosion, local 4.76 mm (0.188 inch) 3.17 mm (0.125 inch) 1.58 mm (0.063 Inch) 1.58 mm (0.063 inch). Mechanical, local 3.17 mm (0.125 inch) 1.58 mm (0.063 inch) 1.58 mm (0.063 inch) 1.58 mm (0.063 inch). Corrosion and mechan- 4.76 mm (0.188 inch) 3.17 mm (0.125 inch) 1.58 mm (0.063 inch) 1.58 mm (0.063 inch). lical, local. NOTES: 1. The perimeter for a local reduction may not exceed a 60.96 cm (24 inch) perimeter. Local reductions in the top shell must be separated from other reductions in the top shell by at least 40.64 cm (16 inches). The cumulative perimeter for local reductions In the bottom shell may not exceed 182.88 cm (72 inches). 2. Any reduction in the tank car shell may not affect the structural strength of the tank car so that the tank car shell no longer conforms to Section 6.2 of the AAR Specifications for Tank Cars (IBR, see $ 171.7 of this subchapter). 3. Any reduction applies only to the outer shell for Class DOT 115 tank cars. 4. For Class DOT 103 and 104 tank cars, the inside diameter may not exceed 243.84 cm (96 inches). (h) Safety system inspections. At a (1) Tank car thermal protection sysminimum, each tank car facility must terns, tank head puncture resistance inspect: 1161 § 180.511 49 CFR Ch. I (10-1-06 Edition) systems, coupler vertical restraint sysroads Tank Car Committee and aptems, and systems used to protect disproved by the Associate Administrator continuities (i.e., skid protection and for Safety, FRA. protective housings) to ensure their in- (1) Inspection and test compliance date tegrity. for tank cars. (1) After July 1, 2000, each (2) Reclosing pressure relief devices tank car with a metal jacket or with a by: thermal protection system shall have (i) Removing the reclosing pressure an inspection and test conforming to relief device from the tank car for inthis section no later than the date the spection; and tank car requires a periodic hydro- (11) Testing the reclosing pressure restatic pressure test (i.e., the marked lief device with air or another gas to due date on the tank car for the hydroensure that it conforms to the start-tostatic test). discharge pressure for the specification (2) After July 1, 1998, each tank car or hazardous material in this subwithout a metal jacket shall have an chapter. inspection and test conforming to this (i) Lining and coating inspection and section no later than the date the tank test. When this subchapter requires a car requires a periodic hydrostatic lining or coating, at a minimum, each pressure test (i.e., the marked due date tank car facility must inspect the linon the tank car for the hydrostatic ing or coating installed on the tank car test). according to the inspection interval (3) For tank cars on a 20-year peritest technique, and acceptance criteria odic hydrostatic pressure test interval established by the owner of the lining (i.e., Class DOT 103W, 104W, 111A60W1, or coating in accordance with para- 111A100W1, and 111A100W3 tank cars), graph (c)(3)(iii) of this section. the next inspection and test date is the (j) Leakage pressure test. (1) After remidpoint between the compliance date assembly of a tank car or service in paragraph (1)(1) or (2) of this section equipment, a tank car facility must and the remaining years until the tank perform a leak test on the tank or would have had a hydrostatic pressure service equipment to detect leakage, if test. any, between manway covers, cover [Amdt. 180-8, 60 FR 49079, Sept. 21, 1995, as plates, and service equipment. The test amended by Amdt. 179-50, 61 FR 33256, June may be conducted with the hazardous 26. 1996; 62 FR 51561, Oct. 1, 1997; 63 FR 52851, material in the tank. When the test Oct. 1, 1998; 66 FR 45391, Aug. 28, 2001; 68 FR pressure exceeds the start-to-discharge 75765, Dec. 31, 2003; 71 FR 54398, Sept. 14, 2006] or burst pressure of a pressure relief device, the device must be rendered in- § 180.511 Acceptable results of inspecoperative. The written procedures and tions and tests. test method for leak testing must en- Provided it conforms with other apsure for the sensitivity and reliability plicable requirements of this subof the test method and for the servicechapter, a tank car is qualified for use ability of components to prevent preif it successfully passes the following mature failure. inspections and tests conducted in ac- (2) Interior heater systems must be cordance with this subpart: tested hydrostatically at 13.87 Bar (200 (a) Visual inspection. A tank car sucpsig) and must show no signs of leakcessfully passes the visual inspection age. when the inspection shows no struc- (k) Alternative inspection and test protural defect that may cause leakage cedures. In lieu of the other requirefrom or failure of the tank before the ments of this section, a person may use next inspection and test interval. an alternative inspection and test pro- (b) Structural integrity inspection and cedure or interval based on a damagetest. A tank car successfully passes the tolerance fatigue evaluation (that instructural integrity inspection and test cludes a determination of the probable when it shows no structural defect that locations and modes of damage due to may initiate cracks or propagate fatigue, corrosion, or accidental damcracks and cause failure of the tank beage), when the evaluation is examined fore the next inspection and test interby the Association of American Railval. 1162 Pipeline and Hazardous Materials Safety Admin., DOT § 180.517 (c) Service life shell thickness. A tank $ 180.515 Markings. car successfully passes the service life (a) When a tank car passes the reshell thickness inspection when the quired inspection and test with accepttank shell and heads show no thickness able results, the tank car facility shall reduction below that allowed in mark the date of the inspection and § 180.509(g). test and the due date of the next in- (d) Safety system inspection. A tank spection and test on the tank car in accar successfully passes the safety syscordance with appendix C of the AAR tem inspection when each thermal pro- Specifications for Tank Cars (IBR, see tection system, tank head puncture re- $171.7 of this subchapter). When a tank sistance system, coupler vertical recar facility performs multiple inspecstraint system, and system used to protion and test at the same time, one tect discontinuities (e.g., breakage date may be used to satisfy the regrooves on bottom outlets and protecquirements of this section. One date tive housings) on the tank car conform also may be shown when multiple into this subchapter. spection and test have the same due date. (e) Lining and coating inspection. A (b) Pressure converted tank cars tank car successfully passes the lining must have the new specification and and coating inspection and test when conversion date permanently marked the lining or coating conforms to the in letters and figures at least 0.95 cm owner's acceptance criteria. (0.375 inch) high on the outside of the (f) Leakage pressure test. A tank car manway nozzle or the edge of the successfully passes the leakage presmanway nozzle flange on the left side sure test when all product piping, fitof the car. The marking may have the tings and closures show no indication last numeral of the specification numof leakage. ber omitted (e.g., "DOT 111A100W" in- (g) Hydrostatic test. A Class 107 tank stead of "DOT 111A100W1"). car or a riveted tank car successfully (c) When pressure tested within six passes the hydrostatic test when it months of installation and protected shows no leakage, distortion, excessive from deterioration, the test date markpermanent expansion, or other eviing of a reclosing pressure relief device dence of weakness that might render is the installation date on the tank the tank car unsafe for transportation car. service. [Amdt. 180-8, 60 FR 49079. Sept. 21, 1995, as amended by Amdt. 179-50, 61 FR 33256, June [Amdt. 180-8, 60 FR 49079, Sept. 21, 1995. as 26, 1996; 63 FR 52851, Oct. 1, 1998; 66 FR 45391, amended by Amdt. 179-50. 61 FR 33256, June Aug. 28, 2001; 68 FR 75765, Dec. 31, 2003] 26, 1996; 66 FR 45187, Aug. 28, 2001] § 180.517 Reporting and record reten- § 180.513 Repairs, alterations, convertion requirements. sions, and modifications. (a) Certification and representation. (a) In order to repair tank cars, the Each owner of a specification tank car tank car facility must comply with the shall retain the certificate of construcrequirements of appendix R of the AAR tion (AAR Form 4-2) and related papers Specifications for Tank Cars (IBR, see certifying that the manufacture of the $171.7 of this subchapter). specification tank car identified in the (b) Unless the exterior tank car shell documents is in accordance with the or interior tank car jacket has a proapplicable specification. The owner tective coating, after a repair that reshall retain the documents throughout quires the complete removal of the the period of ownership of the specitank car jacket, the exterior tank car fication tank car and for one year shell and the interior tank car jacket thereafter. Upon a change of ownermust have a protective coating applied ship, the requirements in Section 1.3.15 of the AAR Specifications for Tank to prevent the deterioration of the Cars (IBR, see $171.7 of this subchapter) tank shell and tank Jacket. apply. [Amdt. 180-2, 54 FR 25032, June 12, 1989, as (b) Inspection and test reporting. Each amended at 68 FR 75765, Dec. 31, 2003] tank car that is inspected as specified 1163 $ 180.519 49 CFR Ch. I (10-1-06 Edition) in $180.509 must have a written report, (b) Pressure test. (1) Each tank must in English, prepared according to this be subjected to the specified hydroparagraph. The owner must retain a static pressure and its permanent excopy of the inspection and test reports pansion determined. Pressure must be until successfully completing the next maintained for 30 seconds and for as inspection and test of the same type. long as necessary to secure complete The inspection and test report must inexpansion of the tank. Before testing, clude the following: the pressure gauge must be shown to be (1) Type of inspection and test peraccurate within 1 percent at test measformed (a checklist is acceptable); (2) The results of each inspection and ure. The expansion gauge must be test performed; shown to be accurate, at test pressure, (3) Owner's reporting mark; to within 1 percent. Expansion must be (4) DOT Specification: recorded in cubic cm. Permanent volu- (5) Inspection and test date (month metric expansion may not exceed 10 and year); percent of total volumetric expansion (6) Location and description of deat test pressure and the tank must not fects found and method used to repair leak or show evidence of distress. each defect; (2) Each tank, except tanks built to (7) The name and address of the tank specification DOT 107A, must also be car facility and the signature of inspecsubjected to interior air pressure test tor. of at least 100 psig under conditions fa- [Amdt. 180-2, 54 FR 25032, June 12, 1989, as vorable to detection of any leakage. No amended at 68 FR 75765, Dec. 31, 2003] leaks may appear. (3) Safety relief valves must be re- § 180.519 Periodic retest and inspection of tank cars other than singletested by air or gas, must start-to-disunit tank car tanks. charge at or below the prescribed pressure and must be vapor tight at or (a) General. Unless otherwise proabove the prescribed pressure. vided in this subpart, tanks designed to be removed from cars for filling and (4) Rupture discs and fusible plugs emptying and tanks built to a Class must be removed from the tank and DOT 107A specification and their safety visually inspected. relief devices must be retested periodi- (5) Tanks must be retested as specically as specified in Retest Table 1 of fied in Retest Table 1 of this paragraph paragraph (b)(5) of this section. Retests (b)(5). and before returning to service may be made at any time during the after repairs involving welding or heat calendar year the retest falls due. treatment: RETEST TABLE 1 Retest interval-years Minimum Retest Pressure relief valve pressure-psig pressure-psig Specification Pressure re- Tank Tank hydro- Start-tolief devices static Tank air test discharge Vapor tight expansion DOT 27 5 2 500 100 375 300 106A500 5 2 500 100 375 300 106A500X 5 2 500 100 375 300 106A800 5 2 800 100 600 480 106A800X 5 2 800 100 600 480 106A800NCI 5 2 800 100 600 480 107A d5 "2 (b) None None None 110A500-W 5 2 500 100 375 300 110A600-W 5 2 600 100 500 360 110A800-W 5 2 800 100 600 480 110A1000-W 5 2 1,000 100 750 600 BE-27 5 2 500 100 375 300 NOTES: If DOT 107A tanks are used for transportation of flammable gases, one rupture disc from each car must be burst at the interval prescribed. The sample disc must burst at a pressure not exceeding the marked test pressure of the tank and not less than 70 percent of the marked test pressure. If the sample disc does not burst within the prescribed limits, all discs on the car must be replaced. bThe hydrostatic expansion test pressure must at least equal the marked test pressure. 1164 Pipeline and Hazardous Materials Safety Admin., DOT $ 180.603 =See $ 180.519(b)(1). "Safety relief valves of the spring-loaded type on tanks used exclusively for fluorinated hydrocarbons and mixtures thereof which are free from corroding components may be relested every 5 years. (6) The month and year of test, folson conducting the retest or inspeclowed by a "V" if visually inspected as tion. described in paragraph (c) of this sec- [Amdt. 180-8, 60 FR 49079. Sept. 21, 1995, as tion, must be plainly and permanently amended by Amdt. 179-50, 61 FR 33257, June stamped into the metal of one head or 26, 1996: 65 FR 58633, Sept. 29, 2000; 66 FR chime of each tank with successful test 45187, 45392, Aug. 28, 2001; 68 FR 75765, Dec. 31, results; for example, 01-90 for January 2003] 1990. On DOT 107A**** tanks, the date must be stamped into the metal of the Subpart G-Qualification and marked end, except that if all tanks Maintenance of Portable Tanks mounted on a car have been tested, the date may be stamped into the metal of SOURCE: 66 FR 33453, June 21, 2001. unless a plate permanently applied to the otherwise noted. bulkhead on the "A" end of the car. Dates of previous tests and all pre- § 180.601 Applicability. scribed markings must be kept legible. This subpart prescribes require- (c) Visual inspection. Tanks of Class ments, in addition to those contained DOT 106A and DOT 110A-W specificain parts 107, 171, 172, 173, and 178 of this tions 179.300 and 179.301 of this subsubchapter, applicable to any person chapter) used exclusively for transresponsible for the continuing qualiporting fluorinated hydrocarbons and fication, maintenance or periodic remixtures thereof, and that are free testing of a portable tank. from corroding components, may be given a periodic complete internal and $ 180.603 Qualification of portable external visual inspection in place of tanks. the periodic hydrostatic retest. Visual (a) Each portable tank used for the inspections shall be made only by comtransportation of hazardous materials petent persons. The tank must be acmust be an authorized packaging. cepted or rejected in accordance with (b) To qualify as an authorized packthe criteria in CGA C-6 (IBR, see § 171.7 aging, each portable tank must conof this subchapter). form to the requirements of this sub- (d) Written records. The results of the chapter and the applicable design specpressure test and visual inspection ification to which the portable tank must be recorded on a suitable data was constructed. sheet. Completed copies of these re- (c) The following portable tanks are ports must be retained by the owner authorized for use provided they conand by the person performing the presform to all applicable safety requiresure test and visual inspection as long ments of this subchapter: 51, 56, 57, 60, as the tank is in service. The informa- IM 101, IM 102 and UN portable tanks. tion to be recorded and checked on (d) A portable tank that also meets these data sheets are: Date of test and the definition of "container" in 49 CFR inspection; DOT specification number; 450.3(a)(3) must conform to the requiretank identification (registered symbol ments in parts 450 through 453 of this and serial number, date of manufacture title for compliance with Annex II of and ownership symbol): type of protecthe Convention for Safe Containers tive coating (painted, etc., and state- (CSC). ment as to need for refinishing or re- (e) Exemption portable tanks based on coating); conditions checked (leakage, DOT 51 portable tanks. The owner of a corrosion, gouges, dents or digs, broken portable tank constructed in accordor damaged chime or protective ring, ance with and used under an exemption fire, fire damage, internal condition); issued prior to August 31, 1996, which test pressure; results of tests; and diswas in conformance with the requireposition of tank (returned to service, ments for Specification DOT 51 portreturned to manufacturer for repair, or able tanks with the exception of the loscrapped); and identification of the percation of fill and discharge outlets, 1165 $ 180.605 49 CFR Ch. I (10-1-06 Edition) shall examine the portable tank and its tank must be tested and inspected in design to determine if it meets the outaccordance with the following schedlet requirements in effect on October 1. ule: 1996. If the owner determines that the (1) Each IM or UN portable tank portable tank is in compliance with all must be given an initial inspection and requirements of the DOT 51 specificatest before being placed into service, a tion, the exemption number stenciled periodic inspection and test at least on the portable tank shall be removed once every 5 years, and an interand the specification plate (or a plate mediate periodic inspection and test at placed adjacent to the specification least every 2.5 years following the iniplate) shall be durably marked "DOT tial inspection and the last 5 year peri- (where ***** is to be reodic inspection and test. placed by the exemption number). Dur- (2) Each Specification 51 portable ing the period the portable tank is in tank must be given a periodic inspecservice, and for one year thereafter, tion and test at least once every five the owner of the portable tank must years. retain on file, at its principal place of (3) Each Specification 56 or 57 portbusiness, a copy of the last exemption able tank must be given a periodic inin effect. spection and test at least once every 2.5 years. § 180.605 Requirements for periodic (4) Each Specification 60 portable testing, inspection and repair of tank must be given a periodic inspecportable tanks. tion and test at the end of the first 4- (a) A portable tank constructed in year period after the original test; at accordance with a DOT specification least once every 2 years thereafter up for which a test or inspection specified to a total of 12 years of service; and at in this subpart has become due, must least once annually thereafter. Rebe tested or inspected prior to being retesting is not required on a rubberturned for transportation. lined tank except before each relining. (b) Conditions requiring test and inspec- (d) Intermediate periodic inspection and tion of portable tanks. Without regard to test. For IM and UN portable tanks the any other test or inspection requireintermediate 2.5 year periodic inspecments, a Specification or UN portable tion and test must include at least an tank must be tested and inspected in internal and external examination of accordance with this section prior to the portable tank and its fittings takfurther use if any of the following coning into account the hazardous mateditions exist: rials intended to be transported; a (1) The portable tank shows evidence leakage test; and a test of the satisfacof dents, corroded or abraded areas, tory operation of all service equipleakage, or any other condition that ment. Sheathing. thermal insulation, might render it unsafe for transporetc. need only be removed to the extent tation service. required for reliable appraisal of the (2) The portable tank has been in an condition of the portable tank. For accident and has been damaged to an portable tanks intended for the transextent that may adversely affect its portation of a single hazardous mateability to retain the hazardous material, the internal examination may be rial. waived if it is leakage tested in accord- (3) The portable tank has been out of ance with the procedures in paragraph hazardous materials transportation (h) of this section prior to each filling, service for a period of one year or or if approved by the Associate Adminmore. istrator. Portable tanks used for dedi- (4) The portable tank has been modicated transportation of refrigerated fied from its original design specificaliquefied gases that are not fitted with tion. inspection openings are excepted from (5) The portable tank is in an unsafe the internal inspection requirement. operating condition based on the exist- (e) Periodic inspection and test. The 5 ence of probable cause. year periodic inspection and test must (c) Schedule for periodic inspections include an internal and external examand tests. Each Specification portable ination and, unless excepted, a pressure 1166 Pipeline and Hazardous Materials Safety Admin., DOT § 180.605 test as specified in this section. fects, and other conditions, including Sheathing. thermal insulation, etc. leakage. that might render the portneed only to be removed to the extent able tank unsafe for filling. discharge required for reliable appraisal of the or transportation; condition of the portable tank. Except (3) Devices for tightening manhole for DOT Specification 56 and 57 portcovers are operative and there is no able tanks, reclosing pressure relief deleakage at manhole covers or gaskets; vices must be removed from the tank (4) Missing or loose bolts or nuts on and tested separately unless they can any flanged connection or blank flange be tested while installed on the portare replaced or tightened; able tank. For portable tanks where (5) All emergency devices and valves the shell and equipment have been are free from corrosion, distortion and pressure-tested separately, after asany damage or defect that could presembly they must be subjected tovent their normal operation. Remote gether to a leakage test and effectively tested and inspected for corrosion. closure devices and self-closing stop- Portable tanks used for the transporvalves must be operated to demtation of refrigerated, liquefied gases onstrate proper operation; are excepted from the requirement for (6) Required markings on the portinternal inspection and the hydraulic able tank are legible and in accordance pressure test during the 5-year periodic with the applicable requirements; and inspection and test, if the portable (7) The framework, the supports and tanks were pressure tested to a minthe arrangements for lifting the portimum test pressure of 1.3 times the deable tank are in satisfactory condition. sign pressure using an inert gas as pre- (h) Pressure test procedures for speciscribed in §178.338-16(a) and (b) of this fication 51, 57, 60, IM or UN portable subchapter before putting the portable tanks. (1) Each Specification 57 porttank into service initially and after able tank must be leak tested by a any exceptional inspections and tests minimum sustained air pressure of at specified in paragraph (f) of this secleast 3 psig applied to the entire tank. tion. Each Specification 51 or 56 portable (f) Exceptional inspection and test. The tank must be tested by a minimum exceptional inspection and test is necpressure (air or hydrostatic) of at least essary when a portable tank shows evi- 2 psig or at least one and one-half dence of damaged or corroded areas, or times the design pressure (maximum leakage, or other conditions that indiallowable working pressure, or re-rated cate a deficiency that could affect the pressure) of the tank, whichever is integrity of the portable tank. The exgreater. The leakage test for portable tent of the exceptional inspection and tanks used for refrigerated liquefied test must depend on the amount of gas must be performed at 90% of damage or deterioration of the portable MAWP. Leakage tests for all other tank. It must include at least the inportable tanks must be at a pressure of spection and a pressure test according at least 25% of MAWP. During each air to paragraph (e) of this section. Prespressure test, the entire surface of all sure relief devices need not be tested or joints under pressure must be coated replaced unless there is reason to bewith or immersed in a solution of soap lieve the relief devices have been afand water, heavy oil, or other material fected by the damage or deterioration. suitable for the purpose of detecting (g) Internal and external examination. leaks. The pressure must be held for a The internal and external examinaperiod of time sufficiently long to astions must ensure that: sure detection of leaks, but in no case (1) The shell is inspected for pitting, less than five minutes. During the air corrosion, or abrasions, dents, distoror hydrostatic test, relief devices may tions, defects in welds or any other be removed, but all the closure fittings conditions, including leakage, that must be in place and the relief device might render the portable tank unsafe openings plugged. Lagging need not be for transportation; removed from a lagged tank If it is pos- (2) The piping, valves, and gaskets sible to maintain the required test are inspected for corroded areas, depressure at constant temperature with 1167 § 180.605 49 CFR Ch. I (10-1-06 Edition) the tank disconnected from the source to be transported in the portable of pressure. tanks. For liquid, solid and non-refrig- (2) Each Specification 60 portable erated liquefied gases, the minimum tank must be retested by completely test pressure for specific hazardous mafilling the tank with water or other liqterials are specified in the applicable T uid having a similar viscosity, the tem- Codes assigned to a particular hazperature of the liquid must not exceed ardous material in the $172.101 Table of 37.7 °C (100 °F) during the test, and apthis subchapter. While under pressure plying a pressure of 60 psig. The portthe tank shall be inspected for leakage, able tank must be capable of holding distortion, or any other condition the prescribed pressure for at least 10 which might render the tank unsafe for minutes without leakage, evidence of service. A portable tank fails to meet impending failure, or failure. All clothe requirements of the pressure test sures shall be in place while the test is if, during the test, there is permanent made and the pressure shall be gauged distortion of the tank exceeding that at the top of the tank. Safety devices permitted by the applicable specificaand/or vents shall be plugged during tion; if there is any leakage; or if there this test. are any deficiencies that would render (3) Each Specification IM or UN portthe portable tank unsafe for transporable tank, except for UN portable tation. Any portable tank that fails tanks used for non-refrigerated and remust be rejected and may not be used frigerated liquefied gases, and all pipagain for the transportation of a hazing, valves and accessories, except ardous material unless the tank is adepressure relief devices, must be quately repaired, and, thereafter, a hydrostatically tested with water, or successful test is conducted in accordother liquid of similar density and visance with the requirements of this cosity, to a pressure not less than 150% paragraph. An approval agency shall of its maximum allowable working witness the hydrostatic or pneumatic pressure. UN portable tanks used for test. Any damage or deficiency that the transportation of non-refrigerated might render the portable tank unsafe liquefied gases must be hydrostatically for service shall be repaired to the sattested with water, or other liquid of isfaction of the witnessing approval similar density and viscosity, to a presagency. The repaired tank must be resure not less than 130% of its maximum tested to the original pressure test reallowable working pressure. UN portquirements. Upon successful compleable tanks used for the transportation tion of the hydrostatic or pneumatic of refrigerated liquefied gases may be test, as applicable. the witnessing aptested hydrostatically or pneumatiproval agency shall apply its name, cally using an inert gas to a pressure identifying mark or identifying numnot less than 1.3 times the design presber in accordance with paragraph (k) of sure. For pneumatic testing, due rethis section. gard for protection of all personnel (i) Rejection criteria. When evidence of must be taken because of the potential any unsafe condition is discovered, the hazard involved in such a test. The portable tank may not be returned to pneumatic test pressure in the portable service until it has been repaired and tank must be reached by gradually inthe pressure test is repeated and creasing the pressure to one-half of the passed. test pressure. Thereafter, the test pres- (j) Repair. The repair of a portable sure must be increased in steps of aptank is authorized, provided such reproximately one-tenth of the test prespairs are made in accordance with the sure until the required test pressure requirements prescribed in the specihas been reached. The pressure must fication for the tank's original design then be reduced to a value equal to and construction. In addition to any four-fifths of the test pressure and held other provisions of the specification, for a sufficient time to permit inspecno portable tank may be repaired so as tion of the portable tank for leaks. The to cause leakage or cracks or so as to minimum test pressure for a portable increase the likelihood of leakage or tank is determined on the basis of the cracks near areas of stress concentrahazardous materials that are intended tion due to cooling metal shrinkage in 1168 Pipeline and Hazardous Materials Safety Admin., DOT Pt. 180, App. B welding operations, sharp fillets, reverby the manufacturer, and the authorsal of stresses, or otherwise. No field ized design approval agency, as appliwelding may be done except to noncable, indicating compliance with the pressure parts. Any cutting, burning or applicable specification of the portable welding operations on the shell of an tank, must be retained in the files of IM or UN portable tank must be done the owner, or his authorized agent, with the approval of the approval agenduring the time that such portable cy and be done in accordance with the tank is used for such service, except for requirements of this subchapter, tak- Specifications 56 and 57 portable tanks. ing into account the pressure vessel [Amdt. 180-2, 54 FR 25032, June 12, 1989, as code used for the construction of the amended at 67 FR 15744, Apr. 3, 2002; 68 FR shell. A pressure test to the original 45042, July 31, 2003) test pressure must be performed after the work is completed. APPENDIX A TO PART 180-INTERNAL (k) Inspection and test markings. (1) SELF-CLOSING STOP VALVE EMER- Each IM or UN portable tank must be GENCY CLOSURE TEST FOR LIQUEFIED durably and legibly marked, in COMPRESSED GASES English, with the date (month and 1. In performing this test, all internal selfyear) of the last pressure test, the idenclosing stop valves must be opened. Each tification markings of the approval emergency discharge control remote actuagency witnessing the test, when reator (on-truck and off-truck) must be operquired, and the date of the last visual ated to ensure that each Internal self-closing inspection. The marking must be stop valve's lever, piston, or other valve indiplaced on or near the metal identificacator has moved to the closed position. tion plate, in letters and numerals of 2. On pump-actuated pressure differential Internal valves, the three-way toggle valve not less than 3 mm (0.118 inches) high handle or its cable attachment must be actiwhen on the metal identification plate, vated to verify that the toggle handle moves and 12 mm (0.47 inches) high when on to the closed position. the portable tank. [64 FR 28052. May 24, 1999. as amended at 67 (2) Each Specification DOT 51, 56, 57 FR 15744, Apr. 3, 2002] or 60 portable tank must be durably and legibly marked, in English, with APPENDIX B TO PART 180-ACCEPTABLE the date (month and year) of the most INTERNAL SELF-CLOSING STOP recent periodic retest. The marking VALVE LEAKAGE TESTS FOR CARGO must be placed on or near the metal TANKS TRANSPORTING LIQUEFIED certification plate and must be in ac- COMPRESSED GASES cordance with $178.3 of this subchapter. The letters and numerals must not be For internal self-closing stop valve leakage testing, leakage is defined as any leakage less than 3 mm (0.118 inches) high when through the internal self-closing valve or to on the metal certification plate, and 12 the atmosphere that is detectable when the mm (0.47 inches) high when on the valve is in the closed position. On some portable tank, except that a portable valves this will require the closure of the tank manufactured under a previously pressure by-pass port. authorized specification may continue (a) Meter Creep Test. to be marked with smaller markings if originally authorized under that speci- 1. An operator of a cargo tank equipped fication (for example, DOT Specificawith a calibrated meter may check the intertion 57 portable tanks). nal self-closing stop valve for leakage through the valve seat using the meter as a (1) Record retention. The owner of each flow measurement indicator. The test is iniportable tank or his authorized agent tiated by starting the delivery process or reshall retain a written record of the turning product to the cargo tank through date and results of all required inspecthe delivery system. This may be performed tions and tests, including an ASME at an idle. After the flow is established, the manufacturer's date report, if applicaoperator closes the internal self-closing stop ble, and the name and address of the valve and monitors the meter flow. The meter flow must stop within 30 seconds with person performing the inspection or no meter creep within 5 seconds after the test, in accordance with the applicable meter stops. specification. The manufacturer's data 2. On pump-actuated pressure differential report, including a certificate(s) signed internal self-closing stop valves, the valve 1169 Pt. 180, App. C 49 CFR Ch. I (10-1-06 Edition) must be closed with the remote actuator to to two threads. The standard reference must assure that it is functioning. On other types have a drawing that includes the diameter of of internal self-closing stop valves, the the ring, and depth and length of each notch. valve(s) may be closed using either the nor- 5. Condemnation Criteria. A cylinder must mal valve control or the discharge control be condemned if the eddy current examinasystem (e.g., remote). tion combined with visual examination re- 3. Rejection criteria: Any detectable meter veals any crack in the neck or shoulder of 2 creep within the first five seconds after inithread lengths or more. tial meter stoppage. 6. Examination equipment records. Records of eddy current inspection equipment shall con- (b) Internal Self-Closing Stop Valve Test. tain the following information: An operator of a cargo tank that is not (i) Equipment manufacturer, model numequipped with a meter may check the interber and serial number. nal self-closing stop valve(s) for leakage as (ii) Probe description and unique identifollows: fication (e.g., serial number, part number, 1. The internal self-closing stop valve must etc.). be in the closed position. 7. Eddy current examination reporting and 2. All of the material in the downstream record retention requirements. Daily records of piping must be evacuated, and the piping eddy current examinations must be mainmust be returned to atmospheric temperatained by the person who performs the reture and pressure. qualification until either the expiration of 3. The outlet must be monitored for 30 secthe requalification period or until the cylonds for detectable leakage. inder is again requalified, whichever occurs 4. Rejection criteria. Any detectable leakfirst. These records shall be made available age is considered unacceptable. for inspection by a representative of the De- [64 FR 28052, May 24. 1999] partment on request. Eddy current examination records shall contain the following in- APPENDIX C TO PART 180-EDDY CURformation: RENT EXAMINATION WITH VISUAL IN- (i) Specification of each standard reference SPECTION FOR DOT 3AL CYLINDERS ring used to perform the eddy current examination. MANUFACTURED OF ALUMINUM (ii) DOT specification or exemption num- ALLOY 6351-T6 ber of the cylinder; manufacturer's name or symbol: owner's name or symbol, if present; 1. Examination Procedure. Each facility perserial number; and, date of manufacture. forming eddy current examination with vis- (iii) Name of test operator performing the ual inspection must develop. update, and eddy current examination. maintain a written examination procedure (iv) Date of eddy current examination. applicable to the test equipment it uses to perform eddy current examinations. (vi) Acceptance/condemnation results (e.g. pass or fail). 2. Visual examinations. Visual examinations (vii) Retester identification number. of the neck and shoulder area of the cylinder must be conducted in accordance with CGA 8. Personnel Qualification Requirements. pamphlet C-6.1 (IBR; see $171.7 of this sub- Each person who performs eddy current and chapter). visual examinations, and evaluates and cer- 3. Eddy Current Equipment. A reference ring tifles retest results must be certified by the and probe for each DOT-3AL cylinder manuemployer that he/she has been properly factured of aluminum alloy 6351-T6 to be intrained and tested in the eddy current and spected must be available at the examinavisual examination procedures. tion facility. Eddy current equipment must 9. Training Records. A record of current be capable of accurately detecting the training must be maintained for each emnotches on the standard reference ring. ployee who performs eddy current and visual 4. Eddy Current Reference Ring. The refexaminations in accordance with $172.704(d). erence ring must be produced to represent [7] FR 51129, Aug. 29, 2006] each cylinder to be tested. The reference ring must include artificial notches to simulate a EFFECTIVE DATE NOTE: At 71 FR 51129, Aug. neck crack. The size of the artificial notch 29, 2006, Appendix C to Part 180 was added, ef- (depth and length) must have a depth less fective Jan. 1, 2007. than or equal to 1/3 of the wall thickness of the neck and a length greater than or equal PARTS 181-185 [RESERVED] 1170