Académique Documents
Professionnel Documents
Culture Documents
Transportation
Parts 178 to 199
As of October 1, 2011
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U.S. GOVERNMENT OFFICIAL EDITION NOTICE
e:\seals\gpologo.eps</GPH>
http://bookstore.gpo.gov
Phone: toll-free (866) 512-1800; DC area (202) 512-1800
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As of October 1, 2011
Title 49, Parts 100 to 185
and
Title 49, Parts 186 to 199
Revised as of October 1, 2010
Is Replaced by
Title 49, Parts 100 to 177
and
Title 49, Parts 178 to 199
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Table of Contents
Page
Explanation ................................................................................................ vii
Title 49:
Finding Aids:
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Cite this Code: CFR
vi
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Explanation
The Code of Federal Regulations is a codification of the general and permanent
rules published in the Federal Register by the Executive departments and agen-
cies of the Federal Government. The Code is divided into 50 titles which represent
broad areas subject to Federal regulation. Each title is divided into chapters
which usually bear the name of the issuing agency. Each chapter is further sub-
divided into parts covering specific regulatory areas.
Each volume of the Code is revised at least once each calendar year and issued
on a quarterly basis approximately as follows:
Title 1 through Title 16..............................................................as of January 1
Title 17 through Title 27 .................................................................as of April 1
Title 28 through Title 41 ..................................................................as of July 1
Title 42 through Title 50 .............................................................as of October 1
The appropriate revision date is printed on the cover of each volume.
LEGAL STATUS
The contents of the Federal Register are required to be judicially noticed (44
U.S.C. 1507). The Code of Federal Regulations is prima facie evidence of the text
of the original documents (44 U.S.C. 1510).
HOW TO USE THE CODE OF FEDERAL REGULATIONS
The Code of Federal Regulations is kept up to date by the individual issues
of the Federal Register. These two publications must be used together to deter-
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To determine whether a Code volume has been amended since its revision date
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EFFECTIVE AND EXPIRATION DATES
Each volume of the Code contains amendments published in the Federal Reg-
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off date for the Code a note has been inserted to reflect the future effective
date. In those instances where a regulation published in the Federal Register
states a date certain for expiration, an appropriate note will be inserted following
the text.
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Many agencies have begun publishing numerous OMB control numbers as amend-
ments to existing regulations in the CFR. These OMB numbers are placed as
close as possible to the applicable recordkeeping or reporting requirements.
OBSOLETE PROVISIONS
Provisions that become obsolete before the revision date stated on the cover
of each volume are not carried. Code users may find the text of provisions in
effect on a given date in the past by using the appropriate numerical list of
sections affected. For the period before April 1, 2001, consult either the List of
CFR Sections Affected, 19491963, 19641972, 19731985, or 19862000, published in
eleven separate volumes. For the period beginning April 1, 2001, a List of CFR
Sections Affected is published at the end of each CFR volume.
[RESERVED] TERMINOLOGY
The term [Reserved] is used as a place holder within the Code of Federal
Regulations. An agency may add regulatory information at a [Reserved] loca-
tion at any time. Occasionally [Reserved] is used editorially to indicate that
a portion of the CFR was left vacant and not accidentally dropped due to a print-
ing or computer error.
INCORPORATION BY REFERENCE
What is incorporation by reference? Incorporation by reference was established
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must approve it. The legal effect of incorporation by reference is that the mate-
rial is treated as if it were published in full in the Federal Register (5 U.S.C.
552(a)). This material, like any other properly issued regulation, has the force
of law.
What is a proper incorporation by reference? The Director of the Federal Register
will approve an incorporation by reference only when the requirements of 1 CFR
part 51 are met. Some of the elements on which approval is based are:
(a) The incorporation will substantially reduce the volume of material pub-
lished in the Federal Register.
(b) The matter incorporated is in fact available to the extent necessary to
afford fairness and uniformity in the administrative process.
(c) The incorporating document is drafted and submitted for publication in
accordance with 1 CFR part 51.
What if the material incorporated by reference cannot be found? If you have any
problem locating or obtaining a copy of material listed as an approved incorpora-
tion by reference, please contact the agency that issued the regulation containing
that incorporation. If, after contacting the agency, you find the material is not
available, please notify the Director of the Federal Register, National Archives
and Records Administration, 8601 Adelphi Road, College Park, MD 20740-6001, or
call 202-741-6010.
CFR INDEXES AND TABULAR GUIDES
A subject index to the Code of Federal Regulations is contained in a separate
volume, revised annually as of January 1, entitled CFR INDEX AND FINDING AIDS.
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This volume contains the Parallel Table of Authorities and Rules. A list of CFR
titles, chapters, subchapters, and parts and an alphabetical list of agencies pub-
lishing in the CFR are also included in this volume.
An index to the text of Title 3The President is carried within that volume.
viii
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The Federal Register Index is issued monthly in cumulative form. This index
is based on a consolidation of the Contents entries in the daily Federal Reg-
ister.
A List of CFR Sections Affected (LSA) is published monthly, keyed to the
revision dates of the 50 CFR titles.
REPUBLICATION OF MATERIAL
There are no restrictions on the republication of material appearing in the
Code of Federal Regulations.
INQUIRIES
For a legal interpretation or explanation of any regulation in this volume,
contact the issuing agency. The issuing agencys name appears at the top of
odd-numbered pages.
For inquiries concerning CFR reference assistance, call 2027416000 or write
to the Director, Office of the Federal Register, National Archives and Records
Administration, 8601 Adelphi Road, College Park, MD 20740-6001 or e-mail
fedreg.info@nara.gov.
SALES
The Government Printing Office (GPO) processes all sales and distribution of
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ELECTRONIC SERVICES
The full text of the Code of Federal Regulations, the LSA (List of CFR Sections
Affected), The United States Government Manual, the Federal Register, Public
Laws, Public Papers of the Presidents of the United States, Compilation of Presi-
dential Documents and the Privacy Act Compilation are available in electronic
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The Office of the Federal Register also offers a free service on the National
Archives and Records Administrations (NARA) World Wide Web site for public
law numbers, Federal Register finding aids, and related information. Connect
to NARAs web site at www.archives.gov/federal-register.
RAYMOND A. MOSLEY,
Director,
Office of the Federal Register.
October 1, 2011.
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THIS TITLE
In the volume containing parts 100177, see 172.101 for the Hazardous Materials
Table. The Federal Motor Vehicle Safety Standards appear in part 571.
For this volume, Susannah C. Hurley was Chief Editor. The Code of Federal
Regulations publication program is under the direction of Michael L. White, as-
sisted by Ann Worley.
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Title 49Transportation
(This book contains parts 178 to 199)
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Subtitle BOther Regulations
Relating to Transportation
(Continued)
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CHAPTER IPIPELINE AND HAZARDOUS
MATERIALS SAFETY ADMINISTRATION,
DEPARTMENT OF TRANSPORTATION
(CONTINUED)
Part Page
178 Specifications for packagings ................................. 7
179 Specifications for tank cars .................................... 257
180 Continuing qualification and maintenance of pack-
agings ................................................................... 315
181189 [Reserved]
190 Pipeline safety programs and rulemaking proce-
dures ..................................................................... 371
191 Transportation of natural and other gas by pipe-
line; annual reports, incident reports, and safety-
related condition reports ..................................... 392
192 Transportation of natural and other gas by pipe-
line: Minimum Federal safety standards ............. 398
193 Liquefied natural gas facilities: Federal safety
standards .............................................................. 512
194 Response plans for onshore oil pipelines ................. 531
195 Transportation of hazardous liquids by pipeline ..... 542
196197 [Reserved]
198 Regulations for grants to aid State pipeline safety
programs .............................................................. 611
199 Drug and alcohol testing ......................................... 614
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PART 178SPECIFICATIONS FOR 178.47 Specification 4DS welded stainless
steel cylinders for aircraft use.
PACKAGINGS 178.50 Specification 4B welded or brazed
steel cylinders.
Sec. 178.51 Specification 4BA welded or brazed
178.1 Purpose and scope. steel cylinders.
178.2 Applicability and responsibility. 178.53 Specification 4D welded steel cyl-
178.3 Marking of packagings. inders for aircraft use.
178.55 Specification 4B240ET welded or
Subpart A [Reserved] brazed cylinders.
178.56 Specification 4AA480 welded steel cyl-
Subpart BSpecifications for Inside inders.
Containers, and Linings 178.57 Specification 4L welded insulated cyl-
178.33 Specification 2P; inner nonrefillable inders.
metal receptacles. 178.58 Specification 4DA welded steel cyl-
178.331 Compliance. inders for aircraft use.
178.332 Type and size. 178.59 Specification 8 steel cylinders with
178.333 Inspection. porous fillings for acetylene.
178.334 Duties of inspector. 178.60 Specification 8AL steel cylinders
178.335 Material. with porous fillings for acetylene.
178.336 Manufacture. 178.61 Specification 4BW welded steel cyl-
178.337 Wall thickness. inders with electric-arc welded longitu-
178.338 Tests. dinal seam.
178.339 Marking. 178.65 Specification 39 non-reusable (non-re-
178.33a Specification 2Q; inner nonrefillable fillable) cylinders.
metal receptacles. 178.68 Specification 4E welded aluminum
178.33a1 Compliance. cylinders.
178.33a2 Type and size. 178.69 Responsibilities and requirements for
178.33a3 Inspection. manufacturers of UN pressure recep-
178.33a4 Duties of inspector. tacles.
178.33a5 Material. 178.70 Approval of UN pressure receptacles.
178.33a6 Manufacture. 178.71 Specifications for UN pressure recep-
178.33a7 Wall thickness. tacles.
178.33a8 Tests.
178.74 Approval of MEGCs.
178.33a9 Marking.
178.33b Specification 2S; inner nonrefillable 178.75 Specifications for MEGCs.
plastic receptacles APPENDIX A TO SUBPART CILLUSTRATIONS:
178.33b1 Compliance. CYLINDER TENSILE SAMPLE
178.33b2 Type and size.
178.33b3 Inspection. Subparts DG [Reserved]
178.33b4 Duties of inspector.
178.33b5 Material. Subpart HSpecifications for Portable
178.33b6 Manufacture. Tanks
178.33b7 Design qualification test.
178.33b8 Production tests. 178.251178.2535 [Reserved]
178.33b9 Marking. 178.255 Specification 60; steel portable
tanks.
Subpart CSpecifications for Cylinders 178.2551 General requirements.
178.2552 Material.
178.35 General requirements for specifica-
178.2553 Expansion domes.
tion cylinders.
178.2554 Closures for manholes and domes.
178.36 Specification 3A and 3AX seamless
178.2555 Bottom discharge outlets.
steel cylinders.
178.37 Specification 3AA and 3AAX seamless 178.2556 Loading and unloading accessories.
steel cylinders. 178.2557 Protection of valves and acces-
178.38 Specification 3B seamless steel cyl- sories.
inders. 178.2558 Safety devices.
178.39 Specification 3BN seamless nickel 178.2559 Compartments.
cylinders. 178.25510 Lining.
178.42 Specification 3E seamless steel cyl- 178.25511 Tank mountings.
inders. 178.25512 Pressure test.
178.44 Specification 3HT seamless steel cyl- 178.25513 Repair of tanks.
178.25514 Marking.
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Pt. 178 49 CFR Ch. I (10111 Edition)
178.275 Specification for UN Portable Tanks 178.33815 Cleanliness.
intended for the transportation of liquid 178.33816 Inspection and testing.
and solid hazardous materials. 178.33817 Pumps and compressors.
178.276 Requirements for the design, con- 178.33818 Marking.
struction, inspection and testing of port- 178.33819 Certification.
able tanks intended for the transpor- 178.340178.343 [Reserved]
tation of non-refrigerated liquefied com- 178.345 General design and construction re-
pressed gases. quirements applicable to Specification
178.277 Requirements for the design, con- DOT 406 ( 178.346), DOT 407 ( 178.347), and
struction, inspection and testing of port- DOT 412 ( 178.348) cargo tank motor vehi-
able tanks intended for the transpor- cles.
tation of refrigerated liquefied gases. 178.3451 General requirements.
178.3452 Material and material thickness.
Subpart I [Reserved] 178.3453 Structural integrity.
178.3454 Joints.
Subpart JSpecifications for Containers for 178.3455 Manhole assemblies.
Motor Vehicle Transportation 178.3456 Supports and anchoring.
178.3457 Circumferential reinforcements.
178.318 Specification MC 201; container for 178.3458 Accident damage protection.
detonators and percussion caps. 178.3459 Pumps, piping, hoses and connec-
178.3181 Scope. tions.
178.3182 Container. 178.34510 Pressure relief.
178.3183 Marking.
178.34511 Tank outlets.
178.320 General requirements applicable to
178.34512 Gauging devices.
all DOT specification cargo tank motor
178.34513 Pressure and leakage tests.
vehicles.
178.34514 Marking.
178.337 Specification MC 331; cargo tank
178.34515 Certification.
motor vehicle primarily for transpor-
178.346 Specification DOT 406; cargo tank
tation of compressed gases as defined in
motor vehicle.
subpart G of part 173 of this subchapter.
178.3461 General requirements.
178.3371 General requirements.
178.3372 Material. 178.3462 Material and thickness of mate-
178.3373 Structural integrity. rial.
178.3374 Joints. 178.3463 Pressure relief.
178.3375 Bulkheads, baffles and ring stiff- 178.3464 Outlets.
eners. 178.3465 Pressure and leakage tests.
178.3376 Closure for manhole. 178.347 Specification DOT 407; cargo tank
178.3377 Overturn protection. motor vehicle.
178.3378 Openings, inlets and outlets. 178.3471 General requirements.
178.3379 Pressure relief devices, piping, 178.3472 Material and thickness of mate-
valves, hoses, and fittings. rial.
178.33710 Accident damage protection. 178.3473 Manhole assemblies.
178.33711 Emergency discharge control. 178.3474 Pressure relief.
178.33712 [Reserved] 178.3475 Pressure and leakage test.
178.33713 Supporting and anchoring. 178.348 Specification DOT 412; cargo tank
178.33714 Gauging devices. motor vehicle.
178.33715 Pumps and compressors. 178.3481 General requirements.
178.33716 Testing. 178.3482 Material and thickness of mate-
178.33717 Marking. rial.
178.33718 Certification. 178.3483 Pumps, piping, hoses and connec-
178.338 Specification MC338; insulated tions.
cargo tank motor vehicle. 178.3484 Pressure relief.
178.3381 General requirements. 178.3485 Pressure and leakage test.
178.3382 Material.
178.3383 Structural integrity. Subpart KSpecifications for Packagings
178.3384 Joints. for Class 7 (Radioactive) Materials
178.3385 Stiffening rings.
178.3386 Manholes. 178.350 Specification 7A; general packaging,
178.3387 Openings. Type A.
178.3388 Pressure relief devices, piping, 178.356 Specification 20PF phenolic-foam in-
valves, and fittings. sulated, metal overpack.
178.3389 Holding time. 178.3561 General requirements.
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Pipeline and Hazardous Materials Safety Admin., DOT Pt. 178
178.358 Specification 21PF fire and shock re- 178.608 Vibration standard.
sistant, phenolic-foam insulated, metal 178.609 Test requirements for packagings for
overpack. infectious substances.
178.3581 General requirements.
178.3582 Materials of construction and Subpart NIBC Performance-Oriented
other requirements. Standards
178.3583 Modification of Specification
21PF1 overpacks. 178.700 Purpose, scope and definitions.
178.3584 Construction of Specification 178.702 IBC codes.
21PF1B overpacks. 178.703 Marking of IBCs.
178.3585 Required markings. 178.704 General IBC standards.
178.3586 Typical assembly detail. 178.705 Standards for metal IBCs.
178.360 Specification 2R; inside containment 178.706 Standards for rigid plastic IBCs.
vessel. 178.707 Standards for composite IBCs.
178.3601 General requirements. 178.708 Standards for fiberboard IBCs.
178.3602 Manufacture. 178.709 Standards for wooden IBCs.
178.3603 Dimensions. 178.710 Standards for flexible intermediate
178.3604 Closure devices. bulk containers.
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178.1 49 CFR Ch. I (10111 Edition)
APPENDIX B TO PART 178ALTERNATIVE (c) Notification. (1) Except as specifi-
LEAKPROOFNESS TEST METHODS cally provided in 178.33718 and
APPENDIX C TO PART 178NOMINAL AND MIN- 178.34510 of this part, the manufac-
IMUM THICKNESSES OF STEEL DRUMS AND
JERRICANS turer or other person certifying com-
APPENDIX D TO PART 178THERMAL RESIST- pliance with the requirements of this
ANCE TEST part, and each subsequent distributor
APPENDIX E TO PART 178FLAME PENETRA- of that packaging must:
TION RESISTANCE TEST (i) Notify each person to whom that
AUTHORITY: 49 U.S.C. 51015128; 49 CFR 1.53. packaging is transferred
(A) Of all requirements in this part
178.1 Purpose and scope. not met at the time of transfer, and
This part prescribes the manufac- (B) With information specifying the
turing and testing specifications for type(s) and dimensions of the closures,
packaging and containers used for the including gaskets and any other com-
transportation of hazardous materials ponents needed to ensure that the
in commerce. packaging is capable of successfully
[Amdt. 17840, 42 FR 2689, Jan. 13, 1977. Redes- passing the applicable performance
ignated by Amdt. 17897, 55 FR 52715, Dec. 21, tests. This information must include
1990] any procedures to be followed, includ-
ing closure instructions for inner pack-
178.2 Applicability and responsi- agings and receptacles, to effectively
bility.
assemble and close the packaging for
(a) Applicability. (1) The requirements the purpose of preventing leakage in
of this part apply to packagings manu- transportation. Closure instructions
factured must provide for a consistent and re-
(i) To a DOT specification, regardless peatable means of closure that is suffi-
of country of manufacture; or cient to ensure the packaging is closed
(ii) To a UN standard, for packagings in the same manner as it was tested.
manufactured within the United For packagings sold or represented as
States. For UN standard packagings being in conformance with the require-
manufactured outside the United ments of this subchapter applicable to
States, see 173.24(d)(2) of this sub- transportation by aircraft, this infor-
chapter. For UN standard packagings mation must include relevant guidance
for which standards are not prescribed to ensure that the packaging, as pre-
in this part, see 178.3(b). pared for transportation, will with-
(2) A manufacturer of a packaging
stand the pressure differential require-
subject to the requirements of this part
ments in 173.27 of this subchapter.
is primarily responsible for compliance
with the requirements of this part. (ii) Retain copies of each written no-
However, any person who performs a tification for the amount of time that
function prescribed in this part shall aligns with the packagings periodic
perform that function in accordance retest date, i.e., every 12 months for
with this part. single or composite packagings and
(b) Specification markings. When this every 24 months for combination pack-
part requires that a packaging be agings; and
marked with a DOT specification or UN (iii) Make copies of all written notifi-
standard marking, marking of the cations available for inspection by a
packaging with the appropriate DOT or representative of the Department.
UN markings is the certification that (2) The notification required in ac-
(1) Except as otherwise provided in cordance with this paragraph (c) may
this section, all requirements of the be in writing or by electronic means,
DOT specification or UN standard, in- including e-mailed transmission or
cluding performance tests, are met; transmission on a CD or similar device.
and If a manufacturer or subsequent dis-
(2) All functions performed by, or on tributor of the packaging utilizes elec-
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behalf of, the person whose name or tronic means to make the required no-
symbol appears as part of the marking tifications, the notification must be
conform to requirements specified in specific to the packaging in question
this part. and must be in a form that can be
10
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Pipeline and Hazardous Materials Safety Admin., DOT 178.3
printed in hard copy by the person re- (3) The markings must be stamped,
ceiving the notification. embossed, burned, printed or otherwise
(d) Except as provided in paragraph marked on the packaging to provide
(c) of this section, a packaging not con- adequate accessibility, permanency,
forming to the applicable specifica- contrast, and legibility so as to be
tions or standards in this part may not readily apparent and understood.
be marked to indicate such conform- (4) Unless otherwise specified, letters
ance. and numerals must be at least 12.0 mm
(e) Definitions. For the purpose of this (0.47 inches) in height except that for
part packagings of less than or equal to 30 L
Manufacturer means the person whose (7.9 gallons) capacity for liquids or 30
name and address or symbol appears as kg (66 pounds) capacity for solids the
part of the specification markings re- height must be at least 6.0 mm (0.2
quired by this part or, for a packaging inches). For packagings having a ca-
marked with the symbol of an approval pacity of 5 L (1 gallon) or 5 kg (11
agency, the person on whose behalf the pounds) or less, letters and numerals
approval agency certifies the pack- must be of an appropriate size.
aging. (5) For packages with a gross mass of
Specification markings mean the pack- more than 30 kg (66 pounds), the mark-
aging identification markings required ings or a duplicate thereof must appear
by this part including, where applica- on the top or on a side of the pack-
ble, the name and address or symbol of aging.
the packaging manufacturer or ap-
(b) A UN standard packaging for
proval agency.
which the UN standard is set forth in
(f) No packaging may be manufac-
this part may be marked with the
tured or marked to a packaging speci-
United Nations symbol and other speci-
fication that was in effect on Sep-
fication markings only if it fully con-
tember 30, 1991, and that was removed
forms to the requirements of this part.
from this part 178 by a rule published
A UN standard packaging for which the
in the FEDERAL REGISTER on December
21, 1990 and effective October 1, 1991. UN standard is not set forth in this
part may be marked with the United
[Amdt. 17897, 55 FR 52715, Dec. 21, 1990; 56 FR Nations symbol and other specification
66284, Dec. 20, 1991, as amended by Amdt. No. markings for that standard as provided
178106, 59 FR 67519, Dec. 29, 1994; Amdt. 178 in the ICAO Technical Instructions or
117, 62 FR 14338, Mar. 26, 1997; 68 FR 45041,
July 31, 2003; 69 FR 34612, June 22, 2004; 75 FR
the IMDG Code subject to the following
5395, Feb. 2, 2010; 75 FR 60339, Sept. 30, 2010] conditions:
(1) The U.S. manufacturer must es-
178.3 Marking of packagings. tablish that the packaging conforms to
(a) Each packaging represented as the applicable provisions of the ICAO
manufactured to a DOT specification Technical Instructions (IBR, see 171.7
or a UN standard must be marked on a of this subchapter) or the IMDG Code
non-removable component of the pack- (IBR, see 171.7 of this subchapter), re-
aging with specification markings con- spectively.
forming to the applicable specification, (2) If an indication of the name of the
and with the following: manufacturer or other identification of
(1) In an unobstructed area, with let- the packaging as specified by the com-
ters, and numerals identifying the petent authority is required, the name
standards or specification (e.g. UN 1A1, and address or symbol of the manufac-
DOT 4B240ET, etc.). turer or the approval agency certifying
(2) Unless otherwise specified in this compliance with the UN standard must
part, with the name and address or be entered. Symbols, if used, must be
symbol of the packaging manufacturer registered with the Associate Adminis-
or, where specifically authorized, the trator.
symbol of the approval agency certi- (3) The letters USA must be used
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178.33 49 CFR Ch. I (10111 Edition)
Order 71, 31 FR 9074, July 1, 1966. Redesig- tainers or less, successively produced
nated at 32 FR 5606, Apr. 5, 1967, and amended per day shall be pressure tested to de-
by Amdt. 178101, 58 FR 50237, Sept. 24, 1993; struction and must not burst below 240
66 FR 45386, Aug. 28, 2001] psig gauge pressure. The container
12
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Pipeline and Hazardous Materials Safety Admin., DOT 178.33a7
[Order 71, 31 FR 9074, July 1, 1966. Redesig- any container shall be 0.008 inch.
nated at 32 FR 5606, Apr. 5, 1967, and amended (b) [Reserved]
by Amdt. 17843, 42 FR 42208, Aug. 22, 1977;
Amdt. 178101, 58 FR 50237, Sept. 24, 1993; 66 [Order 71, 31 FR 9074, July 1, 1966. Redesig-
FR 45387, Aug. 28, 2001] nated at 32 FR 5606, Apr. 5, 1967]
13
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178.33a8 49 CFR Ch. I (10111 Edition)
one liter (61.0 cubic inches). The max- forming the drop test. The closure, or
imum inside diameter shall not exceed sealing component of the container,
3 inches. must not be protected during the test.
[74 FR 2268, Jan. 14, 2009] The orientation of the test container
14
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Pipeline and Hazardous Materials Safety Admin., DOT 178.35
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178.35 49 CFR Ch. I (10111 Edition)
(iv) Obtaining samples for all tests (1) Each cylinder must be marked
and check chemical analyses (NOTE: with the following information:
Recommended locations for test speci- (i) The DOT specification marking
mens taken from welded cylinders are must appear first, followed imme-
depicted in Figures 1 through 5 in Ap- diately by the service pressure. For ex-
pendix C to this subpart for the specific ample, DOT-3A1800.
construction design.); (ii) The serial number must be placed
(v) Witnessing all tests; just below or immediately following
(vi) Verify threads by gauge; the DOT specification marking.
(vii) Reporting volumetric capacity (iii) A symbol (letters) must be
placed just below, immediately before
and tare weight (see report form) and
or following the serial number. Other
minimum thickness of wall noted; and
variations in sequence of markings are
(viii) Verifying that each cylinder is
authorized only when necessitated by a
marked in accordance with the applica- lack of space. The symbol and numbers
ble specification. must be those of the manufacturer.
(4) Inspectors report. Prepare a report The symbol must be registered with
containing, at a minimum, the applica- the Associate Administrator; duplica-
ble information listed in CGA C11 tions are not authorized.
(IBR, see 171.7 of this subchapter). (iv) The inspectors official mark and
Any additional information or mark- date of test (such as 595 for May 1995)
ings that are required by the applicable must be placed near the serial number.
specification must be shown on the test This information must be placed so
report. The signature of the inspector that dates of subsequent tests can be
on the reports certifies that the proc- easily added. An example of the mark-
esses of manufacture and heat treat- ings prescribed in this paragraph (f)(1)
ment of cylinders were observed and is as follows:
found satisfactory. The inspector must
furnish the completed test reports re- DOT-3A1800
1234
quired by this subpart to the maker of
XY
the cylinder and, upon request, to the AB 595
purchaser. The test report must be re-
Or;
tained by the inspector for fifteen
years from the original test date of the DOT-3A18001234XY
AB 595
cylinder.
Where:
(d) Defects and attachments. Cylinders
must conform to the following: DOT-3A = specification number
1800 = service pressure
(1) A cylinder may not be constructed 1234 = serial number
of material with seams, cracks or lam- XY = symbol of manufacturer
inations, or other injurious defects. AB = inspectors mark
(2) Metal attachments to cylinders 595 = date of test
must have rounded or chamfered cor- (2) Additional required marking must
ners or must be protected in such a be applied to the cylinder as follows:
manner as to prevent the likelihood of (i) The word spun or plug must
causing puncture or damage to other be placed near the DOT specification
hazardous materials packages. This re- marking when an end closure in the
quirement applies to anything tempo- finished cylinder has been welded by
rarily or permanently attached to the the spinning process, or effected by
cylinder, such as metal skids. plugging.
(e) Safety devices. Pressure relief de- (ii) As prescribed in specification 3HT
vices and protection for valves, safety ( 178.44) or 3T ( 178.45), if applicable.
devices, and other connections, if ap- (3) Marking exceptions. A DOT 3E cyl-
plied, must be as required or author- inder is not required to be marked with
ized by the appropriate specification, an inspectors mark or a serial number.
and as required in 173.301 of this sub- (4) Unless otherwise specified in the
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Pipeline and Hazardous Materials Safety Admin., DOT 178.36
(5) The size of each marking must be (iii) To calculate the maximum lon-
at least 0.25 inch or as space permits. gitudinal tensile stress due to hydro-
(6) Other markings are authorized static test pressure, the following for-
provided they are made in low stress mula must be used:
areas other than the side wall and are S = A1 P/A2
not of a size and depth that will create
harmful stress concentrations. Such where:
marks may not conflict with any DOT S = tensile stressp.s.i.;
required markings. M = bending moment-inch pounds(wl2)/8;
(g) Manufacturers reports. At or be- w = weight per inch of cylinder filled with
fore the time of delivery to the pur- water;
l = length of cylinder-inches;
chaser, the cylinder manufacturer c = radius (D)/(2) of cylinder-inches;
must have all completed certification I = moment of inertia0.04909 (D4d4) inches
documents listed in CGA C11. The fourth;
manufacturer of the cylinders must re- D = outside diameter-inches;
tain the reports required by this sub- d = inside diameter-inches;
part for 15 years from the original test A1 = internal area in cross section of cyl-
date of the cylinder. inder-square inches;
A2 = area of metal in cross section of cyl-
[Amdt. 178114, 61 FR 25942, May 23, 1996, as inder-square inches;
amended at 66 FR 45185, Aug. 28, 2001; 67 FR P=hydrostatic test pressure-psig.
51652, Aug. 8, 2002; 68 FR 75748, Dec. 31, 2003;
76 FR 43531, July 20, 2011] (b) Steel. Open-hearth or electric steel
of uniform quality must be used. Con-
178.36 Specification 3A and 3AX tent percent may not exceed the fol-
seamless steel cylinders. lowing: Carbon, 0.55; phosphorous, 0.045;
(a) Type size and service pressure. In sulphur, 0.050.
addition to the requirements of 178.35, (c) Identification of material. Material
cylinders must conform to the fol- must be identified by any suitable
lowing: method, except that plates and billets
(1) A DOT-3A cylinder is a seamless for hot-drawn cylinders must be
steel cylinder with a water capacity marked with the heat number.
(nominal) not over 1,000 pounds and a (d) Manufacture. Cylinders must be
service pressure of at least 150 psig. manufactured using equipment and
(2) A DOT3AX is a seamless steel processes adequate to ensure that each
cylinder with a water capacity not less cylinder produced conforms to the re-
than 1,000 pounds and a service pres- quirements of this subpart. No fissure
sure of at least 500 psig, conforming to or other defect is permitted that is
the following requirements: likely to weaken the finished cylinder
appreciably. A reasonably smooth and
(i) Assuming the cylinder is to be
uniform surface finish is required. If
supported horizontally at its two ends
not originally free from such defects,
only and to be uniformly loaded over
the surface may be machined or other-
its entire length consisting of the
wise treated to eliminate these defects.
weight per unit of length of the
The thickness of the bottoms of cyl-
straight cylindrical portion filled with
inders welded or formed by spinning is,
water and compressed to the specified
under no condition, to be less than two
test pressure; the sum of two times the
times the minimum wall thickness of
maximum tensile stress in the bottom
the cylindrical shell; such bottom
fibers due to bending, plus that in the
thicknesses must be measured within
same fibers (longitudinal stress), due to
an area bounded by a line representing
hydrostatic test may not exceed 80 per-
the points of contact between the cyl-
cent of the minimum yield strength of
inder and floor when the cylinder is in
the steel at such maximum stress. Wall
a vertical position.
thickness must be increased when nec-
(e) Welding or brazing. Welding or
essary to meet the requirement.
brazing for any purpose whatsoever is
(ii) To calculate the maximum longi-
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178.36 49 CFR Ch. I (10111 Edition)
and only to the tops and bottoms of pansion to an accuracy of either 1 per-
cylinders having a service pressure of cent or 0.1 cubic centimeter.
500 psig or less. Cylinders, neckrings, (2) Pressure must be maintained for
and footrings must be made of weldable at least 30 seconds and sufficiently
steel, the carbon content of which may longer to ensure complete expansion.
not exceed 0.25 percent except in the Any internal pressure applied after
case of 4130X steel which may be used heat-treatment and previous to the of-
with proper welding procedures. ficial test may not exceed 90 percent of
(2) As permitted in paragraph (d) of the test pressure. If, due to failure of
this section. the test apparatus the test pressure
(3) Cylinders used solely in anhy- cannot be maintained the test may be
drous ammonia service may have a 12 repeated at a pressure increased by 10
inch diameter bar welded within their percent or 100 psig, whichever is the
concave bottoms. lower.
(f) Wall thickness. For cylinders with (3) Permanent, volumetric expansion
service pressure less than 900 psig, the may not exceed 10 percent of the total
wall stress may not exceed 24,000 psig. volumetric expansion at test pressure.
A minimum wall thickness of 0.100 inch (4) Each cylinder must be tested to at
is required for any cylinder over 5 least 53 times service pressure.
inches outside diameter. Wall stress
(j) Flattening test. A flattening test
calculation must be made by using the
must be performed on one cylinder
following formula:
taken at random out of each lot of 200
S = [P(1.3D2+0.4d2)]/(D2d2) or less, by placing the cylinder between
Where: wedge shaped knife edges having a 60
included angle, rounded to 12-inch ra-
S = wall stress in psi;
P = minimum test pressure prescribed for
dius. The longitudinal axis of the cyl-
water jacket test or 450 psig whichever is inder must be at a 90-degree angle to
the greater; knife edges during the test. For lots of
D = outside diameter in inches; 30 or less, flattening tests are author-
d = inside diameter in inches. ized to be made on a ring at least 8
inches long cut from each cylinder and
(g) Heat treatment. The completed cyl-
subjected to same heat treatment as
inder must be uniformly and properly
the finished cylinder.
heat-treated prior to tests.
(h) Openings in cylinders and connec- (k) Physical test. A physical test must
tions (valves, fuse plugs, etc.) for those be conducted to determine yield
openings. Threads are required on open- strength, tensile strength, elongation,
ings. and reduction of area of material as
(1) Threads must be clean cut, even, follows:
without checks, and to gauge. (1) The test is required on 2 speci-
(2) Taper threads, when used, must be mens cut from 1 cylinder taken at ran-
of length not less than as specified for dom out of each lot of 200 or less. For
American Standard taper pipe threads. lots of 30 or less, physical tests are au-
(3) Straight threads having at least 6 thorized to be made on a ring at least
engaged threads are authorized. 8 inches long cut from each cylinder
Straight threads must have a tight fit and subjected to same heat treatment
and calculated shear strength of at as the finished cylinder.
least 10 times the test pressure of the (2) Specimens must conform to the
cylinder. Gaskets, adequate to prevent following:
leakage, are required. (i) Gauge length of 8 inches with a
(i) Hydrostatic test. Each cylinder width of not over 112 inches, a gauge
must successfully withstand a hydro- length of 2 inches with a width of not
static test, as follows: over 112 inches, or a gauge length of at
(1) The test must be by water-jacket, least 24 times thickness with width not
or other suitable methods, operated so over 6 times thickness is authorized
wreier-aviles on DSK3TPTVN1PROD with CFR
as to obtain accurate data. The pres- when cylinder wall is not over 316 inch
sure gauge must permit reading to an thick.
accuracy of 1 percent. The expansion (ii) The specimen, exclusive of grip
gauge must permit reading of total ex- ends, may not be flattened. Grip ends
18
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Pipeline and Hazardous Materials Safety Admin., DOT 178.36
(1) An elongation at least 40 percent graph (m) of this section may be re-
for a 2-inch gauge length or at least 20 moved from the spun cylinder category
percent in other cases and yield
strength not over 73 percent of tensile
19
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178.37 49 CFR Ch. I (10111 Edition)
Carbon ................... 0.25/0.35 ......... 0.28/0.33 ......... 0.10/0.20 ......... 0.20/0.30 ......... 0.270.37 ........ 0.40 max.
Manganese ............ 0.40/0.90 ......... 0.70/0.90 ......... 0.50/0.75 ......... 0.50/0.75 ......... 0.801.40 ........ 1.35/1.65.
Phosphorus ........... 0.04 max ......... 0.04 max ......... 0.04 max ......... 0.04 max ......... 0.035 max ....... 0.04 max.
Sulfur ..................... 0.05 max ......... 0.04 max ......... 0.04 max ......... 0.04 max ......... 0.045 max ....... 0.05 max.
Silicon .................... 0.15/0.35 ......... 0.20/0.35 ......... 0.60/0.90 ......... 0.60/0.90 ......... 0.3 max. .......... 0.10/0.30.
Chromium .............. 0.80/1.10 ......... 0.40/0.60 ......... 0.50/0.65 ......... 0.50/0.65.
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Pipeline and Hazardous Materials Safety Admin., DOT 178.37
(c) Identification of material. Material not exceed 0.25 percent except in the
must be identified by any suitable case of 4130X steel which may be used
method except that plates and billets with proper welding procedure.
for hot-drawn cylinders must be (2) As permitted in paragraph (d) of
marked with the heat number. this section.
(d) Manufacture. Cylinders must be (f) Wall thickness. The thickness of
manufactured using equipment and each cylinder must conform to the fol-
processes adequate to ensure that each lowing:
cylinder produced conforms to the re-
(1) For cylinders with a service pres-
quirements of this subpart. No fissure
or other defects is permitted that is sure of less than 900 psig, the wall
likely to weaken the finished cylinder stress may not exceed 24,000 psi. A min-
appreciably. A reasonably smooth and imum wall thickness of 0.100 inch is re-
uniform surface finish is required. If quired for any cylinder with an outside
not originally free from such defects, diameter of over 5 inches.
the surface may be machined or other- (2) For cylinders with service pres-
wise treated to eliminate these defects. sure of 900 psig or more the minimum
The thickness of the bottoms of cyl- wall must be such that the wall stress
inders welded or formed by spinning is, at the minimum specified test pressure
under no condition, to be less than two may not exceed 67 percent of the min-
times the minimum wall thickness of imum tensile strength of the steel as
the cylindrical shell; such bottom determined from the physical tests re-
thicknesses must be measured within quired in paragraphs (k) and (l) of this
an area bounded by a line representing section and must be not over 70,000 psi.
the points of contact between the cyl- (3) Calculation must be made by the
inder and floor when the cylinder is in formula:
a vertical position.
(e) Welding or brazing. Welding or S = [P(1.3D2+0.4d2)]/(D2d2)
brazing for any purpose whatsoever is Where:
prohibited except as follows:
(1) Welding or brazing is authorized S = wall stress in psi;
for the attachment of neckrings and P = minimum test pressure prescribed for
water jacket test or 450 psig whichever is
footrings which are non-pressure parts,
the greater;
and only to the tops and bottoms of
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178.37 49 CFR Ch. I (10111 Edition)
heat treated prior to tests. Heat treat- for American Standard taper pipe
ment of cylinders of the authorized threads.
analyses must be as follows: (3) Straight threads having at least 6
(1) All cylinders must be quenched by engaged threads are authorized.
oil, or other suitable medium except as Straight threads must have a tight fit
provided in paragraph (g)(5) of this sec- and a calculated shear strength of at
tion. least 10 times the test pressure of the
(2) The steel temperature on quench- cylinder. Gaskets, adequate to prevent
ing must be that recommended for the leakage, are required.
steel analysis, but may not exceed 1750 (i) Hydrostatic test. Each cylinder
F. must successfully withstand a hydro-
(3) All steels must be tempered at a static test as follows:
temperature most suitable for that (1) The test must be by water-jacket,
steel. or other suitable method, operated so
(4) The minimum tempering tempera- as to obtain accurate data. The pres-
ture may not be less than 1000 F ex- sure gauge must permit reading to an
cept as noted in paragraph (g)(6) of this accuracy of 1 percent. The expansion
section. gauge must permit reading of total ex-
(5) Steel 4130X may be normalized at pansion to an accuracy of either 1 per-
a temperature of 1650 F instead of cent or 0.1 cubic centimeter.
being quenched and cylinders so nor-
(2) Pressure must be maintained for
malized need not be tempered.
at least 30 seconds and sufficiently
(6) Intermediate manganese steels
longer to ensure complete expansion.
may be tempered at temperatures not
less than 1150 F., and after heat treat- Any internal pressure applied after
ing each cylinder must be submitted to heat-treatment and previous to the of-
a magnetic test to detect the presence ficial test may not exceed 90 percent of
of quenching cracks. Cracked cylinders the test pressure. If, due to failure of
must be rejected and destroyed. the test apparatus, the test pressure
(7) Except as otherwise provided in cannot be maintained, the test may be
paragraph (g)(6) of this section, all cyl- repeated at a pressure increased by 10
inders, if water quenched or quenched percent or 100 psig, whichever is the
with a liquid producing a cooling rate lower.
in excess of 80 percent of the cooling (3) Permanent volumetric expansion
rate of water, must be inspected by the may not exceed 10 percent of total vol-
magnetic particle, dye penetrant or ul- umetric expansion at test pressure.
trasonic method to detect the presence (4) Each cylinder must be tested to at
of quenching cracks. Any cylinder de- least 53 times the service pressure.
signed to the requirements for speci- (j) Flattening test. A flattening test
fication 3AA and found to have a must be performed on one cylinder
quenching crack must be rejected and taken at random out of each lot of 200
may not be requalified. Cylinders de- or less, by placing the cylinder between
signed to the requirements for speci- wedge shaped knife edges having a 60
fication 3AAX and found to have included angle, rounded to 12-inch ra-
cracks must have cracks removed to dius. The longitudinal axis of the cyl-
sound metal by mechanical means. inder must be at a 90-degree angle to
Such specification 3AAX cylinders will knife edges during the test. For lots of
be acceptable if the repaired area is 30 or less, flattening tests are author-
subsequently examined to assure no de- ized to be made on a ring at least 8
fect, and it is determined that design inches long cut from each cylinder and
thickness requirements are met. subjected to the same heat treatment
(h) Openings in cylinders and connec- as the finished cylinder. Cylinders may
tions (valves, fuse plugs, etc.) for those be subjected to a bend test in lieu of
openings. Threads are required on open- the flattening test. Two bend test
ings. specimens must be taken in accordance
wreier-aviles on DSK3TPTVN1PROD with CFR
(1) Threads must be clean cut, even, with ISO 98091 or ASTM E 290 (IBR, see
without checks, and to gauge. 171.7 of this subchapter), and must be
(2) Taper threads, when used, must be subjected to the bend test specified
of a length not less than as specified therein.
22
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Pipeline and Hazardous Materials Safety Admin., DOT 178.37
(k) Physical test. A physical test must gauge length. Elastic extension cal-
be conducted to determine yield culations must be based on an elastic
strength, tensile strength, elongation, modulus of 30,000,000. In the event of
and reduction of area of material as controversy, the entire stress-strain
follows: diagram must be plotted and the yield
(1) The test is required on 2 speci- strength determined from the 0.2 per-
mens cut from 1 cylinder taken at ran- cent offset.
dom out of each lot of 200 or less. For (iii) For the purpose of strain meas-
lots of 30 or less, physical tests are au- urement, the initial strain must be set
thorized to be made on a ring at least while the specimen is under a stress of
8 inches long cut from each cylinder 12,000 psi, the strain indicator reading
and subjected to the same heat treat- being set at the calculated cor-
ment as the finished cylinder. responding strain.
(2) Specimens must conform to the (iv) Cross-head speed of the testing
following: machine may not exceed 18 inch per
(i) Gauge length of 8 inches with a minute during yield strength deter-
width of not over 112 inches, a gauge mination.
length of 2 inches with a width of not (l) Acceptable results for physical, flat-
over 112 inches, or a gauge length of at tening and bend tests. An acceptable re-
least 24 times the thickness with width sult for physical and flattening tests is
not over 6 times thickness when the elongation of at least 20 percent for 2
thickness of the cylinder wall is not inches of gauge length or at least 10
over 316 inch. percent in other cases. Flattening is re-
(ii) The specimen, exclusive of grip quired, without cracking, to 6 times
ends, may not be flattened. Grip ends the wall thickness of the cylinder. An
may be flattened to within 1 inch of acceptable result for the alternative
each end of the reduced section. bend test is no crack when the cylinder
(iii) When size of cylinder does not is bent inward around the mandrel
permit securing straight specimens, until the interior edges are not further
the specimens may be taken in any lo- apart than the diameter of the man-
cation or direction and may be drel.
straightened or flattened cold, by pres- (m) Leakage test. All spun cylinders
sure only, not by blows. When speci- and plugged cylinders must be tested
mens are so taken and prepared, the in- for leakage by gas or air pressure after
spectors report must show in connec- the bottom has been cleaned and is free
tion with record of physical tests de- from all moisture. Pressure, approxi-
tailed information in regard to such mately the same as but no less than
specimens. the service pressure, must be applied to
(iv) Heating of a specimen for any one side of the finished bottom over an
purpose is not authorized. area of at least 116 of the total area of
(3) The yield strength in tension the bottom but not less than 34 inch in
must be the stress corresponding to a diameter, including the closure, for at
permanent strain of 0.2 percent of the least one minute, during which time
gauge length. The following conditions the other side of the bottom exposed to
apply: pressure must be covered with water
(i) The yield strength must be deter- and closely examined for indications of
mined by either the offset method or leakage. Except as provided in para-
the extension under load method as graph (n) of this section, a cylinder
prescribed in ASTM E 8 (IBR, see 171.7 must be rejected if there is any leak-
of this subchapter). ing.
(ii) In using the extension under (1) A spun cylinder is one in which an
load method, the total strain (or ex- end closure in the finished cylinder has
tension under load) corresponding to been welded by the spinning process.
the stress at which the 0.2 percent per- (2) A plugged cylinder is one in which
manent strain occurs may be deter- a permanent closure in the bottom of a
wreier-aviles on DSK3TPTVN1PROD with CFR
mined with sufficient accuracy by cal- finished cylinder has been effected by a
culating the elastic extension of the plug.
gauge length under appropriate load (3) As a safety precaution, if the
and adding thereto 0.2 percent of the manufacturer elects to make this test
23
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178.38 49 CFR Ch. I (10111 Edition)
24
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Pipeline and Hazardous Materials Safety Admin., DOT 178.38
(1) The test must be by water-jacket, (2) Specimens must conform to the
or other suitable method, operated so following:
as to obtain accurate data. The pres- (i) Gauge length of 8 inches with a
sure gauge must permit reading to an width of not over 112 inches; or a gauge
accuracy of 1 percent. The expansion length of 2 inches with a width of not
gauge must permit reading of total ex- over 112 inches; or a gauge length at
pansion to an accuracy either of 1 per- least 24 times the thickness with a
cent or 0.1 cubic centimeter. width not over 6 times thickness is au-
(2) Pressure must be maintained for thorized when a cylinder wall is not
at least 30 seconds and sufficiently over 316 inch thick.
longer to insure complete expansion. (ii) The specimen, exclusive of grip
Any internal pressure applied after ends, may not be flattened. Grip ends
heat-treatment and previous to the of- may be flattened to within one inch of
ficial test may not exceed 90 percent of each end of the reduced section.
the test pressure. If, due to failure of (iii) When size of cylinder does not
the test apparatus, the test pressure permit securing straight specimens,
cannot be maintained, the test may be the specimens may be taken in any lo-
repeated at a pressure increased by 10 cation or direction and may be
percent or 100 psig, whichever is the straightened or flattened cold, by pres-
lower. sure only, not by blows. When speci-
(3) Permanent volumetric expansion mens are so taken and prepared, the in-
may not exceed 10 percent of total vol- spectors report must show in connec-
umetric expansion at test pressure. tion with record of physical tests de-
(4) Cylinders must be tested as fol- tailed information in regard to such
lows: specimens.
(i) Each cylinder; to at least 2 times (iv) Heating of a specimen for any
service pressure; or purpose is not authorized.
(ii) 1 cylinder out of each lot of 200 or (3) The yield strength in tension
less; to at least 3 times service pres- must be the stress corresponding to a
sure. Others must be examined under permanent strain of 0.2 percent of the
pressure of 2 times service pressure and gauge length. The following conditions
show no defect. apply:
(j) Flattening test. A flattening test (i) The yield strength must be deter-
must be performed on one cylinder mined by either the offset method or
taken at random out of each lot of 200 the extension under load method as
or less, by placing the cylinder between prescribed in ASTM E 8 (IBR, see 171.7
wedge shaped knife edges having a 60 of this subchapter).
included angle, rounded to 12-inch ra- (ii) In using the extension under
dius. The longitudinal axis of the cyl- load method, the total strain (or ex-
inder must be at a 90-degree angle to tension under load) corresponding to
knife edges during the test. For lots of the stress at which the 0.2 percent per-
30 or less, flattening tests are author- manent strain occurs may be deter-
ized to be made on a ring at least 8 mined with sufficient accuracy by cal-
inches long cut from each cylinder and culating the elastic extension of the
subjected to same heat treatment as gauge length under appropriate load
the finished cylinder. and adding thereto 0.2 percent of the
(k) Physical test. A physical test must gauge length. Elastic extension cal-
be conducted to determine yield culations must be based on an elastic
strength, tensile strength, elongation, modulus of 30,000,000. In the event of
and reduction of area of material, as controversy, the entire stress-strain
follows: diagram must be plotted and the yield
(1) The test is required on 2 speci- strength determined from the 0.2 per-
mens cut from 1 cylinder taken at ran- cent offset.
dom out of each lot of 200 or less. For (iii) For the purpose of strain meas-
lots of 30 or less, physical tests are au- urement, the initial strain must be set
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178.39 49 CFR Ch. I (10111 Edition)
(iv) Cross-head speed of the testing is not authorized. Spun cylinders re-
machine may not exceed 18 inch per jected under the provisions of para-
minute during yield strength deter- graph (m) of this section may be re-
mination. moved from the spun cylinder category
(l) Acceptable results for physical and by drilling to remove defective mate-
flattening tests. Either of the following rial, tapping and plugging.
is an acceptable result: (o) Marking. Markings may be
(1) An elongation of at least 40 per- stamped into the sidewalls of cylinders
cent for a 2-inch gauge length or at having a service pressure of 150 psig if
least 20 percent in other cases and all of the following conditions are met:
yield strength not over 73 percent of (1) Wall stress at test pressure may
tensile strength. In this instance, the not exceed 24,000 psi.
flattening test is not required. (2) Minimum wall thickness must be
(2) An elongation of at least 20 per- not less than 0.090 inch.
cent for a 2-inch gauge length or 10 per- (3) Depth of stamping must be no
cent in other cases and yield strength greater than 15 percent of the min-
not over 73 percent of tensile strength. imum wall thickness, but may not ex-
Flattening is required, without crack- ceed 0.015 inch.
ing, to 6 times the wall thickness. (4) Maximum outside diameter of cyl-
(m) Leakage test. All spun cylinders inder may not exceed 5 inches.
and plugged cylinders must be tested (5) Carbon content of cylinder may
for leakage by gas or air pressure after not exceed 0.25 percent. If the carbon
the bottom has been cleaned and is free content exceeds 0.25 percent, the com-
from all moisture, subject to the fol- plete cylinder must be normalized after
lowing conditions and limitations: stamping.
(1) Pressure, approximately the same
(6) Stamping must be adjacent to the
as but no less than service pressure,
top head.
must be applied to one side of the fin-
ished bottom over an area of at least [Amdt. 178114, 61 FR 25942, May 23, 1996, as
116 of the total area of the bottom but amended by 66 FR 45185, 4538645388, Aug. 28,
not less than 34 inch in diameter, in- 2001; 67 FR 51652, Aug. 8, 2002; 68 FR 75748,
cluding the closure, for at least one Dec. 31, 2003]
minute, during which time the other
178.39 Specification 3BN seamless
side of the bottom exposed to pressure nickel cylinders.
must be covered with water and closely
examined for indications of leakage. (a) Type, size and service pressure. A
Except as provided in paragraph (n) of DOT 3BN cylinder is a seamless nickel
this section, a cylinder must be re- cylinder with a water capacity (nomi-
jected if there is any leaking. nal) not over 125 pounds water capacity
(2) A spun cylinder is one in which an (nominal) and a service pressure at
end closure in the finished cylinder has least 150 to not over 500 psig.
been welded by the spinning process. (b) Nickel. The percentage of nickel
(3) A plugged cylinder is one in which plus cobalt must be at least 99.0 per-
a permanent closure in the bottom of a cent.
finished cylinder has been effected by a (c) Identification of material. The ma-
plug. terial must be identified by any suit-
(4) As a safety precaution, if the able method except that plates and bil-
manufacturer elects to make this test lets for hot-drawn cylinders must be
before the hydrostatic test, he should marked with the heat number.
design his apparatus so that the pres- (d) Manufacture. Cylinders must be
sure is applied to the smallest area manufactured using equipment and
practicable, around the point of clo- processes adequate to ensure that each
sure, and so as to use the smallest pos- cylinder produced conforms to the re-
sible volume of air or gas. quirements of this subpart. No defect is
(n) Rejected cylinders. Reheat treat- permitted that is likely to weaken the
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26
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178.42 49 CFR Ch. I (10111 Edition)
the specimens may be taken in any lo- not over 50 percent of tensile strength.
cation or direction and may be Flattening is required, without crack-
straightened or flattened cold, by pres- ing, to 6 times the wall thickness.
sure only, not by blows. When speci- (m) Rejected cylinders. Reheat treat-
mens are so taken and prepared, the in- ment is authorized for rejected cyl-
spectors report must show in connec- inders. Subsequent thereto, cylinders
tion with record of physical tests de- must pass all prescribed tests to be ac-
tailed information in regard to such ceptable. Repair by welding is not au-
specimens. thorized.
(iv) Heating of a specimen for any [Amdt. 178114, 61 FR 25942, May 23, 1996, as
purpose is not authorized. amended by 66 FR 45185, 45386, 45388, Aug. 28,
(3) The yield strength in tension 2001; 67 FR 51652, Aug. 8, 2002; 68 FR 75748,
must be the stress corresponding to a Dec. 31, 2003]
permanent strain of 0.2 percent of the
gauge length. The following conditions 178.42 Specification 3E seamless steel
apply: cylinders.
(i) The yield strength must be deter- (a) Type, size, and service pressure. A
mined by either the offset method or DOT 3E cylinder is a seamless steel
the extension under load method as cylinder with an outside diameter not
prescribed in ASTM E 8 (IBR, see 171.7 greater than 2 inches nominal, a length
of this subchapter). less than 2 feet and a service pressure
(ii) In using the extension under of 1,800 psig.
load method, the total strain (or ex- (b) Steel. Open-hearth or electric steel
tension under load) corresponding to of uniform quality must be used. Con-
the stress at which the 0.2 percent per- tent percent may not exceed the fol-
manent strain occurs may be deter- lowing: Carbon, 0.55; phosphorus, 0.045;
mined with sufficient accuracy by cal- sulphur, 0.050.
culating the elastic extension of the (c) Identification of steel. Materials
gauge length under appropriate load must be identified by any suitable
and adding thereto 0.2 percent of the method.
gauge length. Elastic extension cal- (d) Manufacture. Cylinders must be
culations must be based on an elastic manufactured by best appliances and
modulus of 30,000,000. In the event of methods. No defect is permitted that is
controversy, the entire stress-strain likely to weaken the finished cylinder
diagram must be plotted and the yield appreciably. A reasonably smooth and
strength determined from the 0.2 per- uniform surface finish is required. The
cent offset. thickness of the spun bottom is, under
(iii) For the purpose of strain meas- no condition, to be less than two times
urement, the initial strain must be set the minimum wall thickness of the cy-
while the specimen is under a stress of lindrical shell; such bottom thickness
12,000 psi, and the strain indicator must be measured within an area
reading must be set at the calculated bounded by a line representing the
corresponding strain. points of contact between the cylinder
(iv) Cross-head speed of the testing and floor when the cylinder is in a
machine may not exceed 18 inch per vertical position.
minute during yield strength deter- (e) Openings in cylinders and connec-
mination. tions (valves, fuse plugs, etc.) for those
(l) Acceptable results for physical and openings. Threads conforming to the
flattening tests. Either of the following following are required on openings.
is an acceptable result: (1) Threads must be clean cut, even,
(1) An elongation of at least 40 per- without checks, and to gauge.
cent for a 2 inch gauge length or at (2) Taper threads, when used, must be
least 20 percent in other cases and of length not less than as specified for
yield point not over 50 percent of ten- American Standard taper pipe threads.
sile strength. In this instance, the flat- (3) Straight threads having at least 4
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178.44 49 CFR Ch. I (10111 Edition)
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Pipeline and Hazardous Materials Safety Admin., DOT 178.44
zero psig and the service pressure at a may be straightened or flattened cold
rate not in excess of 10 cycles per by pressure only, not by blows. When
minute. Adequate recording instrumen- specimens are so taken and prepared,
tation must be provided if equipment is the inspectors report must show in
31
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178.44 49 CFR Ch. I (10111 Edition)
connection with the record of physical must be applied to one side of the fin-
tests detailed information in regard to ished bottom over an area of at least
such specimens. 116 of the total area of the bottom but
(ii) Heating of a specimen for any not less than 34 inch in diameter, in-
purpose is not authorized. cluding the closure, for at least one
(3) The yield strength in tension minute, during which time the other
must be the stress corresponding to a side of the bottom exposed to pressure
permanent strain of 0.2 percent of the must be covered with water and closely
gauge length. examined for indications of leakage.
(i) The yield strength must be deter- Except as provided in paragraph (q) of
mined by either the offset method or this section, a cylinder must be re-
the extension under load method as jected if there is leakage.
prescribed in ASTM E 8 (IBR, see 171.7 (2) A spun cylinder is one in which an
of this subchapter). end closure in the finished cylinder has
(ii) In using the extension under been welded by the spinning process.
load method, the total strain (or ex-
(3) A plugged cylinder is one in which
tension under load) corresponding to
a permanent closure in the bottom of a
the stress at which the 0.2 percent per-
finished cylinder has been effected by a
manent strain occurs may be deter-
plug.
mined with sufficient accuracy by cal-
culating the elastic extension of the (4) As a safety precaution, if the
gauge length under appropriate load manufacturer elects to make this test
and adding thereto 0.2 percent of the before the hydrostatic test, the manu-
gauge length. Elastic extension cal- facturer should design the test appa-
culations must be based on an elastic ratus so that the pressure is applied to
modulus of 30,000,000. In the event of the smallest area practicable, around
controversy, the entire stress-strain the point of closure, and so as to use
diagram must be plotted and the yield the smallest possible volume of air or
strength determined from the 0.2 per- gas.
cent offset. (p) Acceptable results of tests. Results
(iii) For the purpose of strain meas- of the flattening test, physical tests,
urement, the initial strain must be set burst test, and cycling test must con-
while the specimen is under a stress of form to the following:
12,000 psi, the strain indicator reading (1) Flattening required without
being set at the calculated cor- cracking to ten times the wall thick-
responding strain. ness of the cylinder.
(iv) Cross-head speed of the testing (2) Physical tests:
machine may not exceed 18 inch per (i) An elongation of at least 6 percent
minute during yield strength deter- for a gauge length of 24 times the wall
mination. thickness.
(n) Magnetic particle inspection. In- (ii) The tensile strength may not ex-
spection must be performed on the in- ceed 165,000 p.s.i.
side of each container before closing
(3) The burst pressure must be at
and externally on each finished con-
least 43 times the test pressure.
tainer after heat treatment. Evidence
of discontinuities, which in the opinion (4) Cycling-at least 10,000 pressuriza-
of a qualified inspector may appre- tions.
ciably weaken or decrease the dura- (q) Rejected cylinders. Reheat treat-
bility of the cylinder, must be cause for ment is authorized for rejected cyl-
rejection. inders. Subsequent thereto, cylinders
(o) Leakage test. All spun cylinders must pass all prescribed tests to be ac-
and plugged cylinders must be tested ceptable. Repair by welding or spinning
for leakage by dry gas or dry air pres- is not authorized. For each cylinder
sure after the bottom has been cleaned subjected to reheat treatment during
and is free from all moisture, subject original manufacture, sidewall meas-
wreier-aviles on DSK3TPTVN1PROD with CFR
to the following conditions and limita- urements must be made to verify that
tions: the minimum sidewall thickness meets
(1) Pressure, approximately the same specification requirements after the
as but not less than service pressure, final heat treatment.
32
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178.45 49 CFR Ch. I (10111 Edition)
P = Minimum test pressure, at least 53 serv- (1) Each cylinder must be heated and
ice pressure; held at the proper temperature for at
D = Outside diameter in inches; least one hour per inch of thickness
d = Inside diameter in inches.
based on the maximum thickness of
(2) Each cylinder must meet the fol- the cylinder and then quenched in a
lowing additional requirement which suitable liquid medium having a cool-
assumes a cylinder horizontally sup- ing rate not in excess of 80 percent of
ported at its two ends and uniformly water. The steel temperature on
loaded over its entire length. This load quenching must be that recommended
consists of the weight per inch of for the steel analysis, but it must
length of the straight cylindrical por- never exceed 1750 F.
tion filled with water compressed to (2) After quenching, each cylinder
the specified test pressure. The wall must be reheated to a temperature
thickness must be increased when nec- below the transformation range but
essary to meet this additional require- not less than 1050 F., and must be held
ment: at this temperature for at least one
(i) The sum of two times the max- hour per inch of thickness based on the
imum tensile stress in the bottom fi- maximum thickness of the cylinder.
bers due to bending (see paragraph Each cylinder must then be cooled
(d)(2)(ii) of this section), plus the max- under conditions recommended for the
imum tensile stress in the same fibers steel.
due to hydrostatic testing (see para- (f) Openings. Openings in cylinders
graph (d)(2)(iii) of this section) may must comply with the following:
not exceed 80 percent of the minimum (1) Openings are permitted on heads
yield strength of the steel at this max- only.
imum stress. (2) The size of any centered opening
(ii) The following formula must be in a head may not exceed one half the
used to calculate the maximum tensile outside diameter of the cylinder.
stress due to bending: (3) Openings in a head must have lig-
S = Mc / I aments between openings of at least
three times the average of their hole
Where:
diameter. No off-center opening may
S = Tensile stress in psi; exceed 2.625 inches in diameter.
M = Bending moment in inch-pounds (wl2/8);
(4) All openings must be circular.
I = Moment of inertia0.04909 (D4d4) in
inches fourth; (5) All openings must be threaded.
c = Radius (D/2) of cylinder in inches; Threads must be in compliance with
w = Weight per inch of cylinder filled with the following:
water; (i) Each thread must be clean cut,
l = Length of cylinder in inches; even, without any checks, and to
D = Outside diameter in inches; gauge.
d = Inside diameter in inches.
(ii) Taper threads, when used, must
(iii) The following formula must be be the American Standard Pipe thread
used to calculate the maximum longi- (NPT) type and must be in compliance
tudinal tensile stress due to hydro- with the requirements of NBS Hand-
static test pressure: book H28 (IBR, see 171.7 of this sub-
chapter).
S = A1 P / A2
(iii) Taper threads conforming to Na-
Where: tional Gas Taper thread (NGT) stand-
S = Tensile stress in psi; ards must be in compliance with the
A1 = Internal area in cross section of cyl- requirements of NBS Handbook H28.
inder in square inches; (iv) Straight threads conforming
P = Hydrostatic test pressure-psig; with National Gas Straight thread
A2 = Area of metal in cross section of cyl- (NGS) standards are authorized. These
inder in square inches. threads must be in compliance with the
wreier-aviles on DSK3TPTVN1PROD with CFR
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Pipeline and Hazardous Materials Safety Admin., DOT 178.45
suitable method, conforming to the fol- specimens must be tested from one of
lowing requirements: the cylinders or a test ring from each
(1) The testing apparatus must be op- four hours or less of production. How-
erated in a manner that will obtain ac- ever, in no case may a test lot based on
curate data. Any pressure gauge used this production period exceed 200 cyl-
must permit reading to an accuracy of inders.
one percent. Any expansion gauge used (3) Each specimen for the tension and
must permit reading of the total ex- Charpy impact tests must be taken
pansion to an accuracy of one percent. from the side wall of a cylinder or from
(2) Any internal pressure applied to a ring which has been heat treated
the cylinder after heat treatment and with the finished cylinders of which
before the official test may not exceed the specimens must be representative.
90 percent of the test pressure. The axis of the specimens must be par-
(3) The pressure must be maintained allel to the axis of the cylinder. Each
sufficiently long to assure complete ex- cylinder or ring specimen for test must
pansion of the cylinder. In no case may be of the same diameter, thickness, and
the pressure be held less than 30 sec- metal as the finished cylinders they
onds. represent. A test ring must be at least
(4) If, due to failure of the test appa- 24 inches long with ends covered during
ratus, the required test pressure can- the heat treatment process so as to
not be maintained, the test must be re- simulate the heat treatment process of
peated at a pressure increased by 10 the finished cylinders it represents.
percent or 100 psig, whichever is lower (4) A test cylinder or test ring need
or, the cylinder must be reheat treated. represent only one of the heats in a
(5) Permanent volumetric expansion furnace batch provided the other heats
of the cylinder may not exceed 10 per- in the batch have previously been test-
cent of its total volumetric expansion ed and have passed the tests and that
at the required test pressure. such tests do not represent more than
(6) Each cylinder must be tested to at 200 cylinders from any one heat.
least 53 times its service pressure. (5) The test results must conform to
(h) Ultrasonic examination. After the the requirements specified in para-
hydrostatic test, the cylindrical sec- graphs (j) and (k) of this section.
tion of each vessel must be examined in (6) When the test results do not con-
accordance with ASTM E 213 for shear form to the requirements specified, the
wave and E 114 for straight beam (IBR, cylinders represented by the tests may
Standard see 171.7 of this subchapter). be reheat treated and the tests re-
The equipment used must be calibrated peated. Paragraph (i)(5) of this section
to detect a notch equal to five percent applies to any retesting.
of the design minimum wall thickness. (j) Basic conditions for acceptable phys-
Any discontinuity indication greater ical testing. The following criteria must
than that produced by the five percent be followed to obtain acceptable phys-
notch must be cause for rejection of ical test results:
the cylinder, unless the discontinuity (1) Each tension specimen must have
is repaired within the requirements of a gauge length of two inches with a
this specification. width not exceeding one and one-half
(i) Basic requirements for tension and inches. Except for the grip ends, the
Charpy impact tests. Cylinders must be specimen may not be flattened. The
subjected to a tension and Charpy im- grip ends may be flattened to within
pact as follows: one inch of each end of the reduced sec-
(1) When the cylinders are heat treat- tion.
ed in a batch furnace, two tension (2) A specimen may not be heated
specimens and three Charpy impact after heat treatment specified in para-
specimens must be tested from one of graph (d) of this section.
the cylinders or a test ring from each (3) The yield strength in tension
batch. The lot size represented by these must be the stress corresponding to a
wreier-aviles on DSK3TPTVN1PROD with CFR
tests may not exceed 200 cylinders. permanent strain of 0.2 percent of the
(2) When the cylinders are heat treat- gage length.
ed in a continuous furnace, two tension (i) This yield strength must be deter-
specimens and three Charpy impact mined by the offset method or the
35
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178.46 49 CFR Ch. I (10111 Edition)
extension under load method de- number obtained may not be more than
scribed in ASTM E 8 (IBR, see 171.7 of 165,000 p.s.i. (Rc 36). When the result of
this subchapter). a hardness test exceeds the maximum
(ii) For the extension under load permitted, two or more retests may be
method, the total strain (or extension made; however, the hardness number
under load) corresponding to the stress obtained in each retest may not exceed
at which the 0.2 percent permanent the maximum permitted.
strain occurs may be determined with (l) Rejected cylinders. Reheat treat-
sufficient accuracy by calculating the ment is authorized for rejected cyl-
elastic extension of the gage length inders. However, each reheat treated
under appropriate load and adding
cylinder must subsequently pass all the
thereto 0.2 percent of the gage length.
prescribed tests. Repair by welding is
Elastic extension calculations must be
based on an elastic modulus of not authorized.
30,000,000. However, when the degree of (m) Markings. Marking must be done
accuracy of this method is question- by stamping into the metal of the cyl-
able the entire stress-strain diagram inder. All markings must be legible and
must be plotted and the yield strength located on a shoulder.
determined from the 0.2 percent offset. (n) Inspectors report. In addition to
(iii) For the purpose of strain meas- the requirements of 178.35, the inspec-
urement, the initial strain must be set tors report for the physical test re-
with the specimen under a stress of port, must indicate the average value
12,000 p.s.i. and the strain indicator for three specimens and the minimum
reading set at the calculated cor- value for one specimen for each lot
responding strain. number.
(iv) The cross-head speed of the test-
ing machine may not exceed 18 inch per [Amdt. 178114, 61 FR 25942, May 23, 1996, as
amended at 66 FR 45385, 43588, Aug. 28, 2001;
minute during the determination of
67 FR 51652, Aug. 8, 2002; 68 FR 48571, Aug. 14,
yield strength.
2003; 68 FR 75748, 75749, Dec. 31, 2003]
(4) Each impact specimen must be
Charpy V-notch type size 10 mm 10 178.46 Specification 3AL seamless
mm taken in accordance with para- aluminum cylinders.
graph 11 of ASTM A 333 (IBR, see 171.7
of this subchapter). When a reduced (a) Size and service pressure. A DOT
size specimen is used, it must be the 3AL cylinder is a seamless aluminum
largest size obtainable. cylinder with a maximum water capac-
(k) Acceptable physical test results. Re- ity of 1000 pounds and minimum service
sults of physical tests must conform to pressure of 150 psig.
the following: (b) Authorized material and identifica-
(1) The tensile strength may not ex- tion of material. The material of con-
ceed 155,000 p.s.i. struction must meet the following con-
(2) The elongation must be at least 16 ditions:
percent for a two-inch gage length. (1) Starting stock must be cast stock
(3) The Charpy V-notch impact prop- or traceable to cast stock.
erties for the three impact specimens (2) Material with seams, cracks, lam-
which must be tested at 0 F may not inations, or other defects likely to
be less than the values shown as fol- weaken the finished cylinder may not
lows: be used.
Size of specimen Average value Minimum value (3) Material must be identified by a
for acceptance (1 specimen only suitable method that will identify the
(mm) (3 specimens) of the 3)
alloy, the aluminum producers cast
10.010.0 .............. 25.0 ft. lbs. ........... 20.0 ft. lbs. number, the solution heat treat batch
10.07.5 ................ 21.0 ft. lbs. ........... 17.0 ft. lbs.
10.05.0 ................ 17.0 ft. lbs. ........... 14.0 ft. lbs. number and the lot number.
(4) The material must be of uniform
wreier-aviles on DSK3TPTVN1PROD with CFR
(4) After the final heat treatment, quality. Only the following heat treat-
each vessel must be hardness tested on able aluminum alloys in table 1 and 2
the cylindrical section. The tensile are permitted as follows:
strength equivalent of the hardness
36
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Pipeline and Hazardous Materials Safety Admin., DOT 178.46
TABLE 1HEAT OR CAST ANALYSIS FOR ALUMINUM; SIMILAR TO ALUMINUM ASSOCIATION1 ALLOY
6061
[CHEMICAL ANALYSIS IN WEIGHT PERCENT2]
Other
Si Mg
Fe Cu Mn Cr Zn Ti Pb Bi
min/ min/ A1
max min/max max min/max max max max max each total
max max max max
0.4/0.8 0.7 0.15/0.4 0.15 0.8/1.2 0.04/0.35 0.25 0.15 0.005 0.005 0.05 0.15 Bal.
1 TheAluminum Association refers to Aluminum Standards and Data 1993, published by the Aluminum Association Inc.
2 Except for Pb and Bi, the chemical composition corresponds with that of Table 1 of ASTM B 221 (IBR, see 171.7 of this
subchapter) for Aluminum Association alloy 6061.
1 D
represents specimen diameters. When the cylinder wall is greater than 316 inch thick, a retest without reheat treatment
using the 4D size specimen is authorized if the test using the 2 inch size specimen fails to meet elongation requirements.
2 When cylinder wall is not over 316-inch thick, 10 percent elongation is authorized when using a 24t6t size test specimen.
(5) All starting stock must be 100 per- have a basic torispherical, hemi-
cent ultrasonically inspected, along spherical, or ellipsoidal interior base
the length at right angles to the cen- configuration where the dish radius is
tral axis from two positions at 90 to no greater than 1.2 times the inside di-
one another. The equipment and con- ameter of the shell. The knuckle radius
tinuous scanning procedure must be ca- may not be less than 12 percent of the
pable of detecting and rejecting inter- inside diameter of the shell. The inte-
nal defects such as cracks which have rior base contour may deviate from the
an ultrasonic response greater than true torispherical, hemispherical or el-
that of a calibration block with a 564- lipsoidal configuration provided that
inch diameter flat bottomed hole. (i) Any areas of deviation are accom-
(6) Cast stock must have uniform panied by an increase in base thick-
equiaxed grain structure not to exceed ness;
500 microns maximum. (ii) All radii of merging surfaces are
(7) Any starting stock not complying equal to or greater than the knuckle
with the provisions of paragraphs (b)(1) radius;
through (b)(6) of this section must be (iii) Each design has been qualified
rejected. by successfully passing the cycling
(c) Manufacture. Cylinders must be tests in this paragraph (c); and
manufactured in accordance with the (iv) Detailed specifications of the
following requirements: base design are available to the inspec-
(1) Cylinder shells must be manufac- tor.
tured by the backward extrusion meth- (3) For free standing cylinders, the
od and have a cleanliness level ade- base thickness must be at least two
quate to ensure proper inspection. No times the minimum wall thickness
fissure or other defect is acceptable along the line of contact between the
that is likely to weaken the finished cylinder base and the floor when the
cylinder below the design strength re- cylinders are in the vertical position.
quirements. A reasonably smooth and (4) Welding or brazing is prohibited.
uniform surface finish is required. If (5) Each new design and any signifi-
not originally free from such defects, cant change to any acceptable design
the surface may be machined or other- must be qualified for production by
wise conditioned to eliminate these de- testing prototype samples as follows:
fects. (i) Three samples must be subjected
wreier-aviles on DSK3TPTVN1PROD with CFR
(2) Thickness of the cylinder base to 100,000 pressure reversal cycles be-
may not be less than the prescribed tween zero and service pressure or
minimum wall thickness of the cylin- 10,000 pressure reversal cycles between
drical shell. The cylinder base must zero and test pressure, at a rate not in
37
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178.46 49 CFR Ch. I (10111 Edition)
excess of 10 cycles per minute without times the average of the diameters of
failure. the two openings.
(ii) Three samples must be pressur- (4) All openings must be circular.
ized to destruction and failure may not (5) All openings must be threaded.
occur at less than 2.5 times the marked Threads must comply with the fol-
cylinder service pressure. Each cyl- lowing:
inder must remain in one piece. Fail- (i) Each thread must be clean cut,
ure must initiate in the cylinder side- even, without checks, and to gauge.
wall in a longitudinal direction. Rate (ii) Taper threads, when used, must
of pressurization may not exceed 200 conform to one of the following:
psig per second. (A) American Standard Pipe Thread
(6) In this specification significant (NPT) type, conforming to the require-
change means a 10 percent or greater ments of NBS Handbook H28 (IBR, see
change in cylinder wall thickness, serv- 171.7 of this subchapter);
ice pressure, or diameter; a 30 percent (B) National Gas Taper Thread (NGT)
or greater change in water capacity or type, conforming to the requirements
base thickness; any change in material; of NBS Handbook H28; or
over 100 percent increase in size of (C) Other taper threads conforming
openings; or any change in the number to other standards may be used pro-
of openings. vided the length is not less than that
(d) Wall thickness. The minimum wall specified for NPT threads.
thickness must be such that the wall (iii) Straight threads, when used,
stress at the minimum specified test must conform to one of the following:
pressure will not exceed 80 percent of (A) National Gas Straight Thread
the minimum yield strength nor exceed (NGS) type, conforming to the require-
67 percent of the minimum ultimate ments of NBS Handbook H28;
tensile strength as verified by physical (B) Unified Thread (UN) type, con-
tests in paragraph (i) of this section. forming to the requirements of NBS
The minimum wall thickness for any Handbook H28;
cylinder with an outside diameter (C) Controlled Radius Root Thread
greater than 5 inches must be 0.125 (UN) type, conforming to the require-
inch. Calculations must be made by the ments of NBS Handbook H28; or
following formula: (D) Other straight threads con-
forming to other recognized standards
S = [P(1.3D2 + 0.4d2)] / (D2 d2) may be used provided that the require-
Where: ments in paragraph (e)(5)(iv) of this
S = Wall stress in psi;
section are met.
P = Prescribed minimum test pressure in (iv) All straight threads must have at
psig (see paragraph (g) of this section); least 6 engaged threads, a tight fit, and
D = Outside diameter in inches; and a factor of safety in shear of at least 10
d = Inside diameter in inches. at the test pressure of the cylinder.
Shear stress must be calculated by
(e) Openings. Openings must comply using the appropriate thread shear area
with the following requirements: in accordance with NBS Handbook H
(1) Openings are permitted in heads 28.
only. (f) Heat treatment. Prior to any test,
(2) The size of any centered opening all cylinders must be subjected to a so-
in a head may not exceed one-half the lution heat treatment and aging treat-
outside diameter of the cylinder. ment appropriate for the aluminum
(3) Other openings are permitted in alloy used.
the head of a cylinder if: (g) Hydrostatic test. Each cylinder
(i) Each opening does not exceed 2.625 must be subjected to an internal test
inches in diameter, or one-half the out- pressure using the water jacket equip-
side diameter of the cylinder; which- ment and method or other suitable
ever is less; equipment and method and comply
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Pipeline and Hazardous Materials Safety Admin., DOT 178.46
39
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178.47 49 CFR Ch. I (10111 Edition)
(ii) In using the extension under (3) The inspector must also deter-
load method, the total strain (or ex- mine that each cylinder complies with
tension under load) corresponding to this specification by:
the stress at which the 0.2 percent per- (i) Selecting the samples for check
manent strain occurs may be deter- analyses performed by other than the
mined with sufficient accuracy by cal- material producer;
culating the elastic extension of the (ii) Verifying that the prescribed
gauge length under appropriate load minimum thickness was met by meas-
and adding thereto 0.2 percent of the uring or witnessing the measurement
gauge length. Elastic extension cal- of the wall thickness; and
culations must be based on an elastic (iii) Verifying that the identification
modulus of 10,000,000 psi. In the event of material is proper.
of controversy, the entire stress-strain (4) Prior to initial production of any
diagram must be plotted and the yield design or design change, verify that the
strength determined from the 0.2 per- design qualification tests prescribed in
cent offset. paragraph (c)(6) of this section have
(iii) For the purpose of strain meas- been performed with acceptable re-
urement, the initial strain must be set sults.
while the specimen is under a stress of (l) Definitions. (1) In this specifica-
6,000 psi, the strain indicator reading tion, a lot means a group of cyl-
being set at the calculated cor- inders successively produced having
responding strain. the same:
(iv) Cross-head speed of the testing (i) Size and configuration;
machine may not exceed 18 inch per
(ii) Specified material of construc-
minute during yield strength deter-
tion;
mination.
(iii) Process of manufacture and heat
(j) Rejected cylinder. Reheat treat-
treatment;
ment of rejected cylinders is author-
ized one time. Subsequent thereto, cyl- (iv) Equipment of manufacture and
inders must pass all prescribed tests to heat treatment; and
be acceptable. (v) Conditions of time, temperature
(k) Duties of inspector. In addition to and atmosphere during heat treatment.
the requirements of 178.35, the inspec- (2) In no case may the lot size exceed
tor shall: 200 cylinders, but any cylinder proc-
(1) Verify compliance with the provi- essed for use in the required destruc-
sions of paragraph (b) of this section tive physical testing need not be count-
by: ed as being one of the 200.
(i) Performing or witnessing the per- (m) Inspectors report. In addition to
formance of the chemical analyses on the information required by 178.35, the
each melt or cast lot or other unit of record of chemical analyses must also
starting material; or include the alloy designation, and ap-
(ii) Obtaining a certified chemical plicable information on iron, titanium,
analysis from the material or cylinder zinc, magnesium and any other appli-
manufacturer for each melt, or cast of cable element used in the construction
material; or of the cylinder.
(iii) Obtaining a certified check anal- [Amdt. 178114, 61 FR 25942, May 23, 1996, as
ysis on one cylinder out of each lot of amended at 66 FR 4538645388, Aug. 28, 2001; 67
200 cylinders or less, if a certificate FR 51652, Aug. 8, 2002; 68 FR 75749, Dec. 31,
containing data to indicate compliance 2003]
with the material specification is ob-
tained. 178.47 Specification 4DS welded
(2) The inspector shall verify ultra- stainless steel cylinders for aircraft
sonic inspection of all material by in- use.
spection or by obtaining the material (a) Type, size, and service pressure. A
producers certificate of ultrasonic in- DOT 4DS cylinder is either a welded
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Pipeline and Hazardous Materials Safety Admin., DOT 178.47
service pressure of at least 500 but not specified range, is acceptable, if satis-
over 900 psig. factory in all other respects, provided
(b) Steel. Types 304, 321 and 347 stain- the tolerances shown in table 2 in this
less steel are authorized with proper paragraph (b) are not exceeded, except
welding procedure. A heat of steel as approved by Associate Adminis-
made under the specifications in table trator. The following chemical anal-
1 in this paragraph (b), check chemical yses are authorized:
analysis of which is slightly out of the
TABLE 1AUTHORIZED MATERIALS
Stainless steels
(c) Identification of material. Materials butt type and means must be provided
must be identified by any suitable for accomplishing complete penetra-
method. tion of the joint.
(d) Manufacture. Cylinders must be (e) Attachments. Attachments to the
manufactured using equipment and container are authorized by fusion
processes adequate to ensure that each welding provided that such attach-
cylinder produced conforms to the re- ments are made of weldable stainless
quirements of this subpart. No defect is
steel in accordance with paragraph (b)
permitted that is likely to weaken the
of this section.
finished cylinder appreciably, a reason-
ably smooth and uniform surface finish (f) Wall thickness. The minimum wall
is required. No abrupt change in wall thickness must be such that the wall
thickness is permitted. Welding proce- stress at the minimum specified test
dures and operators must be qualified pressure may not be over 60,000 psig. A
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41
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178.47 49 CFR Ch. I (10111 Edition)
(1) Calculation for sphere must be but not more than 110 percent, of the
made by the formula: test pressure and maintained at this
pressure for a minimum of 3 minutes.
S = PD / 4tE Total and permanent expansion must
Where: be recorded and included in the inspec-
S = Wall stress in psi; tors report.
P = Test pressure prescribed for water jacket (j) Hydrostatic test. Each cylinder
test, i.e., at least two times service pres- must successfully withstand a hydro-
sure, in psig; static test as follows:
D = Outside diameter in inches; (1) The test must be by water-jacket,
t = Minimum wall thickness in inches;
E = 0.85 (provides 85 percent weld efficiency operated so as to obtain accurate data.
factor which must be applied in the girth The pressure gauge must permit read-
weld area and heat zones which zone must ing to an accuracy of 1 percent. The ex-
extend a distance of 6 times wall thickness pansion gauge must permit reading of
from center of weld); total expansion to an accuracy either
E = 1.0 (for all other areas). of 1 percent or 0.1 cubic centimeter.
(2) Calculation for a cylinder must be (2) Pressure must be maintained for
made by the formula: at least 30 seconds and sufficiently
longer to ensure complete expansion.
S = [P(1.3D2 + 0.4d2)] / (D2 d2) If, due to failure of the test apparatus,
Where: the test pressure cannot be main-
S = Wall stress in psi; tained, the test may be repeated at a
P = Test pressure prescribed for water jacket pressure increased by 10 percent or 100
test, i.e., at least two times service pres- psig, whichever is the lower.
sure, in psig; (3) Permanent volumetric expansion
D = Outside diameter in inches; may not exceed 10 percent of total vol-
d = Inside diameter in inches. umetric expansion at test pressure.
(g) Heat treatment. The seamless (4) Each container must be tested to
hemispheres and cylinders may be at least 2 times service pressure.
stress relieved or annealed for forming. (5) Container must then be inspected.
Welded container must be stress re- Any wall thickness lower than that re-
lieved at a temperature of 775 F 25 quired by paragraph (f) of this section
after process treatment and before hy- must be cause for rejection. Bulges and
drostatic test. cracks must be cause for rejection.
(h) Openings in container. Openings Welded joint defects exceeding require-
must comply with the following: ments of paragraph (k) of this section
(1) Each opening in the container must be cause for rejection.
must be provided with a fitting, boss or (k) Radiographic inspection. Radio-
pad of weldable stainless steel securely graphic inspection is required on all
attached to the container by fusion welded joints which are subjected to in-
welding. ternal pressure, except that at the dis-
(2) Attachments to a fitting, boss, or cretion of the disinterested inspector,
pad must be adequate to prevent leak- openings less than 25 percent of the
age. Threads must comply with the fol- container diameter need not be sub-
lowing: jected to radiographic inspection. Evi-
(i) Threads must be clean cut, even, dence of any defects likely to seriously
without checks, and tapped to gauge. weaken the container is cause for re-
(ii) Taper threads to be of length not jection. Radiographic inspection must
less than as specified for American be performed subsequent to the hydro-
Standard taper pipe threads. static test.
(iii) Straight threads having at least (l) Burst test. One container taken at
4 engaged threads, to have tight fit and random out of 200 or less must be
calculated shear strength at least 10 hydrostatically tested to destruction.
times the test pressure of the con- Rupture pressure must be included as
tainer; gaskets required, adequate to part of the inspectors report.
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Pipeline and Hazardous Materials Safety Admin., DOT 178.50
basic oxygen process steel of uniform dles, bosses, pads, and valve protection
quality must be used. Content percent rings to the tops and bottoms of cyl-
may not exceed the following: Carbon, inders by welding or brazing is author-
0.25; phosphorus, 0.045; sulphur, 0.050. ized. Such attachments and the portion
43
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178.50 49 CFR Ch. I (10111 Edition)
of the container to which they are at- (ii) Taper threads to be of length not
tached must be made of weldable steel, less than as specified for American
the carbon content of which may not Standard taper pipe threads.
exceed 0.25 percent except in the case (iii) Straight threads, having at least
of 4130X steel which may be used with 4 engaged threads, to have tight fit and
proper welding procedure. calculated shear strength at least 10
(f) Wall thickness. The wall thickness times the test pressure of the cylinder;
of the cylinder must comply with the gaskets required, adequate to prevent
following requirements: leakage.
(1) For cylinders with outside diame- (iv) A brass fitting may be brazed to
ters over 6 inches the minimum wall the steel boss or flange on cylinders
thickness must be 0.090 inch. In any used as component parts of hand fire
case, the minimum wall thickness extinguishers.
must be such that calculated wall (2) The closure of a fitting, boss, or
stress at minimum test pressure (para- pad must be adequate to prevent leak-
graph (i)(4) of this section) may not ex- age.
ceed the following values: (i) Hydrostatic test. Cylinders must
(i) 24,000 psi for cylinders without withstand a hydrostatic test as follows:
longitudinal seam. (1) The test must be by water-jacket,
(ii) 22,800 psig for cylinders having or other suitable method, operated so
copper brazed or silver alloy brazed as to obtain accurate data. The pres-
longitudinal seam. sure gauge must permit reading to an
(iii) 18,000 psi for cylinders having accuracy of 1 percent. The expansion
forged lapped welded longitudinal gauge must permit reading of total ex-
seam. pansion to an accuracy either of 1 per-
cent or 0.1 cubic centimeter.
(2) Calculation must be made by the
(2) Pressure must be maintained for
formula:
at least 30 seconds and sufficiently
S = [P(1.3D2 + 0.4d2)] / (D2 d2) longer to ensure complete expansion.
Any internal pressure applied after
Where:
heat-treatment and previous to the of-
S = wall stress in psi; ficial test may not exceed 90 percent of
P = minimum test pressure prescribed for
the test pressure. If, due to failure of
water jacket test or 450 psig whichever is
the greater; the test apparatus, the test pressure
D = outside diameter in inches; cannot be maintained, the test may be
d = inside diameter in inches. repeated at a pressure increased by 10
percent or 100 psig, whichever is the
(g) Heat treatment. Cylinder body and lower.
heads, formed by drawing or pressing, (3) Permanent volumetric expansion
must be uniformly and properly heat may not exceed 10 percent of total vol-
treated prior to tests. umetric expansion at test pressure.
(h) Opening in cylinders. Openings in (4) Cylinders must be tested as fol-
cylinders must conform to the fol- lows:
lowing: (i) At least one cylinder selected at
(1) Each opening in cylinders, except random out of each lot of 200 or less
those for safety devices, must be pro- must be tested as outlined in para-
vided with a fitting, boss, or pad, se- graphs (i)(1), (i)(2), and (i)(3) of this sec-
curely attached to cylinder by brazing tion to at least two times service pres-
or by welding or by threads. Fitting, sure.
boss, or pad must be of steel suitable (ii) All cylinders not tested as out-
for the method of attachment em- lined in paragraph (i)(4)(i) of this sec-
ployed, and which need not be identi- tion must be examined under pressure
fied or verified as to analysis except of at least two times service pressure
that if attachment is by welding, car- and show no defect.
bon content may not exceed 0.25 per- (j) Flattening test. After the hydro-
wreier-aviles on DSK3TPTVN1PROD with CFR
cent. If threads are used, they must static test, a flattening test must be
comply with the following: performed on one cylinder taken at
(i) Threads must be clean cut, even random out or each lot of 200 or less, by
without checks, and tapped to gauge. placing the cylinder between wedge
44
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Pipeline and Hazardous Materials Safety Admin., DOT 178.50
shaped knife edges having a 60 in- prescribed in ASTM E 8 (IBR, see 171.7
cluded angle, rounded to 12-inch radius. of this subchapter).
The longitudinal axis of the cylinder (ii) In using the extension under
must be at a 90-degree angle to knife load method, the total strain (or ex-
edges during the test. For lots of 30 or tension under load) corresponding to
less, flattening tests are authorized to the stress at which the 0.2 percent per-
be made on a ring at least 8 inches long manent strain occurs may be deter-
cut from each cylinder and subjected to mined with sufficient accuracy by cal-
same heat treatment as the finished culating the elastic extension of the
cylinder. 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 cal-
strength, 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 speci- diagram must be plotted and the yield
mens cut from 1 cylinder, or part strength determined from the 0.2 per-
thereof heat-treated as required, taken cent offset.
at random out of each lot of 200 or less. (iii) For the purpose of strain meas-
For lots of 30 or less, physical tests are urement, the initial strain must be set
authorized to be made on a ring at while the specimen is under a stress of
least 8 inches long cut from each cyl- 12,000 psi, and strain indicator reading
inder and subjected to same heat treat- must be set at the calculated cor-
ment as the finished cylinder. responding strain.
(2) Specimens must conform to the (iv) Cross-head speed of the testing
following: machine may not exceed 18 inch per
(i) A gauge length of 8 inches with a minute during yield strength deter-
width of not over 112 inches, a gauge mination.
length of 2 inches with a width of not (l) Acceptable results for physical and
over 112 inches, or a gauge length at flattening tests. Either of the following
least 24 times the thickness with a is an acceptable result:
width not over 6 times the thickness is (1) An elongation of at least 40 per-
authorized when a cylinder wall is not cent for a 2-inch gauge length or at
over 316 inch thick. least 20 percent in other cases and
(ii) The specimen, exclusive of grip yield strength not over 73 percent of
ends, may not be flattened. Grip ends tensile strength. In this instance, a
may be flattened to within one inch of flattening test is not required.
each end of the reduced section. (2) When cylinders are constructed of
(iii) When size of cylinder does not lap welded pipe, flattening test is re-
permit securing straight specimens, quired, without cracking, to 6 times
the specimens may be taken in any lo- the wall thickness. In such case, the
cation or direction and may be rings (crop ends) cut from each end of
straightened or flattened cold, by pres- pipe, must be tested with the weld 45
sure only, not by blows. When speci- or less from the point of greatest
mens are so taken and prepared, the in- stress. If a ring fails, another from the
spectors report must show in connec- same end of pipe may be tested.
tion with record of physical tests de- (m) Rejected cylinders. Reheat treat-
tailed information in regard to such ment is authorized for rejected cyl-
specimens. inder. Subsequent thereto, cylinders
(iv) Heating of a specimen for any must pass all prescribed tests to be ac-
purpose is not authorized. ceptable. Repair of brazed seams by
(3) The yield strength in tension brazing and welded seams by welding is
must be the stress corresponding to a authorized.
permanent strain of 0.2 percent of the (n) Markings. Markings must be
gauge length. The following conditions stamped plainly and permanently in
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178.51 49 CFR Ch. I (10111 Edition)
(2) On side wall adjacent to top head (d) Manufacture. Cylinders must be
for side walls which are not less than manufactured using equipment and
0.090 inch thick. processes adequate to ensure that each
(3) On a cylindrical portion of the cylinder produced conforms to the re-
shell which extends beyond the re- quirements of this subpart. No defect is
cessed bottom of the cylinder, consti- permitted that is likely to weaken the
tuting an integral and non-pressure finished cylinder appreciably. A rea-
part of the cylinder. sonably smooth and uniform surface
(4) On a metal plate attached to the finish is required. Exposed bottom
top of the cylinder or permanent part welds on cylinders over 18 inches long
thereof; sufficient space must be left on must be protected by footrings.
the plate to provide for stamping at (1) Seams must be made as follows:
least six retest dates; the plate must be (i) Minimum thickness of heads and
at least 116-inch thick and must be at- bottoms must be not less than 90 per-
tached by welding, or by brazing. The cent of the required thickness of the
brazing rod must melt at a tempera- side wall.
ture of 1100 F. Welding or brazing (ii) Circumferential seams must be
must be along all the edges of the made by welding or by brazing. Heads
plate. must be attached by brazing and must
(5) On the neck, neckring, valve boss, have a driving fit with the shell, unless
valve protection sleeve, or similar part the shell is crimped, swedged or curled
permanently attached to the top of the over the skirt or flange of the head and
cylinder. must be thoroughly brazed until com-
(6) On the footring permanently at- plete penetration by the brazing mate-
tached to the cylinder, provided the rial of the brazed joint is secured.
water capacity of the cylinder does not Depth of brazing from end of the shell
exceed 25 pounds. must be at least four times the thick-
ness of shell metal.
[Amdt. 178114, 61 FR 25942, May 23, 1996, as (iii) Longitudinal seams in shells
amended at 62 FR 51561, Oct. 1, 1997; 66 FR must be made by copper brazing, cop-
45385, 45388, Aug. 28, 2001; 67 FR 51653, Aug. 8, per alloy brazing, or by silver alloy
2002; 68 FR 75748, Dec. 31, 2003]
brazing. Copper alloy composition
178.51 Specification 4BA welded or must be: Copper 95 percent minimum,
brazed steel cylinders. Silicon 1.5 percent to 3.85 percent, Man-
ganese 0.25 percent to 1.10 percent. The
(a) Type, size, and service pressure. A melting point of the silver alloy braz-
DOT 4BA cylinder is a cylinder, either ing material must be in excess of 1,000
spherical or cylindrical in shape, with F. The plate edge must be lapped at
a water capacity of 1,000 pounds or less least eight times the thickness of
and a service pressure of at least 225 plate, laps being held in position, sub-
and not over 500 psig. Closures made by stantially metal to metal, by riveting
the spinning process are not author- or by electric spot-welding. Brazing
ized. must be done by using a suitable flux
(1) Spherical type cylinders must be and by placing brazing material on one
made from two seamless hemispheres side of seam and applying heat until
joined by the welding of one circum- this material shows uniformly along
ferential seam. the seam of the other side. Strength of
(2) Cylindrical type cylinders must be longitudinal seam: Copper brazed lon-
of circumferentially welded or brazed gitudinal seam must have strength at
construction. least 32 times the strength of the steel
(b) Steel. The steel used in the con- wall.
struction of the cylinder must be as (2) Welding procedures and operators
specified in table 1 of appendix A to must be qualified in accordance with
this part. CGA Pamphlet C3 (IBR, see 171.7 of
(c) Identification of material. Material this subchapter).
wreier-aviles on DSK3TPTVN1PROD with CFR
must be identified by any suitable (e) Welding and brazing. Only the
method except that plates and billets welding or brazing of neckrings,
for hotdrawn cylinders must be marked footrings, handles, bosses, pads, and
with the heat number. valve protection rings to the tops and
46
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178.51 49 CFR Ch. I (10111 Edition)
(i) Hydrostatic test. Each cylinder over 112 inches, or a gauge length at
must successfully withstand a hydro- least 24 times the thickness with a
static test, as follows: width not over 6 times the thickness is
(1) The test must be by water jacket, authorized when a cylinder wall is not
or other suitable method, operated so over 316 inch thick.
as to obtain accurate data. A pressure (ii) The specimen, exclusive of grip
gauge must permit reading to an accu- ends, may not be flattened. Grip ends
racy of 1 percent. An expansion gauge may be flattened to within one inch of
must permit reading of total expansion each end of the reduced section.
to an accuracy of either 1 percent or 0.1 (iii) When size of the cylinder does
cubic centimeter. not permit securing straight speci-
(2) Pressure must be maintained for mens, the specimens may be taken in
at least 30 seconds and sufficiently any location or direction and may be
longer to ensure complete expansion. straightened or flattened cold, by pres-
Any internal pressure applied after sure only, not by blows. When speci-
heat treatment and previous to the of- mens are so taken and prepared, the in-
ficial test may not exceed 90 percent of spectors report must show in connec-
the test pressure. tion with record of physical tests de-
(3) Permanent volumetric expansion tailed information in regard to such
may not exceed 10 percent of the total specimens.
volumetric expansion at test pressure.
(iv) Heating of a specimen for any
(4) Cylinders must be tested as fol-
purpose is not authorized.
lows:
(3) The yield strength in tension
(i) At least one cylinder selected at
random out of each lot of 200 or less must be the stress corresponding to a
must be tested as outlined in para- permanent strain of 0.2 percent of the
graphs (i)(1), (i)(2), and (i)(3) of this sec- gauge length. The following conditions
tion to at least two times service pres- apply:
sure. (i) The yield strength must be deter-
(ii) All cylinders not tested as out- mined by either the offset method or
lined in paragraph (i)(4)(i) of this sec- the extension under load method as
tion must be examined under pressure prescribed in ASTM E 8 (IBR, see 171.7
of at least two times service pressure of this subchapter).
and show no defect. (ii) In using the extension under
(j) Physical test. A physical test must load method, the total strain (or ex-
be conducted to determine yield tension under load), corresponding to
strength, tensile strength, elongation, the stress at which the 0.2 percent per-
and reduction of area of material, as manent strain occurs may be deter-
follows: mined with sufficient accuracy by cal-
(1) The test is required on 2 speci- culating the elastic extension of the
mens cut from one cylinder or part gauge length under appropriate load
thereof having passed the hydrostatic and adding thereto 0.2 percent of the
test and heat-treated as required, gauge length. Elastic extension cal-
taken at random out of each lot of 200 culations must be based on an elastic
or less. Physical tests for spheres are modulus of 30,000,000. In the event of
required on 2 specimens cut from flat controversy, the entire stress-strain
representative sample plates of the diagram must be plotted and the yield
same heat taken at random from the strength determined from the 0.2 per-
steel used to produce the spheres. This cent offset.
flat steel from which 2 specimens are (iii) For the purpose of strain meas-
to be cut must receive the same heat urement, the initial strain reference
treatment as the spheres themselves. must be set while the specimen is
Sample plates must be taken from each under a stress of 12,000 psi, and the
lot of 200 or less spheres. strain indicator reading must be set at
(2) Specimens must conform to the the calculated corresponding strain.
wreier-aviles on DSK3TPTVN1PROD with CFR
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178.53 49 CFR Ch. I (10111 Edition)
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Pipeline and Hazardous Materials Safety Admin., DOT 178.53
permitted that is likely to weaken the threads are used, they must comply
finished container appreciably. A rea- with the following:
sonably smooth and uniform surface (i) Threads must be clean cut, even,
finish is required. Welding procedures without checks, and tapped to gauge.
and operators must be qualified in ac- (ii) Taper threads must be of a length
cordance with CGA Pamphlet C3 (IBR, not less than that specified for Amer-
see 171.7 of this subchapter). ican Standard taper pipe threads.
(e) Wall thickness. The wall stress at (iii) Straight threads, having at least
the minimum test pressure may not ex- 4 engaged threads, must have a tight
ceed 24,000 psi, except where steels fit and calculated shear strength of at
commercially known as 4130X, types least 10 times the test pressure of the
304, 316, 321, and 347 stainless steels are container. Gaskets, adequate to pre-
used, stress at the test pressures may vent leakage, are required.
not exceed 37,000 psi. The minimum (2) Closure of a fitting, boss, or pad
wall thickness for any container hav- must be adequate to prevent leakage.
ing a capacity of 1,100 cubic inches or (h) Hydrostatic test. Each cylinder
less is 0.04 inch. The minimum wall must successfully withstand a hydro-
thickness for any container having a static test, as follows:
capacity in excess of 1,100 cubic inches (1) The test must be by water-jacket,
is 0.095 inch. Calculations must be done or other suitable method, operated so
by the following: as to obtain accurate data. A pressure
(1) Calculation for a sphere must gauge must permit a reading to an ac-
be made by the formula: curacy of 1 percent. An expansion
gauge must permit reading of total ex-
S = PD / 4tE
pansion to an accuracy of either 1 per-
Where: cent or 0.1 cubic centimeter.
S = wall stress in psi; (2) Pressure must be maintained for
P = test pressure prescribed for water jacket at least 30 seconds and sufficiently
test, i.e., at least two times service pres- longer to ensure complete expansion.
sure, in psig; Any internal pressure applied after
D = outside diameter in inches; heat-treatment and previous to the of-
t = minimum wall thickness in inches;
E = 0.85 (provides 85 percent weld efficiency
ficial test may not exceed 90 percent of
factor which must be applied in the girth the test pressure. If, due to failure of
weld area and heat affected zones which the test apparatus, the test pressure
zone must extend a distance of 6 times wall cannot be maintained, the test may be
thickness from center line of weld); repeated at a pressure increased by 10
E = 1.0 (for all other areas). percent or 100 psig, whichever is the
(2) Calculation for a cylinder must be lower.
made by the formula: (3) Permanent volumetric expansion
may not exceed 10 percent of the total
S = [P(1.3D2 + 0.4d2)] / (D2 dT12) volumetric expansion at test pressure.
Where: (4) Containers must be tested as fol-
S = wall stress in psi; lows:
P = test pressure prescribed for water jacket (i) Each container to at least 2 times
test, i.e., at least two times service pres- service pressure; or
sure, in psig; (ii) One container out of each lot of
D = outside diameter in inches; 200 or less to at least 3 times service
d = inside diameter in inches. pressure. Others must be examined
(f) Heat treatment. The completed cyl- under pressure of 2 times service pres-
inders must be uniformly and properly sure and show no defects.
heat-treated prior to tests. (i) Flattening test for spheres and cyl-
(g) Openings in container. Openings in inders. Spheres and cylinders must be
cylinders must comply with the fol- subjected to a flattening test as fol-
lowing: lows:
(1) Each opening in the container, ex- (1) One sphere taken at random out
wreier-aviles on DSK3TPTVN1PROD with CFR
cept those for safety devices, must be of each lot of 200 or less must be sub-
provided with a fitting, boss, or pad, se- jected to a flattening test as follows:
curely attached to the container by (i) The test must be performed after
brazing or by welding or by threads. If the hydrostatic test.
51
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178.53 49 CFR Ch. I (10111 Edition)
(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. Heat-
off (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 sub- must 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 deter-
edges, wedge shaped, 60 angle, rounded mined by either the offset method or
to 12 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 fin- load method, the total strain (or ex-
ished cylinder. tension under load) corresponding to
(j) Physical test and specimens for the stress at which the 0.2 percent per-
spheres and cylinders. Spheres and cyl- manent strain occurs may be deter-
inders must be subjected to a physical mined with sufficient accuracy by cal-
test as follows: culating the elastic extension of the
(1) Physical test for spheres are re- gauge length under appropriate load
quired on 2 specimens cut from a flat and adding thereto 0.2 percent of the
representative sample plate of the gauge length. Elastic extension cal-
same heat taken at random from the culations must be based on an elastic
steel used to produce the sphere. This modulus of 30,000,000. In the event of
flat steel from which the 2 specimens controversy, the entire stress-strain
are to be cut must receive the same diagram must be plotted and the yield
heat-treatment as the spheres them- strength determined from the 0.2 per-
selves. Sample plates must be taken for cent offset.
each lot of 200 or less spheres. (iii) For the purpose of strain meas-
(2) Specimens for spheres must have urement, the initial strain must be set
a gauge length 2 inches with a width while the specimen is under a stress of
not over 112 inches, or a gauge length 12,000 psi and the strain indicator read-
at least 24 times the thickness with a ing being set at the calculated cor-
width not over 6 times the thickness is responding strain.
authorized when a wall is not over 316 (iv) Cross-head speed of the testing
inch thick. machine may not exceed 18 inch per
(3) Physical test for cylinders is re- minute during yield strength deter-
quired on 2 specimens cut from 1 cyl- mination.
inder taken at random out of each lot (k) Acceptable results for physical and
of 200 or less. For lots of 30 or less, flattening tests. Either of the following
physical tests are authorized to be is an acceptable result:
made on a ring at least 8 inches long (1) An elongation of at least 40 per-
cut from each cylinder and subjected to cent for a 2 inch gauge length or at
the same heat treatment as the fin- least 20 percent in other cases and
ished cylinder. yield strength not over 73 percent of
(4) Specimens for cylinders must con- tensile strength. In this instance, the
form to the following: flattening test is not required.
(i) A gauge length of 8 inches with a (2) An elongation of at least 20 per-
width not over 112 inches, or a gauge cent for a 2 inch gauge length or 10 per-
length of 2 inches with a width not cent in other cases. Flattening is re-
over 112 inches, or a gauge length at quired to 50 percent of the original out-
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Pipeline and Hazardous Materials Safety Admin., DOT 178.55
must pass all prescribed tests to be ac- between the cylinder and the floor
ceptable. Repair of welded seams by when the cylinder is in a vertical posi-
welding prior to reheat-treatment is tion. Seams must conform to the fol-
authorized. lowing:
(m) Marking. Marking on each con- (1) Circumferential seams must be by
tainer by stamping plainly and perma- brazing only. Heads must be attached
nently are only authorized where the to shells by the lap brazing method and
metal is at least 0.09 inch thick, or on must overlap not less than four times
a metal nameplate permanently se- the wall thickness. Brazing material
cured to the container by means other must have a melting point of not less
than soft solder, or by means that than 1000 F. Heads must have a driving
would not reduce the wall thickness. fit with the shell unless the shell is
[Amdt. 178114, 61 FR 25942, May 23, 1996, as crimped, swedged, or curled over the
amended at 66 FR 45386, 45388, Aug. 28, 2001; skirt or flange of the head and be thor-
67 FR 51653, Aug. 8, 2002; 68 FR 75748, Dec. 31, oughly brazed until complete penetra-
2003] tion of the joint by the brazing mate-
rial is secured. Brazed joints may be re-
178.55 Specification 4B240ET welded paired by brazing.
or brazed cylinders. (2) Longitudinal seams in shell must
(a) Type, spinning process, size and be by electric resistance welded joints
service pressure. A DOT 4B240ET cyl- only. No repairs to longitudinal joints
inder is a brazed type cylinder made is permitted.
from electric resistance welded tubing. (3) Welding procedures and operators
The maximum water capacity of this must be qualified in accordance with
cylinder is 12 pounds or 333 cubic CGA C3 (IBR, see 171.7 of this sub-
inches and the service must be 240 psig. chapter).
The maximum outside diameter of the (e) Welding or brazing. Only the at-
shell must be five inches and maximum tachment, by welding or brazing, to the
length of the shell is 21 inches. Cyl- tops and bottoms of cylinders of
inders closed in by a spinning process neckrings, footrings, handles, bosses,
are authorized. pads, and valve protection rings is au-
(b) Steel. Open-hearth, basic oxygen, thorized. Provided that such attach-
or electric steel of uniform quality ments and the portion of the container
must be used. Plain carbon steel con- to which they are attached are made of
tent may not exceed the following: Car- weldable steel, the carbon content of
bon, 0.25; phosphorus, 0.045; sulfur, which may not exceed 0.25 percent.
0.050. The addition of other elements (f) Wall thickness. The wall stress
for alloying effect is prohibited. must be at least two times the service
(c) Identification of material. Material pressure and may not exceed 18,000 psi.
must be identified by any suitable The minimum wall thickness is 0.044
method. inch. Calculation must be made by the
(d) Manufacture. Cylinders must be following formula:
manufactured using equipment and
S = [P(1.3D2 + 0.4d2)] / (D2 d2)
processes adequate to ensure that each
cylinder produced conforms to the re- Where:
quirements of this subpart. No defect is S = wall stress in psig;
permitted that is likely to weaken the P = 2 times service pressure;
finished cylinder appreciably. A rea- D = outside diameter in inches;
sonably smooth and uniform surface d = inside diameter in inches.
finish is required. Heads may be at- (g) Heat treatment. Heads formed by
tached to shells by lap brazing or may drawing or pressing must be uniformly
be formed integrally. The thickness of and properly heat treated prior to
the bottom of cylinders welded or tests. Cylinders with integral formed
formed by spinning is, under no condi- heads or bases must be subjected to a
tion, to be less than two times the min- normalizing operation. Normalizing
wreier-aviles on DSK3TPTVN1PROD with CFR
imum wall thickness of the cylindrical and brazing operations may be com-
shell. Such bottom thicknesses must be bined, provided the operation is carried
measured within an area bounded by a out at a temperature in excess of the
line representing the points of contact upper critical temperature of the steel.
53
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178.55 49 CFR Ch. I (10111 Edition)
(4) Cylinders must be tested as fol- (ii) The specimen, exclusive of grip
lows: ends, may not be flattened. Grip ends
(i) At least one cylinder selected at may be flattened to within one inch of
random out of each lot of 200 or less each end of the reduced section.
54
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Pipeline and Hazardous Materials Safety Admin., DOT 178.55
(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 lo- pipe 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 pres- the rings accompany the lot which
sure only, not by blows. When speci- they represent in all thermal proc-
mens are so taken and prepared, the in- essing operations. At least one of the
spectors report must show in connec- rings 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 fin-
apply: ished bottom over an area of at least
(i) The yield strength must be deter- 116 of the total area of the bottom but
mined by either the offset method or not less than 34 inch in diameter, in-
the extension under load method as cluding the closure, for at least 1
prescribed in ASTM E 8 (IBR, see 171.7 minute, during which time the other
of this subchapter). side of the bottom exposed to pressure
(ii) In using the extension under must be covered with water and closely
load method, the total strain (or ex- examined for indications of leakage.
tension under load) corresponding to Except as provided in paragraph (n) of
the stress at which the 0.2 percent per- this section, cylinders which are leak-
manent strain occurs may be deter- ing must be rejected.
mined with sufficient accuracy by cal-
(2) A spun cylinder is one in which an
culating the elastic extension of the
end closure in the finished cylinder has
gauge length under appropriate load
been welded by the spinning process.
and adding thereto 0.2 percent of the
(3) A plugged cylinder is one in which
gauge length. Elastic extension cal-
a permanent closure in the bottom of a
culations must be based on an elastic
finished cylinder has been effected by a
modulus of 30,000,000. In the event of
plug.
controversy, the entire stress-strain
diagram must be plotted and the yield (4) As a safety precaution, if the
strength determined from the 0.2 per- manufacturer elects to make this test
cent offset. before the hydrostatic test, he should
(iii) For the purpose of strain meas- design his apparatus so that the pres-
urement, the initial strain must be set sure is applied to the smallest area
while the specimen is under a stress of practicable, around the point of clo-
12,000 psi and the strain indicator read- sure, and so as to use the smallest pos-
ing being set at the calculated cor- sible volume of air or gas.
responding strain. (n) Rejected cylinders. Repairs of re-
(iv) Cross-head speed of the testing jected cylinders is authorized. Cyl-
machine may not exceed 18 inch per inders that are leaking must be re-
minute during yield strength deter- jected, except that:
mination. (1) Spun cylinders rejected under the
(l) Acceptable results for physical and provisions of paragraph (m) of this sec-
flattening tests. Acceptable results for tion may be removed from the spun
the physical and flattening tests are an cylinder category by drilling to remove
elongation of at least 40 percent for a 2 defective material, tapping, and plug-
inch gauge length or at least 20 percent ging.
in other cases and a yield strength not (2) Brazed joints may be rebrazed.
wreier-aviles on DSK3TPTVN1PROD with CFR
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178.56 49 CFR Ch. I (10111 Edition)
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Pipeline and Hazardous Materials Safety Admin., DOT 178.56
(2) Each opening in the cylinder, ex- (ii) Each cylinder not tested as pre-
cept those for safety devices, must be scribed in paragraph (i)(4)(i) of this sec-
provided with a fitting boss, or pad, se- tion 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 fol- showing a defect must be rejected un-
lowing: 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 speci-
fit 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 hydro-
width not over 112 inches, a gauge
static test as follows:
length of 2 inches with a width not
(1) The test must be by water jacket,
over 112 inches, or a gauge length at
or other suitable method, operated so
least 24 times the thickness with a
as to obtain accurate data. The pres-
width not over 6 times thickness is au-
sure gauge must permit reading to an
thorized when the cylinder wall is not
accuracy of 1 percent. The expansion
over 316 inch thick.
gauge must permit reading of total ex-
(ii) The specimen, exclusive of grip
pansion to an accuracy of either 1 per-
ends, may not be flattened. Grip ends
cent or 0.1 cubic centimeter.
may be flattened to within one inch of
(2) Pressure must be maintained for
each end of the reduced section.
at least 30 seconds or sufficiently
longer to assure complete expansion. (iii) When size of cylinder does not
Any internal pressure applied after permit securing straight specimens,
heat-treatment and before the official the specimens may be taken in any lo-
test may not exceed 90 percent of the cation or direction and may be
test pressure. If, due to failure of test straightened or flattened cold, by pres-
apparatus, the test pressure cannot be sure only, not by blows. When speci-
maintained, the test may be repeated mens are so taken and prepared, the in-
at a pressure increased by 10 percent or spectors report must show in connec-
100 psig, whichever is lower. tion with record of physical tests de-
(3) Permanent volumetric expansion tailed information in regard to such
may not exceed 10 percent of the total specimens.
volumetric expansion at test pressure. (iv) Heating of a specimen for any
(4) Cylinders must be tested as fol- purpose is not authorized.
lows: (3) The yield strength in tension
(i) At least one cylinder selected at must be the stress corresponding to a
random out of each lot of 200 or less permanent strain of 0.2 percent of the
must be tested as described in para- gauge length. The following conditions
graphs (i)(1), (i)(2), and (i)(3) of this sec- apply:
tion, to at least two times service pres- (i) The yield strength must be deter-
sure. If a selected cylinder fails, then mined by either the offset method or
two additional specimens must be se- the extension under load method as
lected at random from the same lot and prescribed in ASTM E 8 (IBR, see 171.7
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178.56 49 CFR Ch. I (10111 Edition)
the stress at which the 0.2 percent per- fail to meet the requirements, the en-
manent strain occurs may be deter- tire 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 cyl-
gauge 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- (l)(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 ac-
controversy, the entire stress-strain cordance with and must meet the re-
diagram must be plotted and the yield
quirements of CGA Pamphlet C3.
strength determined from the 0.2 per-
cent offset. (3) Alternate guided-bend test. This
(iii) For the purpose of strain meas- test may be used and must be as re-
urement, the initial strain reference quired by CGA Pamphlet C3. The spec-
must be set while the specimen is imen must be bent until the elongation
under a stress of 12,000 psi and the at the outer surface, adjacent to the
strain indicator reading being set at root of the weld, between the lightly
the calculated corresponding strain. scribed gage lines-a to b, is at least 20
(iv) Cross-head speed of the testing percent, except that this percentage
machine may not exceed 18 inch per may be reduced for steels having a ten-
minute during yield strength deter- sile strength in excess of 50,000 psi, as
mination. provided in paragraph (k) of this sec-
(k) Elongation. Physical test speci- tion.
mens must show at least a 40 percent (m) Rejected cylinders. Reheat treat-
elongation for 2-inch gauge lengths or ment of rejected cylinders is author-
at least a 20 percent elongation in ized. Subsequent thereto, cylinders
other cases. Except that these elon- must pass all prescribed tests to be ac-
gation percentages may be reduced nu- ceptable. Repair of welded seams by
merically by 2 for 2-inch specimens and welding is authorized.
by 1 in other cases for each 7,500 psi in-
(n) Markings. Markings must be
crement of tensile strength above 50,000
stamped plainly and permanently in
psi to a maximum of four such incre-
ments. one of the following locations on the
(l) Tests of welds. Welds must be test- cylinder:
ed as follows: (1) On shoulders and top heads not
(1) Tensile test. A specimen must be less than 0.087 inch thick.
cut from one cylinder of each lot of 200 (2) On neck, valve boss, valve protec-
or less, or a welded test plate. The tion sleeve, or similar part perma-
welded test plate must be of one of the nently attached to top end of cylinder.
heats in the lot of 200 or less which it (3) On a plate attached to the top of
represents, in the same condition and the cylinder or permanent part thereof:
approximately the same thickness as sufficient space must be left on the
the cylinder wall except that it may plate to provide for stamping at least
not be of a lesser thickness than that six retest dates: the plate must be at
required for a quarter size Charpy im- least 116 inch thick and must be at-
pact specimen. The weld must be made tached by welding or by brazing at a
by the same procedures and subjected temperature of at least 1100 F,
to the same heat treatment as the throughout all edges of the plate.
major weld on the cylinder. The speci- (4) Variations in location of mark-
mens must be taken across the major
ings authorized only when necessitated
seam and must be prepared and tested
by lack of space.
in accordance with and must meet the
requirements of CGA Pamphlet C3. [Amdt. 178114, 61 FR 25942, May 23, 1996, as
Should this specimen fail to meet the amended at 66 FR 45386, Aug. 28, 2001; 67 FR
wreier-aviles on DSK3TPTVN1PROD with CFR
requirements, specimens may be taken 51653, Aug. 8, 2002; 68 FR 75748, 75749, Dec. 31,
from two additional cylinders or weld- 2003]
ed test plates from the same lot and
tested. If either of the latter specimens
58
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Pipeline and Hazardous Materials Safety Admin., DOT 178.57
cave side to the pressure, hemi- must have reasonably true alignment.
spherical or ellipsoidal in shape with (2) All attachments to the sidewalls
the major diameter not more than and heads of the cylinder must be by
twice the minor diameter. Minimum fusion welding and must be of a
59
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178.57 49 CFR Ch. I (10111 Edition)
weldable material complying with the curely attached to, the cylinder body
impact requirements of paragraph (l) of by fusion welding. Attachments to a
this section. fitting, boss or pad may be made by
(3) For welding the cylinder, each welding, brazing, mechanical attach-
procedure and operator must be quali- ment, or threading.
fied in accordance with the sections of (2) Threads must comply with the fol-
CGA Pamphlet C3 that apply. In addi- lowing:
tion, impact tests of the weld must be (i) Threads must be clean-cut, even,
performed in accordance with para- without checks and cut to gauge.
graph (l) of this section as part of the (ii) Taper threads to be of a length
qualification of each welding procedure not less than that specified for NPT.
and operator.
(iii) Straight threads must have at
(4) Brazing, soldering and threading
least 4 engaged threads, tight fit and
are permitted only for joints not made
calculated shear strength at least 10
directly to the cylinder body. Threads
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 ex-
not exceed the least value of the fol- amined 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 deter- defect. The pressure gauge must permit
mined in paragraph (l) of this section. reading to an accuracy of 1 percent.
(3) One-half of the minimum tensile (j) Physical test. A physical test must
strength of the base metal determined be conducted to determine yield
as required in paragraph (j) of this sec- strength, tensile strength, and elon-
tion. gation as follows:
(4) The yield strength of the base (1) The test is required on 2 speci-
metal determined as required in para- mens selected from material of each
graph (l) of this section. heat and in the same condition as that
(5) Further provided that wall stress in the completed cylinder.
for cylinders having longitudinal (2) Specimens must conform to the
seams may not exceed 85 percent of the following:
above value, whichever applies. (i) A gauge length of 8 inches with a
(6) Calculation must be made by the width not over 112 inches, a gauge
following formula: length of 2 inches with width not over
S = [P(1.3D2 + 0.4d2)] / (D2 d2) 112 inches, or a gauge length at least 24
times thickness with a width not over
where:
6 times thickness (authorized when cyl-
S = wall stress in pounds psi;
P = minimum test pressure prescribed for
inder wall is not over 116 inch thick).
pressure test in psig; (ii) The specimen, exclusive of grip
D = outside diameter in inches; ends, may not be flattened. Grip ends
d = inside diameter in inches. may be flattened to within one inch of
(g) Heat treatment. Heat treatment is each end of the reduced section.
not permitted. (iii) When size of the cylinder does
(h) Openings in cylinder. Openings in not permit securing straight speci-
cylinders must conform to the fol- mens, the specimens may be taken in
lowing: any location or direction and may be
(1) Openings are permitted in heads straightened or flattened cold by pres-
only. They must be circular and may sure only, not by blows. When speci-
not exceed 3 inches in diameter or one mens are so taken and prepared, the in-
wreier-aviles on DSK3TPTVN1PROD with CFR
third of the cylinder diameter, which- spectors report must show in connec-
ever is less. Each opening in the cyl- tion with record of physical tests de-
inder must be provided with a fitting, tailed information in regard to such
boss or pad, either integral with, or se- specimens.
60
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Pipeline and Hazardous Materials Safety Admin., DOT 178.57
(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 im-
apply: pact specimen. The weld must be made
(i) The yield strength must be deter- by 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 speci-
prescribed 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 require-
load method, the total strain (or ex- ments of CGA Pamphlet C3. Should
tension under load), corresponding to
this specimen fail to meet the require-
the stress at which the 0.2 percent per-
ments, specimens may be taken from
manent strain occurs may be deter-
two additional cylinders or welded test
mined with sufficient accuracy by cal-
culating the elastic expansion of the plates from the same lot and tested. If
gauge length under appropriate load either of the latter specimens fails to
and adding thereto 0.2 percent of the meet the requirements, the entire lot
gauge length. Elastic extension cal- represented must be rejected.
culations must be based on the elastic (2) Guided bend test. A root bend
modulus of the material used. In the test specimen must be cut from the
event of controversy, the entire stress- cylinder or welded test plate, used for
strain diagram must be plotted and the the tensile test specified in paragraph
yield strength determined from the 0.2 (l)(1) of this section and from any other
percent offset. seam or equivalent welded test plate if
(iii) For the purpose of strain meas- the seam is welded by a procedure dif-
urement, the initial strain reference ferent from that used for the major
must be set while the specimen is seam. Specimens must be taken across
under a stress of 12,000 psi and the the particular seam being tested and
strain indicator reading being set at must be prepared and tested in accord-
the calculated corresponding strain. ance with and must meet the require-
(iv) Cross-head speed of the testing ments of CGA Pamphlet C3.
machine may not exceed 18 inch per (3) Alternate guided-bend test. This
minute during yield strength deter- test may be used and must be as speci-
mination. fied in CGA Pamphlet C3. The speci-
(k) Acceptable results for physical tests. men must be bent until the elongation
Physical properties must meet the lim- at the outer surface, adjacent to the
its specified in paragraph (o)(1), table 1, root of the weld, between the lightly
of this section, for the particular steel scribed gage lines a to b, is at least 20
in the annealed condition. The speci- percent, except that this percentage
mens must show at least a 20 percent may be reduced for steels having a ten-
elongation for a 2-inch gage length. Ex-
sile strength in excess of 100,000 psig, as
cept that the percentage may be re-
provided in paragraph (c) of this sec-
duced numerically by 2 for each 7,500
tion.
psi increment of tensile strength above
100,000 psi to a maximum of 5 such in- (4) Impact tests. One set of three im-
crements. Yield strength and tensile pact test specimens (for each test)
strength must meet the requirements must be prepared and tested for deter-
of paragraph (o)(1), table 1, of this sec- mining the impact properties of the de-
tion. posited weld metal
(l) Tests of welds. Welds must be test- (i) As part of the qualification of the
ed as follows: welding procedure.
wreier-aviles on DSK3TPTVN1PROD with CFR
(1) Tensile test. A specimen must be (ii) As part of the qualification of the
cut from one cylinder of each lot of 200 operators.
or less, or welded test plate. The weld- (iii) For each heat of welding rodor
ed test plate must be of one of the wire used.
61
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Pipeline and Hazardous Materials Safety Admin., DOT 178.57
Type 304 stainless steel. Chemical anal- an outer jacket made of steel or alu-
ysis must conform to ASTM A240, Type minum.
304 Stainless Steel. A heat of steel (ii) Flammable cryogenic liquids.
made under table 1 and table 2 in this Cylinders intended for use in the trans-
paragraph (o)(1) is acceptable, even portation of flammable cryogenic liq-
though its check chemical analysis is uid must have an outer jacket made of
slightly out of the specified range, if it steel.
is satisfactory in all other respects, (p) Markings. (1) Markings must be
provided the tolerances shown in table stamped plainly and permanently on
3 in this paragraph (o)(1) are not ex-
shoulder or top head of jacket or on a
ceeded. The following chemical anal-
permanently attached plate or head
yses and physical properties are au-
thorized: protective ring.
(2) The letters ST, followed by the
TABLE 1AUTHORIZED MATERIALS design service temperature (for exam-
ple, ST423F), must be marked on cyl-
Chemical analysis,
Designation inders having a design service tempera-
limits in percent
ture of colder than minus 320 F only.
Carbon 1 ............................................. 0.08 max.
Manganese ........................................ 2.00 max. Location to be just below the DOT
Phosphorus ........................................ 0.045 max. mark.
Sulphur .............................................. 0.030 max. (3) The maximum weight of contents,
Silicon ................................................ 1.00 max.
Nickel ................................................. 8.0010.50. in pounds (for example, Max. Content
Chromium .......................................... 18.0020.00. 51 #), must be marked on cylinders
Molybdenum ...................................... None.
Titanium ............................................. None. having a design service temperature
Columbium ......................................... None. colder than minus 320 F only. Loca-
1 The carbon analysis must be reported to the nearest hun- tion to be near symbol.
dredth of one percent. (4) Special orientation instructions
must be marked on the cylinder (for
TABLE 2PHYSICAL PROPERTIES
example, THIS END UP), if the cyl-
Physical inder is used in an orientation other
properties
(annealed) than vertical with openings at the top
of the cylinder.
Tensile strength, p.s.i. (minimum) ....................... 75,000
Yield strength, p.s.i. (minimum) ........................... 30,000
(5) If the jacket of the cylinder is
Elongation in 2 inches (minimum) percent .......... 30.0 constructed of aluminum, the letters
Elongation other permissible gauge lengths AL must be marked after the service
(minimum) percent ........................................... 15.0
pressure marking. Example: DOT-4L150
AL.
TABLE 3CHECK ANALYSIS TOLERANCES (6) Except for serial number and jack-
Tolerance et material designation, each marking
over the prescribed in this paragraph (p) must
Limit or specified range maximum
Elements be duplicated on each cylinder by any
(percent) limit or under
the minimum suitable means.
limit
(q) Inspectors report. In addition to
Carbon ............... To 0.030, incl ................... 0.005 the information required by 178.35, the
Over 0.30 to 0.20, incl ..... 0.01
Manganese ........ To 1.00 incl ...................... .03 inspectors reports must contain infor-
Over 1.00 to 3.00, incl ..... 0.04 mation on:
Phosphorus 1 ..... To 0.040, incl ................... 0.005
Over 0.040 to 0.020 incl .. 0.010
(1) The jacket material and insula-
Sulphur .............. To .40 incl ........................ 0.005 tion type;
Silicon ................ To 1.00, incl ..................... 0.05 (2) The design service temperature
Nickel ................. Over 5.00 to 10.00, incl ... 0.10
Over 10.00 to 20.00, incl 0.15 ( F); and
Chromium .......... Over 15.00 to 20.00, incl 0.20
(3) The impact test results, on a lot
1 Rephosphorized steels not subject to check analysis for
basis.
phosphorus.
wreier-aviles on DSK3TPTVN1PROD with CFR
(2) Outer jacket. (i) Nonflammable [Amdt. 178114, 61 FR 25942, May 23, 1996, as
amended at 66 FR 4538645388, Aug. 28, 2001; 67
cryogenic liquids. Cylinders intended
FR 51653, Aug. 8, 2002; 68 FR 75748, Dec. 31,
for use in the transportation of non- 2003]
flammable cryogenic liquid must have
63
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178.58 49 CFR Ch. I (10111 Edition)
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Pipeline and Hazardous Materials Safety Admin., DOT 178.58
P = test pressure prescribed for water jacket (i) Hydrostatic test. Each cylinder
test, i.e., at least 2 times service pressure, must successfully withstand a hydro-
in psig; static test as follows:
D = outside diameter in inches;
d = inside diameter in inches. (1) The test must be by water-jacket,
or other suitable method, operated so
(g) Heat treatment. The completed as to obtain accurate data. The pres-
containers must be uniformly and sure gauge must permit reading to an
properly heat-treated prior to tests. accuracy of 1 percent. The expansion
Heat-treatment of containers of the au- gauge must permit reading of total ex-
thorized analysis must be as follows: pansion to accuracy either of 1 percent
(1) All containers must be quenched or 0.1 cubic centimeter.
by oil, or other suitable medium except (2) Pressure must be maintained for
as provided in paragraph (g)(4) of this at least 30 seconds and sufficiently
section. longer to ensure complete expansion.
(2) The steel temperature on quench- Any internal pressure applied after
ing must be that recommended for the heat-treatment and previous to the of-
steel analysis, but may not exceed 1,750 ficial test may not exceed 90 percent of
F. the test pressure. If, due to failure of
(3) The steel must be tempered at the the test apparatus, the test pressure
temperature most suitable for the cannot be maintained, the test may be
analysis except that in no case shall repeated at a pressure increased by 10
the tempering temperature be less than percent or 100 psig, whichever is the
1,000 F. lower.
(4) The steel may be normalized at a (3) Permanent volumetric expansion
temperature of 1,650 F instead of being may not exceed 10 percent of total vol-
quenched, and containers so normal- umetric expansion at test pressure.
ized need not be tempered. (4) Each container must be tested to
(5) All cylinders, if water quenched or at least 2 times service pressure.
quenched with a liquid producing a
(j) Burst test. One container taken at
cooling rate in excess of 80 percent of
random out of 200 or less must be
the cooling rate of water, must be in-
hydrostatically tested to destruction.
spected by the magnetic particle or dye
The rupture pressure must be included
penetrant method to detect the pres-
as part of the inspectors report.
ence of quenching cracks. Any cylinder
found to have a quench crack must be (k) Flattening test. Spheres and cyl-
rejected and may not be requalified. inders must be subjected to a flat-
tening test as follows:
(h) Openings in container. Openings in
the container must comply with the (1) Flattening test for spheres. One
following requirements: sphere taken at random out of each lot
(1) Each opening in the container of 200 or less must be subjected to a
must be provided with a fitting, boss, flattening test as follows:
or pad of weldable steel securely at- (i) The test must be performed after
tached to the container by fusion weld- the hydrostatic test.
ing. (ii) The test must be at the weld be-
(2) Attachments to a fitting, boss, or tween the parallel steel plates on a
pad must be adequate to prevent leak- press with a welded seam, at right an-
age. Threads must comply with the fol- gles to the plates. Any projecting ap-
lowing: purtenances may be cut off (by me-
(i) Threads must be clean cut, even, chanical means only) prior to crushing.
without checks, and tapped to gauge. (2) Flattening test for cylinders. One
(ii) Taper threads to be of length not cylinder taken at random out of each
less than as specified for American lot of 200 or less, must be subjected to
Standard taper pipe threads. a flattening test as follows:
(iii) Straight threads, having at least (i) The test must be performed after
4 engaged threads, to have tight fit and the hydrostatic test.
wreier-aviles on DSK3TPTVN1PROD with CFR
calculated shear strength at least 10 (ii) The test cylinder must be placed
times the test pressure of the con- between wedge-shaped knife edges hav-
tainer; gaskets required, adequate to ing a 60 angle, rounded to a 12-inch ra-
prevent leakage. dius.
65
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178.58 49 CFR Ch. I (10111 Edition)
gauge length. The following conditions [Amdt. 178114, 61 FR 25942, May 23, 1996, as
apply: amended at 66 FR 45386, 45388, Aug. 28, 2001;
(i) The yield strength must be deter- 67 FR 51654, Aug. 8, 2002; 67 FR 61015, Sept. 27,
mined by either the offset method or 2002; 68 FR 75748, Dec. 31, 2003]
66
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Pipeline and Hazardous Materials Safety Admin., DOT 178.59
as to obtain accurate data. The pres- the stress at which the 0.2 percent per-
sure gauge must permit reading to an manent strain occurs may be deter-
accuracy of 1 percent. The expansion mined with sufficient accuracy by cal-
gauge must permit reading of total ex- culating the elastic extension of the
67
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178.59 49 CFR Ch. I (10111 Edition)
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 C12.
culations must be based on an elastic (2) When the porosity of each cyl-
modulus 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 cyl-
strength determined from the 0.2 off- inder fails, each cylinder in the lot
set. may be tested individually and those
(iii) For the purpose of strain meas- cylinders that pass the test are accept-
urement, 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 read- dried before insertion in cylinders, po-
ing being set at the calculated cor- rosity 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 18 inch per (4) The porosity of the filling mate-
minute during yield strength deter- rial 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 (nomi-
must 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 treat- acetone sol-
ment of rejected cylinder is authorized. Percent porosity of filler vent percent
shell capac-
Subsequent thereto, cylinders must ity by vol-
pass all prescribed tests to be accept- ume
able. Repair by welding is authorized. 90 to 92 ............................................................. 43.4
(l) Porous filling. (1) Cylinders must 87 to 90 ............................................................. 42.0
be filled with a porous material in ac- 83 to 87 ............................................................. 40.0
80 to 83 ............................................................. 38.6
cordance with the following: 75 to 80 ............................................................. 36.2
(i) The porous material may not dis- 70 to 75 ............................................................. 33.8
integrate or sag when wet with solvent 65 to 70 ............................................................. 31.4
or when subjected to normal service;
(ii) The porous filling material must (ii) Having volumetric capacity of 20
be uniform in quality and free of voids, pounds or less water capacity (nomi-
except that a well drilled into the fill- nal), may not exceed the following:
ing material beneath the valve is au- Maximum
thorized if the well is filled with a ma- acetone sol-
terial of such type that the functions vent percent
Percent porosity of filler shell capac-
of the filling material are not im- ity by vol-
paired; ume
(iii) Overall shrinkage of the filling 90 to 92 ............................................................. 41.8
material is authorized if the total 83 to 90 ............................................................. 38.5
clearance between the cylinder shell 80 to 83 ............................................................. 37.1
75 to 80 ............................................................. 34.8
and filling material, after solvent has 70 to 75 ............................................................. 32.5
been added, does not exceed 12 of 1 per- 65 to 70 ............................................................. 30.2
cent of the respective diameter or
length, but not to exceed 18 inch, meas- (m) Tare weight. The tare weight is
ured diametrically and longitudinally; the combined weight of the cylinder
(iv) The clearance may not impair proper, porous filling, valve, and sol-
the functions of the filling material; vent, without removable cap.
(v) The installed filling material (n) Duties of inspector. In addition to
must meet the requirements of CGA C the requirements of 178.35, the inspec-
12 (IBR, see 171.7 of this subchapter); tor is required to
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Pipeline and Hazardous Materials Safety Admin., DOT 178.60
of each lot of 200 or less, plates, shells, (b) Authorized steel. The authorized
or tubes used. steel is as specified in table I of appen-
(2) Verify compliance of cylinder dix A to this part.
shells with all shell requirements; in- (c) Identification of steel. Material
spect inside before closing in both ends; must be identified by any suitable
verify heat treatment as proper; obtain method except that plates and billets
all samples for all tests and for check for hot-drawn cylinders must be
analyses; witness all tests; verify marked with heat number.
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
cylinder produced conforms to the re-
(3) Prepare report on manufacture of
quirements of this subpart. No defect is
steel shells in form prescribed in
permitted that is likely to weaken the
178.35. Furnish one copy to manufac-
finished cylinder appreciably. A rea-
turer and three copies to the company sonably smooth and uniform surface
that is to complete the cylinders. finish is required. Welding procedures
(4) Determine porosity of filling and and operators must be qualified in ac-
tare weights; verify compliance of cordance with CGA Pamphlet C3 (IBR,
marking with prescribed requirements; see 171.7 of this subchapter).
obtain necessary copies of steel shell (e) Footrings. Exposed bottom welds
reports; and furnish complete reports on cylinders over 18 inches long must
required by this specification to the be protected by footrings.
person who has completed the manu- (f) Welding or brazing. Welding or
facture of the cylinders and, upon re- brazing for any purpose whatsoever is
quest, to the purchaser. The test re- prohibited except as follows:
ports must be retained by the inspector (1) The attachment to the tops or
for fifteen years from the original test bottoms of cylinders of neckrings,
date of the cylinder. footrings, handlers, bosses, pads, and
(o) Marking. (1) Marking on each cyl- valve protecting rings is authorized
inder must be stamped plainly and per- provided that such attachments and
manently on or near the shoulder, top the portion of the container to which
head, neck or valve protection collar they are attached are made of weldable
which is permanently attached to the steel, the carbon content of which may
cylinder and forming integral part not exceed 0.25 percent.
thereof. (2) Heat treatment is not required
(2) Tare weight of cylinder, in pounds after welding or brazing weldable low
and ounces, must be marked on the carbon parts to attachments, specified
cylinder. in paragraph (f)(1) of this section, of
(3) Cylinders, not completed, when similar material which have been pre-
viously welded or brazed to the top or
delivered must each be marked for
bottom of cylinders and properly heat
identification of each lot of 200 or less.
treated, provided such subsequent
[Amdt. 178114, 61 FR 25942, May 23, 1996, as welding or brazing does not produce a
amended at 66 FR 45386, Aug. 28, 2001; 67 FR temperature in excess of 400 F in any
61016, Sept. 27, 2002; 67 FR 51654, Aug. 8, 2002; part of the top or bottom material.
68 FR 75748, 75749, Dec. 31, 2003] (g) Wall thickness; wall stress. The wall
thickness/wall stress of the cylinder
178.60 Specification 8AL steel cyl- must conform to the following:
inders with porous fillings for acet-
ylene. (1) The calculated wall stress at 750
psi may not exceed 35,000 psi, or one-
(a) Type and service pressure. A DOT half of the minimum ultimate strength
8AL cylinder is a seamless steel cyl- of the steel as determined in paragraph
inder with a service pressure of 250 (l) of this section, whichever value is
psig. However, the attachment of heads the smaller. The measured wall thick-
wreier-aviles on DSK3TPTVN1PROD with CFR
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178.60 49 CFR Ch. I (10111 Edition)
S = [P(1.3D2 + 0.4d2)] / (D2 d2) sure of between 500 and 600 psig and
Where:
show no defect. If a hydrostatically
tested cylinder fails, each cylinder in
S = wall stress in pounds psi;
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- (l) 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 speci-
ameter over 5 inches, the minimum mens cut longitudinally from 1 cyl-
wall 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 treat- gauge length of 8 inches with a width
ment must be accomplished after all not over 112 inches, a gauge length 2
forming and welding operations, except inches with a width not over 112 inches,
that when brazed joints are used, heat or a gauge length at least 24 times
treatment must follow any forming thickness with a width not over 6 times
and welding operations but may be thickness is authorized when a cylinder
done before, during, or after the braz- wall is not over 316 inch thick.
ing operations. Liquid quenching is not (3) The yield strength in tension
authorized. must be the stress corresponding to a
(i) Openings. Standard taper pipe
permanent strain of 0.2 percent of the
threads required in all openings. The
gauge length. The following conditions
length of the opening may not be less
apply:
than as specified for American Stand-
ard pipe threads; tapped to gauge; (i) The yield strength must be deter-
clean cut, even, and without checks. mined by either the offset method or
(j) Hydrostatic test. Each cylinder the extension under load method as
must successfully withstand a hydro- prescribed in ASTM E 8 (IBR, see 171.7
static test as follows: of this subchapter).
(1) The test must be by water-jacket, (ii) In using the extension under
or other suitable method, operated so load method, the total strain (or ex-
as to obtain accurate data. The pres- tension under load) corresponding to
sure gauge must permit reading to an the stress at which the 0.2 percent per-
accuracy of 1 percent. The expansion manent strain occurs may be deter-
gauge must permit reading of total ex- mined with sufficient accuracy by cal-
pansion to an accuracy of either 1 per- culating the elastic extension of the
cent or 0.1 cubic centimeter. gauge length under appropriate load
(2) Pressure must be maintained for and adding thereto 0.2 percent of the
at least 30 seconds and sufficiently gauge length. Elastic extension cal-
longer to ensure complete expansion. culations must be based on an elastic
Any internal pressure applied after modulus of 30,000,000. In the event of
heat-treatment and previous to the of- controversy, the entire stress-strain
ficial test may not exceed 90 percent of diagram must be plotted and the yield
the test pressure. strength determined from the 0.2 off-
(3) Permanent volumetric expansion set.
may not exceed 10 percent of total vol- (iii) For the purpose of strain meas-
umetric expansion at test pressure. urement, the initial strain must be set
wreier-aviles on DSK3TPTVN1PROD with CFR
(4) One cylinder out of each lot of 200 while the specimen is under a stress of
or less must be hydrostatically tested 12,000 psi, the strain indicator reading
to at least 750 psig. Cylinders not so being set at the calculated cor-
tested must be examined under pres- responding strain.
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Pipeline and Hazardous Materials Safety Admin., DOT 178.60
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178.61 49 CFR Ch. I (10111 Edition)
this section; and furnish complete test basic oxygen carbon steel of uniform
reports required by this specification quality. Content percent may not ex-
to the person who has completed the ceed the following: Carbon 0.25, Man-
manufacturer of the cylinders and, ganese 0.60, Phosphorus 0.045, Sulfur
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Pipeline and Hazardous Materials Safety Admin., DOT 178.61
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178.61 49 CFR Ch. I (10111 Edition)
E = joint efficiency of the longitudinal seam ficial test may not exceed 90 percent of
(from paragraph (d) of this section). the test pressure.
(g) Heat treatment. Each cylinder (3) Permanent volumetric expansion
must be uniformly and properly heat may not exceed 10 percent of the total
treated prior to test by the applicable volumetric expansion at test pressure.
method referenced in Table 1 of appen- (4) Cylinders must be tested as fol-
dix A to this part. Heat treatment lows:
must be accomplished after all forming (i) At least 1 cylinder selected at ran-
and welding operations. Heat treat- dom out of each lot of 200 or less must
ment is not required after welding or be tested as outlined in paragraphs
brazing of weldable low carbon parts to (i)(1), (i)(2), and (i)(3) of this section to
attachments of similar material which at least two times service pressure.
have been previously welded to the top (ii) All cylinders not tested as out-
or bottom of cylinders and properly lined in paragraph (i)(4)(i) of this sec-
heat treated, provided such subsequent tion must be examined under pressure
welding or brazing does not produce a of at least two times service pressure
temperature in excess of 400 F in any and show no defect.
part of the top or bottom material. (5) One finished cylinder selected at
(h) Openings in cylinders. Openings in random out of each lot of 500 or less
the cylinder must conform to the fol- successively produced must be
lowing: hydrostatically tested to 4 times serv-
(1) All openings must be in the heads ice pressure without bursting.
or bases. (j) Physical tests. Cylinders must be
(2) Openings in cylinders must be pro- subjected to a physical test as follows:
vided with adequate fittings, bosses, or (1) Specimens must be taken from
pads, integral with or securely at- one cylinder after heat treatment and
tached to the cylinder by welding. chosen at random from each lot of 200
(3) Threads must comply with the fol- or less, as follows:
lowing: (i) Body specimen. One specimen
(i) Threads must be clean cut and to must be taken longitudinally from the
gauge. body section at least 90 degrees away
(ii) Taper threads must be of length from the weld.
not less than as specified for American (ii) Head specimen. One specimen
Standard Taper Pipe threads. must be taken from either head on a
(iii) Straight threads, having at least cylinder when both heads are made of
4 engaged threads, to have tight fit and the same material. However, if the two
calculated shear strength at least 10 heads are made of differing materials,
times the test pressure of the cylinder; a specimen must be taken from each
gaskets required, adequate to prevent head.
leakage. (iii) If due to welded attachments on
(4) Closure of fittings, boss or pads the top head there is insufficient sur-
must be adequate to prevent leakage. face from which to take a specimen, it
(i) Hydrostatic test. Cylinders must may be taken from a representative
withstand a hydrostatic test, as fol- head of the same heat treatment as the
lows: test cylinder.
(1) The test must be by water-jacket, (2) Specimens must conform to the
or other suitable method, operated so following:
as to obtain accurate data. The pres- (i) A gauge length of 8 inches with a
sure gauge must permit readings to an width not over 112 inches, a gauge
accuracy of 1 percent. The expansion length of 2 inches with a width not
gauge must permit readings of total over 112 inches, or a gauge length at
volumetric expansion to an accuracy least 24 times thickness with a width
either of 1 percent or 0.1 cubic centi- not over 6 times thickness is author-
meter. ized when a cylinder wall is not over 316
(2) Pressure must be maintained for inch thick.
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Pipeline and Hazardous Materials Safety Admin., DOT 178.61
(iii) When size of the cylinder does (l) Tests of welds. Welds must be sub-
not permit securing straight speci- jected to the following tests:
mens, the specimens may be taken in (1) Tensile test. A specimen must be
any location or direction and may be cut from one cylinder of each lot of 200
straightened or flattened cold, by pres- or less. The specimen must be taken
sure only, not by blows when speci- from across the longitudinal seam and
mens are so taken and prepared, the in- must be prepared and tested in accord-
spectors report must show in connec- ance with and must meet the require-
tion with record of physical tests de- ments of CGA Pamphlet C3.
tailed information in regard to such (2) Guided bend test. A root test speci-
specimens.
men must be cut from the cylinder
(iv) Heating of a specimen for any
used for the tensile test specified in
purpose is not authorized.
paragraph (l)(1) of this section. Speci-
(3) The yield strength in tension
mens must be taken from across the
must be the stress corresponding to a
permanent strain of 0.2 percent of the longitudinal seam and must be pre-
gauge length. The following conditions pared and tested in accordance with
apply: and must meet the requirements of
(i) The yield strength must be deter- CGA Pamphlet C3.
mined by either the off-set method (3) Alternate guided bend test. This
or the extension under load method test may be used and must be as re-
as prescribed in ASTM E 8 (IBR, see quired by CGA Pamphlet C3. The spec-
171.7 of this subchapter). imen must be bent until the elongation
(ii) In using the extension under at the outer surface, adjacent to the
load method, the total strain (or ex- root of the weld, between the lightly
tension under load), corresponding to scribed gauge lines a to b, must be at
the stress at which the 0.2-percent per- least 20 percent, except that this per-
manent strain occurs may be deter- centage may be reduced for steels hav-
mined with sufficient accuracy by cal- ing a tensile strength in excess of 50,000
culating the elastic extension of the psi, as provided in paragraph (k) of this
gauge length under appropriate load section.
and adding thereto 0.2 percent of the (m) Radiographic examination. Welds
gauge length. Elastic extension cal- of the cylinders must be subjected to a
culations must be based on an elastic radiographic examination as follows:
modulus of 30,000,000. In the event of (1) Radiographic inspection must
controversy, the entire stress-strain conform to the techniques and accept-
diagram must be plotted and the yield ability criteria set forth in CGA Pam-
strength determined from the 0.2-per- phlet C3. When fluoroscopic inspection
cent offset.
is used, permanent film records need
(iii) For the purpose of strain meas-
not be retained.
urement, the initial strain reference
must be set while the specimen is (2) Should spot radiographic exam-
under a stress of 12,000 psi and the ination fail to meet the requirements
strain indicator reading being set at of paragraph (m)(1) of this section, two
the calculated corresponding strain. additional welds from the same lot of
(iv) Cross-head speed of the testing 50 cylinders or less must be examined,
machine may not exceed 18 inch per and if either of these fail to meet the
minute during yield strength deter- requirements, each cylinder must be
mination. examined as previously outlined; only
(k) Elongation. Physical test speci- those passing are acceptable.
mens must show at least a 40 percent (n) Rejected cylinders. (1) Unless oth-
elongation for a 2-inch gauge length or erwise stated, if a sample cylinder or
at least a 20 percent elongation in specimen taken from a lot of cylinders
other cases. Except that these elon- fails the prescribed test, then two addi-
gation percentages may be reduced nu- tional specimens must be selected from
wreier-aviles on DSK3TPTVN1PROD with CFR
merically by 2 for 2-inch specimens and the same lot and subjected to the pre-
by 1 in other cases for each 7,500 psi in- scribed test. If either of these fails the
crement of tensile strength above 50,000 test, then the entire lot must be re-
psi to a maximum of four increments. jected.
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178.65 49 CFR Ch. I (10111 Edition)
(2) Reheat treatment of rejected cyl- (2) Test pressure. The minimum test
inders is authorized. Subsequent there- pressure is the maximum pressure of
to, cylinders must pass all prescribed contents at 130 F or 180 p.s.i.g. which-
tests to be acceptable. Repair of welded ever is greater.
seams by welding is authorized pro- (3) Pressure of contents. The term
vided that all defective metal is cut pressure of contents as used in this
away and the joint is rewelded as pre- specification means the total pressure
scribed for original welded joints. of all the materials to be shipped in the
(o) Markings. Markings must be cylinder.
stamped plainly and permanently in (b) Material; steel or aluminum. The
any of the following locations on the cylinder must be constructed of either
cylinder: steel or aluminum conforming to the
(1) On shoulders and top heads when following requirements:
they are not less than 0.087-inch thick. (1) Steel. (i) The steel analysis must
(2) On a metal plate attached to the conform to the following:
top of the cylinder or permanent part Ladle Check
thereof; sufficient space must be left on analysis analysis
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
at least 116-inch thick and must be at- Sulfur, maximum percent ...................... .05 .06
tached by welding, or by brazing. The
brazing rod is to melt at a temperature (ii) For a cylinder made of seamless
of 1100 F Welding or brazing must be steel tubing with integrally formed
along all the edges of the plate. ends, hot drawn, and finished, content
(3) On the neck, valve boss, valve pro- percent for the following may not ex-
tection sleeve, or similar part perma- ceed: Carbon, 0.55; phosphorous, 0.045;
nently attached to the top of the cyl- sulfur, 0.050.
inder. (iii) For non-heat treated welded
(4) On the footring permanently at- steel cylinders, adequately killed deep
tached to the cylinder, provided the drawing quality steel is required.
water capacity of the cylinder does not (iv) Longitudinal or helical welded
exceed 25 pounds. cylinders are not authorized for service
(p) Inspectors report. In addition to pressures in excess of 500 p.s.i.g.
the information required by 178.35, the (2) Aluminum. Aluminum is not au-
inspectors report must indicate the thorized for service pressures in excess
type and amount of radiography. of 500 psig. The analysis of the alu-
minum must conform to the Aluminum
[Amdt. 178114, 61 FR 25942, May 23, 1996, as
amended at 64 FR 51919, Sept. 27, 1999; 66 FR
Association standard for alloys 1060,
45386, 45388, Aug. 28, 2001; 67 FR 51654, Aug. 6, 1100, 1170, 3003, 5052, 5086, 5154, 6061, and
2002; 67 FR 61016, Sept. 27, 2002; 68 FR 57633, 6063, as specified in its publication en-
Oct. 6, 2003; 68 FR 75748, Dec. 31, 2003] titled Aluminum Standards and
Data (IBR, see 171.7 of this sub-
178.65 Specification 39 non-reusable chapter).
(non-refillable) cylinders. (3) Material with seams, cracks, lam-
(a) Type, size, service pressure, and test inations, or other injurious defects not
pressure. A DOT 39 cylinder is a seam- permitted.
less, welded, or brazed cylinder with a (4) Material used must be identified
service pressure not to exceed 80 per- by any suitable method.
cent of the test pressure. Spherical (c) Manufacture. (1) General manufac-
pressure vessels are authorized and turing requirements are as follows:
covered by references to cylinders in (i) The surface finish must be uni-
this specification. form and reasonably smooth.
(1) Size limitation. Maximum water ca- (ii) Inside surfaces must be clean,
pacity may not exceed: (i) 55 pounds dry, and free of loose particles.
wreier-aviles on DSK3TPTVN1PROD with CFR
(1,526 cubic inches) for a service pres- (iii) No defect of any kind is per-
sure of 500 p.s.i.g. or less, and (ii) 10 mitted if it is likely to weaken a fin-
pounds (277 cubic inches) for a service ished cylinder.
pressure in excess of 500 p.s.i.g. (2) Requirements for seams:
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Pipeline and Hazardous Materials Safety Admin., DOT 178.65
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178.68 49 CFR Ch. I (10111 Edition)
(i) Markings. (1) The markings re- circumferential weld. The circumferen-
quired by this section must be durable tial weld may not be closer to the point
and waterproof. The requirements of of tangency of the cylindrical portion
178.35(h) do not apply to this section. with the shoulder than 20 times the
78
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Pipeline and Hazardous Materials Safety Admin., DOT 178.68
stress at twice service pressure may seconds and sufficiently longer to in-
not exceed the lesser value of either of sure complete expansion. Any internal
the following: pressure applied previous to the official
(i) 20,000 psi. test may not exceed 90 percent of the
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178.68 49 CFR Ch. I (10111 Edition)
test pressure. If, due to failure of the (IBR, see 171.7 of this subchapter). The
test apparatus, the test pressure can- root of the weld (inside surface of the
not be maintained, the test may be re- cylinder) must be located away from
peated at a pressure increased by 10 the ram of the jig. The specimen must
percent over the pressure otherwise not show a crack or other open defect
specified. exceeding 18 inch in any direction upon
(3) Permanent volumetric expansion completion of the test. Should this
may not exceed 12 percent of total vol- specimen fail to meet the require-
umetric expansion at test pressure. ments, specimens may be taken from
(4) Cylinders having a calculated wall each of 2 additional cylinders from the
stress of 18,000 psi or less at test pres- same lot and tested. If either of the lat-
sure may be tested as follows:
ter specimens fails to meet require-
(i) At least one cylinder selected at
ments, the entire lot represented must
random out of each lot of 200 or less
must be tested in accordance with be rejected.
paragraphs (h)(1), (h)(2), and (h)(3) of (ii) Alternatively, the specimen may
this section. be tested in a guided bend test jig as il-
(ii) All cylinders not tested as pro- lustrated in Figure 12.1 of The Alu-
vided in paragraph (h)(4)(i) of this sec- minum Associations 2002 publication,
tion must be examined under pressure Welding Aluminum: Theory and Prac-
of at least 2 times service pressure and tice. The root of the weld (inside sur-
show no defect. face of the cylinder) must be located
(5) One finished cylinder selected at away from the mandrel of the jig. No
random out of each lot of 1,000 or less specimen must show a crack or other
must be hydrostatically tested to 4 open defect exceeding 18 inch in any di-
times the service pressure without rection upon completion of the test.
bursting. Inability to meet this re- Should this specimen fail to meet the
quirement must result in rejection of requirements, specimens may be taken
the lot. from each of 2 additional cylinders
(i) Flattening test. After hydrostatic from the same lot and tested. If either
testing, a flattening test is required on of the latter specimens fails to meet
one section of a cylinder, taken at ran- requirements, the entire lot rep-
dom out of each lot of 200 or less as fol- resented must be rejected.
lows:
(j) Physical test. A physical test must
(1) If the weld is not at midlength of
be conducted to determine yield
the cylinder, the test section must be
no less in width than 30 times the cyl- strength, tensile strength, elongation,
inder wall thickness. The weld must be and reduction of area of material as
in the center of the section. Weld rein- follows:
forcement must be removed by machin- (1) The test is required on 2 speci-
ing or grinding so that the weld is flush mens cut from one cylinder or part
with the exterior of the parent metal. thereof taken at random out of each
There must be no evidence of cracking lot of 200 or less.
in the sample when it is flattened be- (2) Specimens must conform to the
tween flat plates to no more than 6 following:
times the wall thickness. (i) A gauge length of 8 inches with a
(2) Guided bend test. A bend test speci- width not over 112 inches, a gauge
men must be cut from the cylinder length of 2 inches with a width not
used for the physical test specified in over 112 inches.
paragraph (j) of this section. Specimen (ii) The specimen, exclusive of grip
must be taken across the seam, must ends, may not be flattened. Grip ends
be a minimum of 112 inches wide, edges may be flattened to within 1 inch of
must be parallel and rounded with a
each end of the reduced section.
file, and back-up strip, if used, must be
removed by machining. The specimen (iii) When size of cylinder does not
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Pipeline and Hazardous Materials Safety Admin., DOT 178.69
paragraph (j) of this section. Specimen ciate Administrator will notify the
must be taken across the seam, must manufacturer in writing of the results
be 112 inches wide, edges must be par- of the audit. The notification will con-
allel and rounded with a file, and back- tain the conclusions of the audit and
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178.70 49 CFR Ch. I (10111 Edition)
any corrective action required. The As- ministrator will notify the manufac-
sociate Administrator may perform turer of the findings.
periodic audits to ensure that the man- (b) Design type approvals. The manu-
ufacturer operates in accordance with facturer must have each pressure re-
the quality system. Reports of periodic ceptacle design type reviewed by an IIA
audits will be provided to the manufac- and approved by the Associate Admin-
turer. The manufacturer must bear the istrator in accordance with 178.70. A
cost of audits. cylinder is considered to be of a new
(2) Quality system documentation. The design, compared with an existing ap-
manufacturer must be able to dem- proved design, as stated in the applica-
onstrate a documented quality system. ble ISO design, construction and test-
Management must review the adequacy ing standard.
of the quality system to assure that it
(c) Production inspection and certifi-
is effective and conforms to the re-
quirements in 178.70. The quality sys- cation. The manufacturer must ensure
tem records must be in English and that each UN pressure receptacle is in-
must include detailed descriptions of spected and certified in accordance
the following: with 178.71.
(i) The organizational structure and [71 FR 33885, June 12, 2006]
responsibilities of personnel with re-
gard to design and product quality; 178.70 Approval of UN pressure re-
(ii) The design control and design ceptacles.
verification techniques, processes, and (a) Initial design-type approval. The
procedures used when designing the manufacturer of a UN pressure recep-
pressure receptacles; tacle must obtain an initial design
(iii) The relevant procedures for pres- type approval from the Associate Ad-
sure receptacle manufacturing, quality ministrator. The initial design type ap-
control, quality assurance, and process proval must be of the pressure recep-
operation instructions; tacle design as it is intended to be pro-
(iv) Inspection and testing meth- duced. The manufacturer must arrange
odologies, measuring and testing equip- for an IIA, approved by the Associate
ment, and calibration data;
Administrator in accordance with sub-
(v) The process for meeting customer part I of part 107 of this chapter, to
requirements;
perform a pre-audit of its pressure re-
(vi) The process for document control ceptacle manufacturing operation prior
and document revision;
to having an audit conducted by the
(vii) The system for controlling non- Associate Administrator or his des-
conforming material and records, in-
ignee.
cluding procedures for identification,
segregation, and disposition; (b) IIA pre-audit. The manufacturer
must submit an application for initial
(viii) Production, processing and fab-
rication, including purchased compo- design type approval to the IIA for re-
nents, in-process and final materials; view. The IIA will examine the manu-
and facturers application for initial design
(ix) Training programs for relevant type approval for completeness. An in-
personnel. complete application will be returned
(3) Maintenance of quality system. The to the manufacturer with an expla-
manufacturer must maintain the qual- nation. If an application is complete,
ity system as approved by the Asso- the IIA will review all technical docu-
ciate Administrator. The manufacturer mentation, including drawings and cal-
shall notify the Associate Adminis- culations, to verify that the design
trator of any intended changes to the meets all requirements of the applica-
approved quality system prior to mak- ble UN pressure receptacle standard
ing the change. The Associate Adminis- and specification requirements. If the
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Pipeline and Hazardous Materials Safety Admin., DOT 178.70
duction IIA that will perform the func- sign type approval;
tions prescribed in paragraph (e) of this (4) Ensure that the various design
section. The IIA must be approved in type approval examinations and tests
writing by the Associate Administrator are performed accurately;
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178.70 49 CFR Ch. I (10111 Edition)
(5) Verify that each pressure recep- the Associate Administrator will no-
tacle is marked in accordance with the tify the applicant in writing and pro-
applicable requirements in 178.72; and vide the reason for the denial. The
(6) Furnish complete test reports to manufacturer may request that the As-
the manufacturer and upon request to sociate Administrator reconsider the
the purchaser. The test reports and decision. The application request
certificate of compliance must be re- must
tained by the IIA for at least 20 years (1) Be written in English and filed
from the original test date of the pres- within 60 days of receipt of the deci-
sure 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 informa-
are found satisfactory, PHMSA will tion needed to support the request to
schedule an on-site audit of the pres- reconsider.
sure receptacle manufacturers quality (i) Appeal. (1) A manufacturer whose
system, manufacturing processes, in- reconsideration request is denied may
spections, and test procedures. appeal to the PHMSA Administrator.
(2) During the audit, the manufac- The appeal must
turer will be required to produce pres- (i) Be written in English and filed
sure receptacles to the technical stand- within 60 days of receipt of the Asso-
ards for which approval is sought. ciate Administrators decision on re-
(3) The production IIA must witness consideration;
the required inspections and (ii) State in detail any alleged errors
verifications on the pressure recep- of fact and law;
tacles during the production run. The (iii) Enclose any additional informa-
IIA selected by the manufacturer for tion needed to support the appeal; and
production inspection and testing may (iv) State in detail the modification
be different from the IIA who per- of the final decision sought.
formed the design type approval (2) The PHMSA Administrator will
verifications. grant or deny the relief and inform the
(4) If the procedures and controls are appellant in writing of the decision.
deemed acceptable, test sample pres- PHMSA Administrators decision is the
sure receptacles will be selected at ran- final administrative action.
dom from the production lot and sent (j) Termination of a design type ap-
to a laboratory designated by the Asso- proval certificate. (1) The Associate Ad-
ciate Administrator for verification ministrator may terminate an approval
testing. certificate issue under this section if it
(5) If the pressure receptacle test is determined that, because of a change
samples are found to conform to all the in circumstances, the approval no
applicable requirements, the Associate longer is needed or no longer would be
Administrator will issue approvals to granted if applied for; information
the manufacturer and the production upon which the approval was based is
IIA to authorize the manufacture of fraudulent or substantially erroneous;
the pressure receptacles. The approved or termination of the approval is nec-
design type approval certificate will be essary to adequately protect against
returned to the manufacturer. risks to life and property.
(6) Upon the receipt of the approved (2) Before an approval is terminated,
design type approval certificate from the Associate Administrator will pro-
the Associate Administrator, the pres- vide the manufacturer and the ap-
sure receptacle manufacturer must proval agency
sign the certificate. (i) Written notice of the facts or con-
(g) Recordkeeping. The production IIA duct believed to warrant the with-
and the manufacturer must retain a drawal;
copy of the design type approval cer- (ii) Opportunity to submit oral and
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Pipeline and Hazardous Materials Safety Admin., DOT 178.71
(3) If the Associate Administrator de- that could result in the release of the
termines that a certificate of approval pressure receptacle contents during
must be withdrawn to preclude a sig- normal conditions of handling and
nificant and imminent adverse affect transport. Manifold piping leading to
on public safety, the procedures in shut-off valves must be sufficiently
paragraph (j)(2)(ii) and (iii) of this sec- flexible to protect the valves and the
tion need not be provided prior to with- piping from shearing or releasing the
drawal of the approval, but shall be pressure receptacle contents. The fill-
provided as soon as practicable there- ing and discharge valves and any pro-
after. tective caps must be secured against
[71 FR 33886, June 12, 2006, as amended at 71 unintended opening. The valves must
FR 54397, Sept. 14, 2006] conform to ISO 10297 (IBR, see 171.7 of
this subchapter) and be protected as
178.71 Specifications for UN pressure specified in 173.301b(f) of this sub-
receptacles. chapter.
(a) General. Each UN pressure recep- (3) UN pressure receptacles that can-
tacle must meet the requirements of not be handled manually or rolled,
this section. Requirements for ap- must be equipped with devices (e.g.,
proval, qualification, maintenance, and skids, rings, straps) ensuring that they
testing are contained in 178.70, and can be safely handled by mechanical
subpart C of part 180 of this subchapter. means and so arranged as not to impair
(b) Definitions. The following defini- the strength of, nor cause undue
tions apply for the purposes of design stresses, in the pressure receptacle.
and construction of UN pressure recep- (4) Pressure receptacles filled by vol-
tacles under this subpart: ume must be equipped with a level in-
Alternative arrangement means an ap- dicator.
proval granted by the Associate Ad- (e) Bundles of cylinders. UN pressure
ministrator for a MEGC that has been receptacles assembled in bundles must
designed, constructed or tested to the be structurally supported and held to-
technical requirements or testing gether as a unit and secured in a man-
methods other than those specified for ner that prevents movement in rela-
UN pressure receptacles in part 178 or tion to the structural assembly and
part 180 of this subchapter. movement that would result in the
Bundle of cylinders. See 171.8 of this concentration of harmful local
subchapter. stresses. The frame design must ensure
Design type means a pressure recep- stability under normal operating con-
tacle design as specified by a particular ditions.
pressure receptacle standard. (1) The frame must securely retain
Design type approval means an overall all the components of the bundle and
approval of the manufacturers quality must protect them from damage during
system and design type of each pres- conditions normally incident to trans-
sure receptacle to be produced within portation. The method of cylinder re-
the manufacturers facility. straint must prevent any vertical or
UN tube. See 171.8 of this subchapter. horizontal movement or rotation of the
(c) Following the final heat treat- cylinder that could cause undue strain
ment, all cylinders, except those se- on the manifold. The total assembly
lected for batch testing must be sub- must be able to withstand rough han-
jected to a proof pressure or a hydrau- dling, including being dropped or over-
lic volumetric expansion test. turned.
(d) Service equipment. (1) Except for (2) The frame must include features
pressure relief devices, UN pressure re- designed for the handling and transpor-
ceptacle equipment, including valves, tation of the bundle. The lifting rings
piping, fittings, and other equipment must be designed to withstand a design
subjected to pressure must be designed load of 2 times the maximum gross
and constructed to withstand at least weight. Bundles with more than one
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1.5 times the test pressure of the pres- lifting ring must be designed such that
sure receptacle. a minimum sling angle of 45 degrees to
(2) Service equipment must be config- the horizontal can be achieved during
ured or designed to prevent damage lifting using the lifting rings. If four
85
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178.71 49 CFR Ch. I (10111 Edition)
lifting rings are used, their design (3) ISO 20703: Gas cylindersRefill-
must be strong enough to allow the able welded aluminum-alloy cyl-
bundle to be lifted by two rings. Where indersDesign, construction and test-
two or four lifting rings are used, dia- ing (IBR, see 171.7 of this subchapter).
metrically opposite lifting rings must (g) Design and construction require-
be aligned with each other to allow for ments for UN refillable seamless steel cyl-
correct lifting using shackle pins. If inders. In addition to the general re-
the bundle is filled with forklift pock- quirements of this section, UN refill-
ets, it must contain two forklift pock- able seamless steel cylinders must con-
ets on each side from which it is to be form to the following ISO standards, as
lifted. The forklift pockets must be po- applicable:
sitioned symmetrically consistent with (1) ISO 98091: Gas cylindersRefill-
the bundle center of gravity. able seamless steel gas cylindersDe-
(3) The frame structural members sign, construction and testingPart 1:
must be designed for a vertical load of Quenched and tempered steel cylinders
2 times the maximum gross weight of with tensile strength less than 1 100
the bundle. Design stress levels may MPa. (IBR, see 171.7 of this sub-
not exceed 0.9 times the yield strength chapter).
of the material. (2) ISO 98092: Gas cylindersRefill-
(4) The frame must not contain any able seamless steel gas cylindersDe-
protrusions from the exterior frame
sign, construction and testingPart 2:
structure that could cause a hazardous
Quenched and tempered steel cylinders
condition.
with tensile strength greater than or
(5) The frame design must prevent
equal to 1 100 MPa. (IBR, see 171.7 of
collection of water or other debris that
this subchapter).
would increase the tare weight of bun-
dles filled by weight. (3) ISO 98093: Gas cylindersRefill-
(6) The floor of the bundle frame able seamless steel gas cylindersDe-
must not buckle during normal oper- sign, construction and testingPart 3:
ating conditions and must allow for the Normalized steel cylinders. (IBR, see
drainage of water and debris from 171.7 of this subchapter).
around the base of the cylinders. (h) Design and construction require-
(7) If the frame design includes mov- ments for UN refillable seamless aluminum
able doors or covers, they must be ca- alloy cylinders. In addition to the gen-
pable of being secured with latches or eral requirements of this section, UN
other means that will not become dis- refillable seamless aluminum cylinders
lodged by operational impact loads. must conform to ISO 7866: Gas cyl-
Valves that need to be operated in nor- indersRefillable seamless aluminum
mal service or in an emergency must alloy gas cylindersDesign, construc-
be accessible. tion and testing. (IBR, see 171.7 of this
(8) For bundles of cylinders, pressure subchapter). The use of Aluminum
receptacle marking requirements only alloy 6351T6 or equivalent is prohib-
apply to the individual cylinders of a ited.
bundle and not to any assembly struc- (i) Design and construction require-
ture. ments for UN non-refillable metal cyl-
(f) Design and construction require- inders. In addition to the general re-
ments for UN refillable welded cylinders. quirements of this section, UN non-re-
In addition to the general requirements fillable metal cylinders must conform
of this section, UN refillable welded to ISO 11118: Gas cylindersNon-refill-
cylinders must conform to the fol- able metallic gas cylindersSpecifica-
lowing ISO standards, as applicable: tion and test methods. (IBR, see 171.7
(1) ISO 4706: Gas cylindersRefillable of this subchapter.)
welded steel cylindersTest pressure (j) Design and construction require-
60 bar and below (IBR, see 171.7 of this ments for UN refillable seamless steel
subchapter). tubes. In addition to the general re-
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Pipeline and Hazardous Materials Safety Admin., DOT 178.71
between 150 L and 3000 LDesign, con- ments of this section, metal hydride
struction and testing. (IBR, see 171.7 storage systems must conform to the
of this subchapter). following ISO standards, as applicable:
(k) Design and construction require- ISO 16111: Transportable gas storage
ments for UN acetylene cylinders. In ad- devicesHydrogen absorbed in revers-
dition to the general requirements of ible metal hydride (IBR, see 171.7 of
this section, UN acetylene cylinders this subchapter).
must conform to the following ISO (n) Material compatibility. In addition
standards, as applicable: to the material requirements specified
(1) For the cylinder shell: in the UN pressure receptacle design
(i) ISO 98091: Gas cylindersRefill- and construction ISO standards, and
able seamless steel gas cylindersDe- any restrictions specified in part 173
sign, construction and testingPart 1:
for the gases to be transported, the re-
Quenched and tempered steel cylinders
quirements of the following standards
with tensile strength less than 1 100
must be applied with respect to mate-
MPa.
rial compatibility:
(ii) ISO 98093: Gas cylindersRefill-
able seamless steel gas cylindersDe- (1) ISO 111141: Transportable gas cyl-
sign, construction and testingPart 3: indersCompatibility of cylinder and
Normalized steel cylinders. valve materials with gas contents
(2) The porous mass in an acetylene Part 1: Metallic materials. (IBR, see
cylinder must conform to ISO 38072: 171.7 of this subchapter).
Cylinders for acetyleneBasic require- (2) ISO 111142: Transportable gas cyl-
mentsPart 2: Cylinders with fusible indersCompatibility of cylinder and
plugs. (IBR, see 171.7 of this sub- valve materials with gas contents
chapter). Part 2: Non-metallic materials. (IBR,
(l) Design and construction require- see 171.7 of this subchapter).
ments for UN composite cylinders. (1) In (o) Protection of closures. Closures and
addition to the general requirements of their protection must conform to the
this section, UN composite cylinders requirements in 173.301(f) of this sub-
must be designed for unlimited service chapter.
life and conform to the following ISO (p) Marking of UN refillable pressure re-
standards, as applicable: ceptacles. UN refillable pressure recep-
(i) ISO 111191: Gas cylinders of com- tacles must be marked clearly and leg-
posite constructionSpecification and ibly. The required markings must be
test methodsPart 1: Hoop-wrapped permanently affixed by stamping, en-
composite gas cylinders. (IBR, see
graving, or other equivalent method,
171.7 of this subchapter).
on the shoulder, top end or neck of the
(ii) ISO 111192: Gas cylinders of com-
pressure receptacle or on a perma-
posite constructionSpecification and
nently affixed component of the pres-
test methodsPart 2: Fully-wrapped
fibre reinforced composite gas cyl- sure receptacle, such as a welded col-
inders with load-sharing metal liners. lar. Except for the UN mark, the
(IBR, see 171.7 of this subchapter). minimum size of the marks must be 5
(iii) ISO 111193: Gas cylinders of mm for pressure receptacles with a di-
composite constructionSpecification ameter greater than or equal to 140
and test methodsPart 3: Fully mm, and 2.5 mm for pressure recep-
wrapped fibre reinforced composite gas tacles with a diameter less than 140
cylinders with non-load sharing metal- mm. The minimum size of the UN
lic or non-metallic liners. (IBR, see mark must be 5 mm for pressure recep-
171.7 of this subchapter). tacles with a diameter less than 140
(2) ISO 111192 and ISO 111193 gas mm, and 10 mm for pressure recep-
cylinders of composite construction tacles with a diameter of greater than
manufactured in accordance with the or equal to 140 mm. The depth of the
requirements for underwater use must markings must not create harmful
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178.71 49 CFR Ch. I (10111 Edition)
(2) The ISO standard, for example two significant figures rounded down
ISO 98091, used for design, construc- to the last digit. For acetylene cyl-
tion and testing. Acetylene cylinders inders, the tare weight must be marked
must be marked to indicate the porous on the cylinders in kilograms. The tare
mass and the steel shell, for example: weight is the sum of the empty weight,
ISO 38072/ISO 98091. mass of the valve, any coating and all
(3) The mark of the country where permanently attached parts (e.g., fit-
the approval is granted. The letters tings and accessories) that are not re-
USA must be marked on UN pressure moved during filling. The tare weight
receptacles approved by the United must be expressed to two significant
States. The manufacturer must obtain figures rounded down to the last digit.
an approval number from the Associate The tare weight does not include the
Administrator. The manufacturer ap- cylinder cap or any outlet cap or plug
proval number must follow the country not permanently attached to the cyl-
of approval mark, separated by a slash inder.
(for example, USA/MXXXX). Pressure (9) The minimum wall thickness of
receptacles approved by more than one the pressure receptacle in millimeters
national authority may contain the followed by the letters MM. This
mark of each country of approval, sep- mark is not required for pressure re-
arated by a comma. ceptacles with a water capacity less
(4) The identity mark or stamp of the than or equal to 1.0 L or for composite
IIA. cylinders.
(5) The date of the initial inspection, (10) For pressure receptacles intended
the year (four digits) followed by the for the transport of compressed gases
month (two digits) separated by a and UN 1001 acetylene, dissolved, the
slash, for example 2006/04. working pressure in bar, proceeded by
(6) The test pressure in bar, preceded the letters PW.
by the letters PH and followed by (11) For liquefied gases, the water ca-
the letters BAR. pacity in liters expressed to three sig-
(7) The rated charging pressure of the nificant digits rounded down to the
metal hydride storage system in bar, last digit, followed by the letter L. If
preceded by the letters RCP and fol- the value of the minimum or nominal
lowed by the letters BAR. water capacity is an integer, the digits
(8) The empty or tare weight. Except after the decimal point may be omit-
for acetylene cylinders, empty weight ted.
is the mass of the pressure receptacle (12) Identification of the cylinder
in kilograms, including all integral thread type (e.g., 25E).
parts (e.g., collar, neck ring, foot ring, (13) The country of manufacture. The
etc.), followed by the letters KG. The letters USA must be marked on cyl-
empty weight does not include the inders manufactured in the United
mass of the valve, valve cap or valve States.
guard or any coating. The empty (14) The serial number assigned by
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Pipeline and Hazardous Materials Safety Admin., DOT 178.71
(16) Identification of aluminum alloy, (1) The top grouping contains manu-
if applicable. facturing marks and must appear con-
(17) Stamp for nondestructive test- secutively in the sequence given in
ing, if applicable. paragraphs (p)(13) through (19) of this
(18) Stamp for underwater use of section.
composite cylinders, if applicable. (2) The middle grouping contains
(19) For metal hydride storage sys- operational marks described in para-
tems having a limited life, the date of graphs (p)(6) through (11) of this sec-
expiration indicated by the word
tion.
FINAL, followed by the year (four
digits), the month (two digits) and sep- (3) The bottom grouping contains
arated by a slash. certification marks and must appear
(q) Marking sequence. The marking re- consecutively in the sequence given in
quired by paragraph (p) of this section paragraphs (p)(1) through (5) of this
must be placed in three groups as section.
shown in the example below:
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178.71 49 CFR Ch. I (10111 Edition)
wreier-aviles on DSK3TPTVN1PROD with CFR
(r) Other markings. Other markings depth that will create harmful stress
are allowed in areas other than the side concentrations. Such marks must not
wall, provided they are made in low conflict with required marks.
stress areas and are not of a size and
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Pipeline and Hazardous Materials Safety Admin., DOT 178.74
(s) Marking of UN non-refillable pres- valid for the entire series. The design
sure receptacles. Unless otherwise speci- approval certificate must refer to the
fied in this paragraph, each UN non-re- prototype test report, the materials of
fillable pressure receptacle must be construction of the manifold, the
clearly and legibly marked as pre- standards to which the pressure recep-
scribed in paragraph (p) of this section. tacles are made and an approval num-
In addition, permanent stenciling is ber. The compliance requirements or
authorized. Except when stenciled, the test methods applicable to MEGCs as
marks must be on the shoulder, top end specified in this subpart may be varied
or neck of the pressure receptacle or on when the level of safety is determined
a permanently affixed component of to be equivalent to or exceed the re-
the pressure receptacle (e.g., a welded quirements of this subchapter and is
collar). approved in writing by the Associate
(1) The marking requirements and se- Administrator. A design approval may
quence listed in paragraphs (p)(1) serve for the approval of smaller
through (19) of this section are re- MEGCs made of materials of the same
quired, except the markings in para- type and thickness, by the same fab-
graphs (p)(8), (9), (12) and (18) are not rication techniques and with identical
applicable. The required serial number supports, equivalent closures and other
marking in paragraph (p)(14) may be appurtenances.
replaced by the batch number. (2) Each application for design ap-
(2) Each receptacle must be marked proval must be in English and contain
with the words DO NOT REFILL in the following information:
letters of at least 5 mm in height. (i) Two complete copies of all engi-
(3) A non-refillable pressure recep- neering drawings, calculations, and
tacle, because of its size, may sub- test data necessary to ensure that the
stitute the marking required by this design meets the relevant specifica-
paragraph with a label. Reduction in tion.
marking size is authorized only as pre- (ii) The manufacturers serial number
scribed in ISO 7225, Gas cylindersPre- that will be assigned to each MEGC.
cautionary labels. (IBR, see 171.7 of (iii) A statement as to whether the
this subchapter). design type has been examined by any
(4) Each non-refillable pressure re- approval agency previously and judged
ceptacle must also be legibly marked unacceptable. Affirmative statements
by stenciling the following statement: must be documented with the name of
Federal law forbids transportation if the approval agency, reason for non-ac-
refilled-penalty up to $500,000 fine and 5 ceptance, and the nature of modifica-
years in imprisonment (49 U.S.C. tions made to the design type.
5124). (b) Actions by the approval agency. The
(5) No person may mark a non-refill- approval agency must review the appli-
able pressure receptacle as meeting the cation for design type approval, includ-
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
[76 FR 3385, Jan. 19, 2011, as amended at 76 specification and to determine whether
FR 43532, July 20, 2011] it is complete and conforms to the re-
quirements of this section. An incom-
178.74 Approval of MEGCs. plete application will be returned to
(a) Application for design type ap- the applicant with the reasons why the
proval. (1) Each new MEGC design type application was returned. If the appli-
must have a design approval certifi- cation is complete and all applicable
cate. An owner or manufacturer must requirements of this section are met,
apply to an approval agency that is ap- the approval agency must prepare a
proved by the Associate Administrator MEGC design approval certificate con-
in accordance with subpart E of part taining the manufacturers name and
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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
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178.74 49 CFR Ch. I (10111 Edition)
Design Type Approval Certificate ap- ance with the procedures in this sec-
plication, the approval agency and the tion and that the MEGC is suitable for
manufacturer must each maintain a its intended purpose and meets the re-
copy of the approved drawings, calcula- quirements of this subchapter. When a
tions, and test data for at least 20 series of MEGCs is manufactured with-
years. out change in the design type, the cer-
(c) Approval agencys responsibilities. tificate may be valid for the entire se-
The approval agency is responsible for ries of MEGCs representing a single de-
ensuring that the MEGC conforms to sign type. The approval number must
the design type approval. The approval consist of the distinguishing sign or
agency must: mark of the country (USA for the
(1) Witness all tests required for the United States of America) where the
approval of the MEGC specified in this approval was granted and a registra-
section and 178.75. tion number.
(2) Ensure, through appropriate in- (6) Retain on file a copy of each ap-
spection, that each MEGC is fabricated proval certificate for at least 20 years.
in all respects in conformance with the (d) Manufacturers responsibilities. The
approved drawings, calculations, and manufacturer is responsible for compli-
test data. ance with the applicable specifications
(3) Determine and ensure that the for the design and construction of
MEGC is suitable for its intended use MEGCs. The manufacturer of a MEGC
and that it conforms to the require- must:
ments of this subchapter. (1) Comply with all the requirements
(4) Apply its name, identifying mark of the applicable ISO standard specified
or identifying number, and the date the in 178.71;
approval was issued, to the metal iden- (2) Obtain and use an approval agen-
tification marking plate attached to cy to review the design, construction
the MEGC upon successful completion and certification of the MEGC;
of all requirements of this subpart. (3) Provide a statement in the manu-
Any approvals by the Associate Admin- facturers data report certifying that
istrator authorizing design or con- each MEGC manufactured complies
struction alternatives (Alternate Ar- with the relevant specification and all
rangements) of the MEGC (see para- the applicable requirements of this
graph (a) of this section) must be indi- subchapter; and
cated on the metal identification plate (4) Retain records for the MEGCs for
as specified in 178.75(j). at least 20 years. When required by the
(5) Prepare an approval certificate specification, the manufacturer must
for each MEGC or, in the case of a se- provide copies of the records to the ap-
ries of identical MEGCs manufactured proval agency, the owner or lessee of
to a single design type, for each series the MEGC, and to a representative of
of MEGCs. The approval certificate DOT, upon request.
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 de-
framework test specified in ISO 14963 nial. The manufacturer may request
(IBR, see 171.7 of this subchapter); that the Associate Administrator re-
(iii) The results of the initial inspec- consider the decision. The application
tion and test specified in paragraph (h) request must
of this section; (1) Be written in English and filed
(iv) The results of the impact test within 90 days of receipt of the deci-
specified in 178.75(i)(4); sion;
(v) Certification documents verifying (2) State in detail any alleged errors
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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 accord- reconsider.
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Pipeline and Hazardous Materials Safety Admin., DOT 178.74
(f) Appeal. (1) A manufacturer whose pare a new approval certificate for the
reconsideration request is denied may modified MEGC and submit the certifi-
appeal to the PHMSA Administrator. cate to the Associate Administrator for
The appeal must approval. After receiving approval
(i) Be in writing and filed within 90 from the Associate Administrator, the
days of receipt of the Associate Admin- approval agency must ensure that any
istrator s decision on reconsideration; necessary changes are made to the
(ii) State in detail any alleged errors metal identification plate. A copy of
of fact and law; each newly issued approval certificate
(iii) Enclose any additional informa- must be retained by the approval agen-
tion needed to support the appeal; and cy and the MEGCs owner for at least
(iv) State in detail the modification 20 years. The approval agency must
of the final decision sought. perform the following activities:
(2) The Administrator will grant or (i) Retain a set of the approved re-
deny the relief and inform the appel- vised drawings, calculations, and data
lant in writing of the decision. The Ad- as specified in 178.69(b)(4) for at least
ministrators decision is the final ad- 20 years;
ministrative action. (ii) Ensure through appropriate in-
(g) Modifications to approved MEGCs. spection that all modifications con-
(1) Prior to modification of any ap- form to the revised drawings, calcula-
proved MEGC that may affect conform- tions, and test data; and
ance and safe use, and that may in- (iii) Determine the extent to which
volve a change to the design type or af- retesting of the modified MEGC is nec-
fect its ability to retain the hazardous essary based on the nature of the pro-
material in transportation, the posed modification, and ensure that all
MEGCs owner must inform the ap- required retests are satisfactorily per-
proval agency that prepared the initial formed.
approval certificate for the MEGC or, if (h) Termination of Approval Certificate.
the initial approval agency is unavail- (1) The Associate Administrator may
able, another approval agency, of the terminate an approval issued under
nature of the modification and request this section if he or she determines
certification of the modification. The that
owner must supply the approval agency (i) Because of a change in cir-
with all revised drawings, calculations, cumstances, the approval no longer is
and test data relative to the intended needed or no longer would be granted if
modification. The MEGCs owner must applied for;
also provide a statement as to whether (ii) Information upon which the ap-
the intended modification has been ex- proval was based is fraudulent or sub-
amined and determined to be unaccept- stantially erroneous;
able by any approval agency. The writ- (iii) Termination of the approval is
ten statement must include the name necessary to adequately protect
of the approval agency, the reason for against risks to life and property; or
non-acceptance, and the nature of (iv) The MEGC does not meet the
changes made to the modification since specification.
its original rejection. (2) Before an approval is terminated,
(2) The approval agency must review the Associate Administrator will pro-
the request for modification. If the ap- vide the person
proval agency determines that the pro- (i) Written notice of the facts or con-
posed modification does not conform to duct believed to warrant the termi-
the relevant specification, the approval nation;
agency must reject the request in ac- (ii) An opportunity to submit oral
cordance with paragraph (d) of this sec- and written evidence; and
tion. If the approval agency determines (3) An opportunity to demonstrate or
that the proposed modification con- achieve compliance with the applicable
forms fully with the relevant specifica- requirements.
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tion, the request is accepted. If modi- (i) Imminent Danger. If the Associate
fication to an approved MEGC alters Administrator determines that a cer-
any information on the approval cer- tificate of approval must be terminated
tificate, the approval agency must pre- to preclude a significant and imminent
93
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178.75 49 CFR Ch. I (10111 Edition)
adverse effect on public safety, the As- ble of being loaded and discharged
sociate Administrator may terminate without the removal of its structural
the certificate immediately. In such equipment. It must possess stabilizing
circumstances, the opportunities of members external to the pressure re-
paragraphs (h)(2) and (3) of this section ceptacles to provide structural integ-
need not be provided prior to termi- rity for handling and transport. MEGCs
nation of the approval, but must be must be designed and constructed with
provided as soon as practicable there- supports to provide a secure base dur-
after. ing transport and with lifting and tie-
[71 FR 33890, June 12, 2006] down attachments that are adequate
for lifting the MEGC including when
178.75 Specifications for MEGCs. loaded to its maximum permissible
(a) General. Each MEGC must meet gross mass. The MEGC must be de-
the requirements of this section. In a signed to be loaded onto a transport ve-
MEGC that meets the definition of a hicle or vessel and equipped with skids,
container within the terms of the mountings or accessories to facilitate
International Convention for Safe Con- mechanical handling.
tainers (CSC) must meet the require- (2) MEGCs must be designed, manu-
ments of the CSC as amended and 49 factured and equipped to withstand,
CFR parts 450 through 453, and must without loss of contents, all normal
have a CSC approval plate. handling and transportation condi-
(b) Alternate Arrangements. The tech- tions. The design must take into ac-
nical requirements applicable to count the effects of dynamic loading
MEGCs may be varied when the level of and fatigue.
safety is determined to be equivalent (3) Each pressure receptacle of a
to or exceed the requirements of this MEGC must be of the same design type,
subchapter. Such an alternate arrange- seamless steel, and constructed and
ment must be approved in writing by tested according to one of the following
the Associate Administrator. MEGCs ISO standards:
approved to an Alternate Arrangement (i) ISO 98091: Gas cylindersRefill-
must be marked as required by para- able seamless steel gas cylindersDe-
graph (j) of this section. sign, construction and testingPart 1:
(c) Definitions. The following defini- Quenched and tempered steel cylinders
tions apply: with tensile strength less than 1 100
Leakproofness test means a test using MPa. (IBR, see 171.7 of this sub-
gas subjecting the pressure receptacles chapter);
and the service equipment of the MEGC (ii) ISO 98092: Gas cylindersRefill-
to an effective internal pressure of not able seamless steel gas cylindersDe-
less than 20% of the test pressure. sign, construction and testingPart 2:
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 re- equal to 1 100 MPa. (IBR, see 171.7 of
ceptacles. this subchapter);
Maximum permissible gross mass or (iii) ISO 98093: Gas cylindersRefill-
MPGM means the heaviest load author- able seamless steel gas cylindersDe-
ized for transport (sum of the tare sign, construction and testingPart 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 cylindersRefill-
tem (measuring instruments, piping able seamless steel tubes of water ca-
and safety devices). pacity between 150 L and 3000 LDe-
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 stabi- fittings, and pipework must be con-
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Pipeline and Hazardous Materials Safety Admin., DOT 178.75
(5) Contact between dissimilar met- proof strength and, for austenitic
als that could result in damage by gal- steels, the 1 percent proof strength.
vanic action must be prevented by ap- (11) MEGCs must be capable of being
propriate means. electrically grounded to prevent elec-
(6) The materials of the MEGC, in- trostatic discharge when intended for
cluding any devices, gaskets, and ac- flammable gases.
cessories, must have no adverse effect (12) The pressure receptacles of a
on the gases intended for transport in MEGC must be secured in a manner to
the MEGC. prevent movement that could result in
(7) MEGCs must be designed to with- damage to the structure and con-
stand, without loss of contents, at centration of harmful localized
least the internal pressure due to the stresses.
contents, and the static, dynamic and (e) Service equipment. (1) Service
thermal loads during normal condi- equipment must be arranged so that it
tions of handling and transport. The is protected from mechanical damage
design must take into account the ef- by external forces during handling and
fects of fatigue, caused by repeated ap- transportation. When the connections
plication of these loads through the ex- between the frame and the pressure re-
pected life of the MEGC. ceptacles allow relative movement be-
(8) MEGCs and their fastenings must, tween the subassemblies, the equip-
under the maximum permissible load, ment must be fastened to allow move-
be capable of withstanding the fol- ment to prevent damage to any work-
lowing separately applied static forces ing part. The manifolds, discharge fit-
(for calculation purposes, acceleration tings (pipe sockets, shut-off devices),
due to gravity (g) = 9.81 m/s2): and shut-off valves must be protected
(i) In the direction of travel: 2g from damage by external forces. Mani-
(twice the MPGM multiplied by the ac- fold piping leading to shut-off valves
celeration due to gravity); must be sufficiently flexible to protect
(ii) Horizontally at right angles to the valves and the piping from shear-
the direction of travel: 1g (the MPGM ing, or releasing the pressure recep-
multiplied by the acceleration due to tacle contents. The filling and dis-
gravity. When the direction of travel is charge devices, including flanges or
not clearly determined, the forces must threaded plugs, and any protective caps
be equal to twice the MPGM); must be capable of being secured
(iii) Vertically upwards: 1g (the against unintended opening.
MPGM multiplied by the acceleration (2) Each pressure receptacle intended
due to gravity); and for the transport of Division 2.3 gases
(iv) Vertically downwards: 2g (twice must be equipped with an individual
the MPGM (total loading including the shut-off valve. The manifold for Divi-
effect of gravity) multiplied by the ac- sion 2.3 liquefied gases must be de-
celeration 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 ap- isolated 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 re- valves may be a backflow prevention
lation to the guaranteed yield valve. (ii) The filling and discharge de-
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178.75 49 CFR Ch. I (10111 Edition)
relief valve must be provided to pre- devices must be of sufficient size to en-
vent excessive pressure build-up. able the required discharge to pass un-
(iv) The main isolation valves on a restricted to the pressure relief device.
MEGC must be clearly marked to indi- A shut-off valve installed between the
cate their directions of closure. All pressure receptacle and the pressure re-
shutoff valves must close by a clock- lief device is prohibited, except where
wise motion of the handwheel. duplicate devices are provided for
(v) Each shut-off valve or other maintenance or other reasons, and the
means of closure must be designed and shut-off valves serving the devices ac-
constructed to withstand a pressure tually in use are locked open, or the
equal to or greater than 1.5 times the shut-off valves are interlocked so that
test pressure of the MEGC. at least one of the duplicate devices is
(vi) All shut-off valves with screwed always operable and capable of meeting
spindles must close by a clockwise mo- the requirements of paragraph (f)(1) of
tion of the handwheel. For other shut- this section. No obstruction is per-
off valves, the open and closed posi- mitted in an opening leading to or
tions and the direction of closure must leaving from a vent or pressure-relief
be clearly shown. device that might restrict or cut-off
(vii) All shut-off valves must be de- the flow from the pressure receptacle
signed and positioned to prevent unin- to that device. The opening through all
tentional opening. piping and fittings must have at least
(viii) Ductile metals must be used in the same flow area as the inlet of the
the construction of valves or acces- pressure relief device to which it is
sories. connected. The nominal size of the dis-
(4) The piping must be designed, con- charge piping must be at least as large
structed and installed to avoid damage as that of the pressure relief device.
due to expansion and contraction, me- (3) Location of pressure-relief de-
chanical shock and vibration. Joints in vices: For liquefied gases, each pres-
tubing must be brazed or have an sure relief device must, under max-
equally strong metal union. The melt- imum filling conditions, be in commu-
ing point of brazing materials must be nication with the vapor space of the
no lower than 525 C (977 F). The rated pressure receptacles. The devices, when
pressure of the service equipment and installed, must be arranged to ensure
of the manifold must be not less than the escaping vapor is discharged up-
two-thirds of the test pressure of the wards and unrestrictedly to prevent
pressure receptacles. impingement of escaping gas or liquid
(f) Pressure relief devices. Each pres- upon the MEGC, its pressure recep-
sure receptacle must be equipped with tacles or personnel. For flammable,
one or more pressure relief devices as pyrophoric and oxidizing gases, the es-
specified in 173.301(f) of this sub- caping gas must be directed away from
chapter. When pressure relief devices the pressure receptacle in such a man-
are 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 re- flow of gas are permissible provided the
lief devices. Pressure relief devices required pressure relief device capacity
must be of a type that will resist dy- is 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 de- intended to be filled by mass, it must
vices: CGA S1.1 (IBR, see 171.7 of this be equipped with one or more gauging
subchapter) must be used to determine devices. Glass level-gauges and gauges
wreier-aviles on DSK3TPTVN1PROD with CFR
the relief capacity of individual pres- made of other fragile material are pro-
sure receptacles. hibited.
(2) Connections to pressure-relief de- (h) MEGC supports, frameworks, lifting
vices: Connections to pressure relief and tie-down attachments. (1) MEGCs
96
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Pipeline and Hazardous Materials Safety Admin., DOT 178.75
must be designed and constructed with (i) Initial inspection and test. The pres-
a support structure to provide a secure sure receptacles and items of equip-
base during transport. MEGCs must be ment of each MEGC must be inspected
protected against damage to the pres- and tested before being put into service
sure receptacles and service equipment for the first time (initial inspection
resulting from lateral and longitudinal and test). This initial inspection and
impact and overturning. The forces test of an MEGC must include the fol-
specified in paragraph (d)(8) of this sec- lowing:
tion, and the safety factor specified in (1) A check of the design characteris-
paragraph (d)(10) of this section must tics.
be considered in this aspect of the de- (2) An external examination of the
sign. Skids, frameworks, cradles or MEGC and its fittings, taking into ac-
other similar structures are accept- count the hazardous materials to be
able. If the pressure receptacles and transported.
service equipment are so constructed
(3) A pressure test performed at the
as to withstand impact and over-
test pressures specified in
turning, additional protective support
173.304b(b)(1) and (2) of this sub-
structure is not required (see para-
graph (h)(4) of this section). chapter. The pressure test of the mani-
(2) The combined stresses caused by fold may be performed as a hydraulic
pressure receptacle mountings (e.g. test or by using another liquid or gas.
cradles, frameworks, etc.) and MEGC A leakproofness test and a test of the
lifting and tie-down attachments must satisfactory operation of all service
not cause excessive stress in any pres- equipment must also be performed be-
sure receptacle. Permanent lifting and fore the MEGC is placed into service.
tie-down attachments must be When the pressure receptacles and
equipped to all MEGCs. Any welding of their fittings have been pressure-tested
mountings or attachments onto the separately, they must be subjected to a
pressure receptacles is prohibited. leakproof test after assembly.
(3) The effects of environmental cor- (4) An MEGC that meets the defini-
rosion must be taken into account in tion of container in the CSC (see 49
the design of supports and frameworks. CFR 450.3(a)(2)) must be subjected to an
(4) When MEGCs are not protected impact test using a prototype rep-
during transport as specified in para- resenting each design type. The proto-
graph (h)(1) of this section, the pres- type MEGC must be shown to be capa-
sure receptacles and service equipment ble of absorbing the forces resulting
must be protected against damage re- from an impact not less than 4 times (4
sulting from lateral or longitudinal im- g) the MPGM of the fully loaded
pact or overturning. External fittings MEGC, at a duration typical of the me-
must be protected against release of chanical shocks experienced in rail
the pressure receptacles contents upon transport. A listing of acceptable
impact or overturning of the MEGC on methods for performing the impact test
its fittings. Particular attention must is provided in the UN Recommenda-
be paid to the protection of the mani- tions (IBR, see 171.7 of this sub-
fold. Examples of protection include: chapter).
(i) Protection against lateral impact, (j) Marking. (1) Each MEGC must be
which may consist of longitudinal bars; equipped with a corrosion resistant
(ii) Protection against overturning, metal plate permanently attached to
which may consist of reinforcement the MEGC in a conspicuous place read-
rings or bars fixed across the frame; ily accessible for inspection. The pres-
(iii) Protection against rear impact, sure receptacles must be marked ac-
which may consist of a bumper or cording to this section. Affixing the
frame; metal plate to a pressure receptacle is
(iv) Protection of the pressure recep- prohibited. At a minimum, the fol-
tacles and service equipment against lowing information must be marked on
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98
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99
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101
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103
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178.251178.2535 49 CFR Ch. I (10111 Edition)
[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
1787, 34 FR 18250, Nov. 14, 1969; 68 FR 75750, connections will not cause leakage of
Dec. 31, 2003] tanks.
104
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Pipeline and Hazardous Materials Safety Admin., DOT 178.25513
105
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178.25514 49 CFR Ch. I (10111 Edition)
[29 FR 18972, Dec. 29, 1964. Redesignated at 32 (3) Witness all tests required for the
FR 5606, Apr. 5, 1967, and amended by Amdt. approval of the portable tank specified
17883, 50 FR 11066, Mar. 19, 1985; 68 FR 75750, in this section and part 180, subpart G
Dec. 31, 2003] of this subchapter.
106
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Pipeline and Hazardous Materials Safety Admin., DOT 178.273
(4) Ensure, through appropriate in- series of identical portable tanks man-
spection that each portable tank is fab- ufactured to a single design type, for
ricated in all respects in conformance each series of portable tanks. The ap-
with the approved drawings, calcula- proval certificate must include all the
tions, and test data. information required to be displayed on
(5) Determine and ensure that the the metal identification plate required
portable tank is suitable for its in- by 178.274(i). The approval certificate
tended use and that it conforms to the must certify that the approval agency
requirements of this subchapter. designated to approve the portable
(6) For UN portable tanks intended tank has approved the portable tank in
for non-refrigerated and refrigerated accordance with the procedures in sub-
liquefied gases and Division 6.1 liquids part E of part 107 of this subchapter
which meet the inhalation toxicity cri- and that the portable tank is suitable
teria (Zone A or B) as defined in for its intended purpose and meets the
173.132 of this subchapter, or that are requirements of this subchapter. When
designated as toxic by inhalation mate- a series of portable tanks is manufac-
rials in the 172.101 Table of this sub- tured without change in the design
chapter, the approval agency must en- type, the certificate may be valid for
sure that: the entire series of portable tanks rep-
(i) The portable tank has been de- resenting a single design type. For UN
signed, constructed, certified, and portable tanks, the certificate must
stamped in accordance with the re- refer to the prototype test report, the
quirements in Division 1 of Section hazardous material or group of haz-
VIII of the ASME Code (IBR, see 171.7 ardous materials allowed to be trans-
of this subchapter). Other design codes ported, the materials of construction of
may be used if approved by the Asso- the shell and lining (when applicable)
ciate Administrator (see 178.274(b)(1)); and an approval number. The approval
(ii) All applicable provisions of the number must consist of the distin-
design and construction have been met guishing sign or mark of the country
to the satisfaction of the designated (USA for the United States of Amer-
approval agency in accordance with the ica) where the approval was granted
rules established in the ASME Code and a registration number.
and that the portable tank meets the (iii) Retain a copy of each approval
requirements of the ASME Code and all certificate.
the applicable requirements specified (8) For UN portable tanks, the ap-
in this subchapter; proval certificate must also include the
(iii) The inspector has carried out all following:
the inspections specified by the rules (i) The results of the applicable
established in the ASME Code; and framework and rail impact test speci-
(iv) The portable tank is marked fied in part 180, subpart G, of this sub-
with a U stamp code symbol under the chapter; and
authority of the authorized inde- (ii) The results of the initial inspec-
pendent inspector. tion and test in 178.274(j).
(7) Upon successful completion of all (9) The approval agency shall be inde-
requirements of this subpart, the ap- pendent from the manufacturer. The
proval agency must: approval agency and the authorized in-
(i) Apply its name, identifying mark spector may be the same entity.
or identifying number, and the date (c) Manufacturers responsibilities. The
upon which the approval was issued, to manufacturer is responsible for compli-
the metal identification marking plate ance with the applicable specifications
attached to the portable tank. Any ap- for the design and construction of port-
provals for UN portable tanks author- able tanks. In addition to responsi-
izing design or construction alter- bility for compliance, manufacturers
natives (Alternate Arrangements) ap- are responsible for ensuring that the
proved by the Associate Administrator contracted approval agency and au-
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178.273 49 CFR Ch. I (10111 Edition)
(1) Comply with all the applicable re- (2) A statement as to whether the in-
quirements of the ASME Code and of tended modification has been examined
this subpart including, but not limited and determined to be unacceptable by
to, ensuring that the quality control, any approval agency. The written
design calculations and required tests statement must include the name of
are performed and that all aspects of the approving agency, the reason for
the portable tank meet the applicable nonacceptance, and the nature of
requirements. changes made to the modification since
(2) Obtain and use a designated ap- its original rejection.
proval agency, if applicable, and obtain (3) The approval agency shall review
and use a DOT-designated approval the request for modification, and if it
agency to approve the design, construc- is determined that the proposed modi-
tion and certification of the portable fication is in full compliance with the
tank. relevant DOT specification, including a
(3) Provide a statement in the manu- UN portable tank, the request shall be
facturers data report certifying that approved and the approval agency shall
each portable tank that is manufac- perform the following activities:
tured complies with the relevant speci- (i) Return one set of the approved re-
fication and all the applicable require- vised drawings, calculations, and test
ments of this subchapter. data to the applicant. The second and
(4) Maintain records of the qualifica- third sets of the approved revised draw-
tion of portable tanks for at least 5 ings, calculations, and data shall be re-
years and provide copies to the ap- tained by the approval agency as re-
proval agency, the owner or lessee of quired in 107.404(a)(3) of this sub-
the tank. Upon request, provide these chapter.
records to a representative of DOT.
(ii) Ensure through appropriate in-
(d) Denial of application for approval.
spection that all modifications con-
If an approval agency finds that a port-
form to the revised drawings, calcula-
able tank cannot be approved for any
tions, and test data.
reason, it shall notify the applicant in
writing and shall provide the applicant (iii) Determine the extent to which
with the reasons for which the ap- retesting of the modified tank is nec-
proval is denied. A copy of the notifica- essary based on the nature of the pro-
tion letter shall be provided to the As- posed modification, and ensure that all
sociate Administrator. An applicant required retests are satisfactorily per-
aggrieved 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 ap-
the 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
UN portable tank which may affect made to the metal identification plate.
conformance and the safe use of the A copy of each newly issued approval
portable tank, which may involve a certificate shall be retained by the ap-
change to the design type or which proval agency and by the owner of each
may affect its ability to retain haz- portable tank.
ardous material in transportation, the (4) If the approval agency determines
person desiring to make such modifica- that the proposed modification is not
tion shall inform the approval agency in compliance with the relevant DOT
that issued the initial approval of the specification, the approval agency
portable tank (or if unavailable, an- shall deny the request in accordance
other approval agency) of the nature of with paragraph (d) of this section.
the modification and request approval (f) Termination of Approval Certificate.
of the modification. The person desir- (1) The Associate Administrator may
ing to modify the tank must supply the terminate an approval issued under
wreier-aviles on DSK3TPTVN1PROD with CFR
approval agency with three sets of all this section if he determines that
revised drawings, calculations, and test (i) Information upon which the ap-
data relative to the intended modifica- proval was based is fraudulent or sub-
tion. stantially erroneous; or
108
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178.274 49 CFR Ch. I (10111 Edition)
Maximum allowable working pressure (b) General design and construction re-
(MAWP) is defined according to the quirements. (1) The design temperature
hazardous materials intended to be range for the shell must be 40 C to 50
transported in the portable tank. See C (40 F to 122 F) for hazardous ma-
178.275, 178.276 and 178.277, as applica- terials transported under normal con-
ble. ditions of transportation, except for
Maximum permissible gross mass portable tanks used for refrigerated
(MPGM) means the sum of the tare liquefied gases where the minimum de-
mass of the portable tank and the sign temperature must not be higher
heaviest hazardous material authorized than the lowest (coldest) temperature
for transportation. (for example, service temperature) of
Mild steel means a steel with a guar- the contents during filling, discharge
anteed minimum tensile strength of 360 or transportation. For hazardous mate-
N/mm2 to 440 N/mm2 and a guaranteed rials handled under elevated tempera-
minimum elongation at fracture as ture conditions, the design tempera-
specified in paragraph (c)(10) of this ture must not be less than the max-
section. imum temperature of the hazardous
Offshore portable tank means a port- material during filling, discharge or
able tank specially designed for re- transportation. More severe design
peated use in the transportation of haz- temperatures must be considered for
ardous materials to, from and between portable tanks subjected to severe cli-
offshore facilities. An offshore portable matic conditions (for example, portable
tank is designed and constructed in ac- tanks 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 must have an ASME certifi-
Shell means the part of the portable cation and U stamp when used for Haz-
tank which retains the hazardous ma- ard Zone A or B toxic by inhalation liq-
terials intended for transportation, in- uids, or when used for non-refrigerated
cluding openings and closures, but does or refrigerated liquefied compressed
not include service equipment or exter- gases. Shells must be made of metallic
nal structural equipment. materials suitable for forming. Non-
Structural equipment means the rein- metallic materials may be used for the
forcing, fastening, protective and stabi- attachments and supports between the
lizing members external to the shell. shell and jacket, provided their mate-
Test pressure means the maximum rial properties at the minimum and
gauge pressure at the top of the shell maximum design temperatures are
during the hydraulic pressure test proven to be sufficient. For welded
equal to not less than 1.5 times the de- shells, only a material whose
sign pressure for liquids and 1.3 for liq- weldability has been fully dem-
uefied compressed gases and refrig- onstrated may be used. Welds must be
erated liquefied gases. In some in- of high quality and conform to a level
stances a pneumatic test is authorized of integrity at least equivalent to the
as an alternative to the hydraulic test. welding requirements specified in Sec-
The minimum test pressures for port- tion VIII of the ASME Code for the
able tanks intended for specific liquid welding of pressure vessels. When the
and solid hazardous materials are spec- manufacturing process or the materials
wreier-aviles on DSK3TPTVN1PROD with CFR
ified in the applicable portable tank T make it necessary, the shells must be
codes (such as T1T23) assigned to suitably heat-treated to guarantee ade-
these hazardous materials in the quate toughness in the weld and in the
172.101 Table of this subchapter. heat-affected zones. In choosing the
110
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178.274 49 CFR Ch. I (10111 Edition)
mary membrane stress s (sigma) in the (2) Shells (cylindrical portions, heads
shell must not exceed 0.75 Re or 0.50 and manhole covers) not more than 1.80
Rm, whichever is lower, at the test m in diameter may not be less than 5
pressure, where: mm thick in the reference steel or of
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Pipeline and Hazardous Materials Safety Admin., DOT 178.274
equivalent thickness in the metal to be d1 = 1.8m, unless the formula is used to de-
used. Shells more than 1.80 m in diame- termine the equivalent minimum thick-
ter may not be less than 6 mm (0.2 ness for a portable tank shell that is re-
quired to have a minimum thickness of
inches) thick in the reference steel or
8mm or 10mm according to the applicable
of equivalent thickness in the metal to T code indicated in the 172.101 Table of
be used. For portable tanks used only this subchapter. When reference steel
for the transportation of powdered or thicknesses of 8mm or 10mm are specified,
granular solid hazardous materials of d1 is equal to the actual diameter of the
Packing Group II or III, the minimum shell but not less than 1.8m;
thickness requirement may be reduced Rm1 = guaranteed minimum tensile strength
to 5 mm in the reference steel or of (in N/mm 2) of the metal to be used;
equivalent thickness in the metal to be A1 = guaranteed minimum elongation at
used regardless of the shell diameter. fracture (in %) of the metal to be used ac-
cording to recognized material standards.
For vacuum-insulated tanks, the ag-
gregate thickness of the jacket and the (6) The wall and all parts of the shell
shell must correspond to the minimum may not have a thickness less than
thickness prescribed in this paragraph, that prescribed in paragraphs (d)(2),
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 cor-
prescribed 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 limita- is protected against the risk of me-
tions specified in the UN Recommenda- chanical damage by external forces
tions (IBR, see 171.7 of this sub- during 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 ex-
regardless of the material of construc- ternal discharge fittings (pipe sockets,
tion, except for portable tanks used for shut-off devices) and the internal stop-
liquefied compressed gases where the valve and its seating must be protected
cylindrical portions, ends (heads) and against mechanical damage by exter-
manhole covers of all shells must not nal forces (for example, by using shear
be less than 4 mm (0.2 inch) thick re- sections). Each internal self-closing
gardless of the material of construc- stop-valve must be protected by a
tion. shear section or sacrificial device lo-
(5) When steel is used, that has char- cated 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 ac- would cause failure of the internal self-
cording to the following formula: closing stop valve. The filling and dis-
charge devices (including flanges or
21.4e 0 d1
e1 = threaded plugs) and any protective
1.8m 3 Rm1 A1 caps must be capable of being secured
against unintended opening.
Where: (2) Each filling or discharge opening
e1 = required equivalent thickness (in mm) of of a portable tank must be clearly
the metal to be used;
marked to indicate its function.
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178.274 49 CFR Ch. I (10111 Edition)
into account the temperatures ex- (vi) when practicable, the device
pected during transport. All stop- must show the manufacturers name
valves with screwed spindles must and product number.
close by a clockwise motion of the (2) Connections to pressure relief de-
handwheel. For other stop-valves, the vices. Connections to pressure relief de-
position (open and closed) and direc- vices must be of sufficient size to en-
tion of closure must be clearly indi- able the required discharge to pass un-
cated. All stop-valves must be designed restricted to the safety device. No stop-
to prevent unintentional opening. valve may be installed between the
(4) Piping must be designed, con- shell and the pressure relief devices ex-
structed and installed to avoid the risk cept where duplicate devices are pro-
of damage due to thermal expansion vided for maintenance or other reasons
and contraction, mechanical shock and and the stop-valves serving the devices
vibration. All piping must be of a suit- actually in use are locked open or the
able metallic material. Welded pipe stop-valves are interlocked so that at
joints must be used wherever possible. least one of the devices is always in
(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 pres-
union. 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 lique- of minimum back-pressure on the re-
fied 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 rea-
the 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 acces- vapor 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 per- materials, 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 cor- flect the flow of vapor are permissible
responding to the rated pressure for provided the required relief-device ca-
frangible 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 over-
standard cubic meters of air per second turning.
wreier-aviles on DSK3TPTVN1PROD with CFR
(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 41261 it must be equipped with one or more
(IBR, see 171.7 of this subchapter); and gauging devices. Glass level-gauges and
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Pipeline and Hazardous Materials Safety Admin., DOT 178.274
gauges made of other fragile material, ment resulting from lateral and longi-
which are in direct communication tudinal impact and overturning, or the
with the contents of the tank are pro- shell and service equipment must be
hibited. A connection for a vacuum constructed to withstand the forces re-
gauge must be provided in the jacket of sulting from impact or overturning.
a vacuum-insulated portable tank. External fittings must be protected so
(h) Portable tank supports, frameworks, as to preclude the release of the shell
lifting and tie-down attachments. (1) contents upon impact or overturning of
Portable tanks must be designed and the portable tank on its fittings. Ex-
constructed with a support structure to amples of protection include:
provide a secure base during transport. (i) Protection against lateral impact
The forces and safety factors specified which may consist of longitudinal bars
in paragraphs (c)(1) and (c)(2) of this protecting the shell on both sides at
section, respectively, must be taken the level of the median line;
into account in this aspect of the de- (ii) Protection of the portable tank
sign. Skids, frameworks, cradles or against overturning which may consist
other similar structures are accept- of 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 dam- damage 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 14963 (IBR, see 171.7 of this sub-
bility. 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 re-
fitted 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 resist-
must be designed so that the center of ant metal plate permanently attached
gravity of the filled tank is approxi- to the portable tank in a conspicuous
mately centered within the points of place and readily accessible for inspec-
attachment 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 environ- must be marked with at least the infor-
mental 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 clos- the plate by stamping or by any other
ing forklift pockets must be a perma- equivalent method:
nent part of the framework or perma-
nently attached to the framework. Sin- Country of manufacture
gle compartment portable tanks with a UN
length less than 3.65 m (12 ft.) need not Approval Country
have forklift pockets that are capable Approval Number
of being closed off provided that: Alternative Arrangements (see 178.274(a)(2))
(i) The shell, including all the fit- AA
Manufacturers name or mark
tings, are well protected from being hit
Manufacturers serial number
by the forklift blades; and
Approval Agency (Authorized body for the
(ii) The distance between forklift design approval)
pockets (measured from the center of Owners registration number
each pocket) is at least half of the Year of manufacture
wreier-aviles on DSK3TPTVN1PROD with CFR
maximum length of the portable tank. Pressure vessel code to which the shell is de-
(5) During transport, portable tanks signed
must be adequately protected against Test pressurellllbar gauge.
damage to the shell, and service equip- MAWPllllbar gauge.
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178.274 49 CFR Ch. I (10111 Edition)
External design pressure (not required for (1) A check of the design characteris-
portable tanks used for refrigerated lique- tics.
fied gases)llllbar gauge. (2) An internal and external examina-
Design temperature rangellll C
tion of the portable tank and its fit-
tollll C. (For portable tanks used for
refrigerated liquefied gases, the minimum tings, taking into account the haz-
design temperature must be marked.) ardous materials to be transported. For
Water capacity at 20 C/llllliters. UN portable tanks used for refrigerated
Water capacity of each compartment at 20 liquefied gases, a pressure test using an
Cllllliters. inert gas may be conducted instead of
Initial pressure test date and witness identi- a hydrostatic test. An internal inspec-
fication. tion is not required for a portable tank
MAWP for heating/cooling systemllllbar used for the dedicated transportation
gauge.
Shell material(s) and material standard ref-
of refrigerated liquefied gases that are
erence(s). not filled with an inspection opening.
Equivalent thickness in reference (3) A pressure test as specified in
steelllllmm. paragraph (i) of this section.
Lining material (when applicable). (4) A leakage test.
Date and type of most recent periodic test(s). (5) A test of the satisfactory oper-
MonthllllYearllll Test ation of all service equipment includ-
pressurellllbar gauge. ing pressure relief devices must also be
Stamp of approval agency that performed or
performed. When the shell and its fit-
witnessed the most recent test.
tings have been pressure-tested sepa-
For portable tanks used for refrigerated
rately, they must be subjected to a
liquefied gases:
leakage test after reassembly. All
Either thermally insulated or vacuum in-
welds, subject to full stress level in the
sulatedllll.
Effectiveness of the insulation system (heat shell, must be inspected during the ini-
influx)llllWatts (W). tial test by radiographic, ultrasonic, or
Reference holding timelllldays or hours another suitable non-destructive test
and initial pressurellllbar/kPa gauge method. This does not apply to the
and degree of fillingllllin kg for each jacket.
refrigerated liquefied gas permitted for (6) Effective January 1, 2008, each
transportation. new UN portable tank design type
(2) The following information must meeting the definition of container
be marked either on the portable tank in the Convention for Safe Containers
itself or on a metal plate firmly se- (CSC) (see 49 CFR 450.3(a)(2)) must be
cured to the portable tank: subjected to the dynamic longitudinal
impact test prescribed in Part IV, Sec-
Name of the operator.
tion 40 of the UN Manual of Tests and
Name of hazardous materials being trans-
ported and maximum mean bulk tempera- Criteria (see IBR, 171.7 of this sub-
ture (except for refrigerated liquefied chapter). A UN portable tank design
gases, the name and temperature are only type impact-tested prior to January 1,
required when the maximum mean bulk 2008, in accordance with the require-
temperature is higher than 50 C). ments of this section in effect on Octo-
Maximum permissible gross mass ber 1, 2005, need not be retested. UN
(MPGM)llllkg. portable tanks used for the dedicated
Unladen (tare) massllllkg.
transportation of Helium, refrigerated
NOTE TO PARAGRAPH (i)(2): For the identi- liquid, UN1963, and Hydrogen, refrig-
fication of the hazardous materials being erated liquid, UN1966, that are
transported refer to part 172 of this sub- marked NOT FOR RAIL TRANS-
chapter.
PORT in letters of a minimum height
(3) If a portable tank is designed and of 10 cm (4 inches) on at least two sides
approved for open seas operations, such of the portable tank are excepted from
as offshore oil exploration, in accord- the dynamic longitudinal impact test.
ance with the IMDG Code, the words (7) The following tests must be com-
OFFSHORE PORTABLE TANK must pleted on a portable tank or a series of
wreier-aviles on DSK3TPTVN1PROD with CFR
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Pipeline and Hazardous Materials Safety Admin., DOT 178.275
portable tank unsafe for transportation resulting from their compression dur-
and use: ing filling without pressure relief by a
(i) Longitudinal inertia. The portable maximum ullage temperature of 65 C
tank loaded to its maximum gross (149 F) and a liquid expansion due to
weight must be positioned with its lon- an increase in mean bulk temperature
gitudinal axis vertical. It shall be held of 35 C (95 F); and
in this position for five minutes by sup- (C) A head pressure determined on
port at the lower end of the base struc- the basis of the forces specified in
ture providing vertical and lateral re- 178.274(c) of this subchapter, but not
straint and by support at the upper end
less than 0.35 bar (35 kPa).
of the base structure providing lateral
restraint only. (2) Maximum allowable working pres-
(ii) Lateral inertia. The portable tank sure (MAWP) means a pressure that
loaded to its maximum gross weight must not be less than the highest of
must be positioned for five minutes the following pressures measured at
with its transverse axis vertical. It the top of the shell while in operating
shall be held in this position for five position:
minutes by support at the lower side of (i) The maximum effective gauge
the base structure providing vertical pressure allowed in the shell during
and lateral restraint and by support at filling or discharge; or
the upper side of the base structure (ii) The maximum effective gauge
providing lateral restraint only. pressure to which the shell is designed
[66 FR 33440, June 21, 2001, as amended at 67 which must be not less than the design
FR 15744, Apr. 3, 2002; 68 FR 45041, July 31, pressure.
2003; 68 FR 57633, Oct. 6, 2003; 68 FR 75751, (c) Service equipment. (1) In addition
Dec. 31, 2003; 69 FR 76185, Dec. 20, 2004; 70 FR to the requirements specified in
34399, June 14, 2005; 71 FR 78634, Dec. 29, 2006; 178.274, for service equipment, all
72 FR 55696, Oct. 1, 2007; 73 FR 4719, Jan. 28,
2008] openings in the shell, intended for fill-
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
(b)(1); however, the amendment could not be
ated stop-valve located as close to the
incorporated due to inaccurate amendatory shell as reasonably practicable. Other
instruction. openings, except for openings leading
to venting or pressure relief devices,
178.275 Specification for UN Portable must be equipped with either a stop-
Tanks intended for the transpor- valve or another suitable means of clo-
tation of liquid and solid hazardous sure located as close to the shell as
materials.
reasonably practicable.
(a) In addition to the requirements of (2) All portable tanks must be fitted
178.274, this section sets forth defini- with a manhole or other inspection
tions and requirements that apply to openings of a suitable size to allow for
UN portable tanks intended for the internal inspection and adequate ac-
transportation of liquid and solid haz- cess for maintenance and repair of the
ardous materials.
interior. Compartmented portable
(b) Definitions and requirements(1)
tanks must have a manhole or other
Design pressure means the pressure to
inspection openings for each compart-
be used in calculations required by the
ment.
recognized pressure vessel code. The
design pressure must not be less than (3) For insulated portable tanks, top
the highest of the following pressures: fittings must be surrounded by a spill
(i) The maximum effective gauge collection reservoir with suitable
pressure allowed in the shell during drains.
filling or discharge; or (4) Piping must be designed, con-
(ii) The sum of structed and installed to avoid the risk
(A) The absolute vapor pressure (in of damage due to thermal expansion
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178.275 49 CFR Ch. I (10111 Edition)
(d) Bottom openings. (1) Certain haz- from the valve itself within 30 seconds
ardous materials may not be trans- of actuation; and
ported in portable tanks with bottom (E) The valve must continue to be ef-
openings. When the applicable T code fective in the event of damage to the
or portable tank special provision, as external device for controlling the op-
referenced for materials in the 172.101 eration of the valve;
Table of this subchapter, specifies that (ii) An external stop-valve fitted as
bottom openings are prohibited, there close to the shell as reasonably prac-
must be no openings below the liquid ticable;
level of the shell when it is filled to its (iii) A liquid tight closure at the end
maximum permissible filling limit. of the discharge pipe, which may be a
When an existing opening is closed, it bolted blank flange or a screw cap; and
must be accomplished by internally (iv) For UN portable tanks, with bot-
and externally welding one plate to the
tom outlets, used for the transpor-
shell.
tation of liquid hazardous materials
(2) Bottom discharge outlets for port-
that are Class 3, PG I or II, or PG III
able tanks carrying certain solid, crys-
with a flash point of less than 100 F (38
tallizable or highly viscous hazardous
C); Division 5.1, PG I or II; or Division
materials must be equipped with at
6.1, PG I or II, the remote means of clo-
least two serially fitted and mutually
sure must be capable of thermal acti-
independent shut-off devices. Use of
vation. The thermal means of activa-
only two shut-off devices is only au-
tion must activate at a temperature of
thorized when this paragraph is ref-
not more than 250 F (121 C).
erenced in the applicable T Code indi-
cated for each hazardous material in (e) Pressure relief devices. All portable
the 172.101 Table of this subchapter. tanks must be fitted with at least one
The design of the equipment must be to pressure relief device. All relief devices
the satisfaction of the approval agency must be designed, constructed and
and must include: marked in accordance with the require-
(i) An external stop-valve fitted as ments of this subchapter.
close to the shell as reasonably prac- (f) Vacuum-relief devices. (1) A shell
ticable; and which is to be equipped with a vacuum-
(ii) A liquid tight closure at the end relief device must be designed to with-
of the discharge pipe, which may be a stand, without permanent deformation,
bolted blank flange or a screw cap. an external pressure of not less than
(3) Except as provided in paragraph 0.21 bar (21.0 kPa). The vacuum-relief
(d)(2) of this section, every bottom dis- device must be set to relieve at a vacu-
charge outlet must be equipped with um setting not greater than 0.21 bar (
three serially fitted and mutually inde- 21.0 kPa) unless the shell is designed
pendent shut-off devices. The design of for a higher external over pressure, in
the equipment must include: which case the vacuum-relief pressure
(i) A self-closing internal stop-valve, of the device to be fitted must not be
which is a stop-valve within the shell greater than the tank design vacuum
or within a welded flange or its com- pressure. A shell that is not fitted with
panion flange, such that: a vacuum-relief device must be de-
(A) The control devices for the oper- signed to withstand, without perma-
ation of the valve are designed to pre- nent deformation, an external pressure
vent any unintended opening through of not less than 0.4 bar (40.0 kPa).
impact or other inadvertent act; (2) Vacuum-relief devices used on
(B) The valve is operable from above portable tanks intended for the trans-
or below; portation of hazardous materials meet-
(C) If possible, the setting of the ing the criteria of Class 3, including
valve (open or closed) must be capable elevated temperature hazardous mate-
of being verified from the ground; rials transported at or above their
(D) Except for portable tanks having flash point, must prevent the imme-
wreier-aviles on DSK3TPTVN1PROD with CFR
a capacity less than 1,000 liters (264.2 diate passage of flame into the shell or
gallons), it must be possible to close the portable tank must have a shell ca-
the valve from an accessible position pable of withstanding, without leak-
on the portable tank that is remote age, an internal explosion resulting
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Pipeline and Hazardous Materials Safety Admin., DOT 178.275
from the passage of flame into the must be fitted with a pressure relief de-
shell. vice which, except as provided in para-
(g) Pressure relief devices. (1) Each graph (g)(3) of this section, may be a
portable tank with a capacity not less frangible disc when this disc is set to
than 1,900 liters (501.9 gallons) and rupture at a nominal pressure equal to
every independent compartment of a the test pressure at any temperature
portable tank with a similar capacity, within the design temperature range.
must be provided with one or more (5) When the shell is fitted for pres-
pressure relief devices of the reclosing sure discharge, a suitable pressure re-
type. Such portable tanks may, in ad- lief device must provide the inlet line
dition, have a frangible disc or fusible to the portable tank and set to operate
element in parallel with the reclosing at a pressure not higher than the
devices, except when the applicable T MAWP of the shell, and a stop-valve
code assigned to a hazardous material must be fitted as close to the shell as
requires that the frangible disc precede practicable to minimize the potential
the pressure relief device, according to for damage.
paragraph (g)(3) of this section, or (6) Setting of pressure relief devices. (i)
when no bottom openings are allowed. Pressure relief devices must operate
The pressure relief devices must have only in conditions of excessive rise in
sufficient capacity to prevent rupture temperature. The shell must not be
of the shell due to over pressurization subject to undue fluctuations of pres-
or vacuum resulting from filling, dis- sure during normal conditions of trans-
charging, heating of the contents or portation.
fire. (ii) The required pressure relief de-
(2) Pressure relief devices must be de- vice 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 haz- test 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 re- at all lower pressures. This require-
quirements of this subchapter. Except ment does not prevent the use of vacu-
for a portable tank in dedicated service um-relief or combination pressure re-
that 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), pro-
frangible disc preceding (such as, be- vided that the pressure in the shell at
tween the lading and the reclosing the fusing temperature will not exceed
pressure relief device) a reclosing pres- the 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 de- in 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 port- which exceeds 2.65 bar (265.0 kPa); how-
able tank operator to check to deter- ever, fusible elements are authorized
mine if the disc is leak free. The fran- on portable tanks for the transpor-
gible disc must rupture at a nominal tation of certain organometallic mate-
pressure 10% above the start-to-dis- rials in accordance with 172.102, spe-
wreier-aviles on DSK3TPTVN1PROD with CFR
charge pressure of the reclosable pres- cial provision TP36 of this subchapter.
sure relief device. Fusible elements used on portable
(4) Every portable tank with a capac- tanks intended for the transport of ele-
ity less than 1,900 liters (501.9 gallons) vated temperature hazardous materials
119
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178.275 49 CFR Ch. I (10111 Edition)
1.00 0.607
FA0.82 ZT 1.02 0.611
Q = 12.4 1.04 0.615
LC M 1.06 0.620
1.08 0.624
Where: 1.10 0.628
Q = minimum required rate of discharge in 1.12 0.633
1.14 0.637
cubic meters of air per second (m3/s) at con- 1.16 0.641
ditions: 1 bar and 0 C (273 K); 1.18 0.645
F = for uninsulated shells: 1; for insulated 1.20 0.649
shells: U(649t)/13.6 but in no case is less 1.22 0.652
ER01OC08.002</MATH>
1.38 0.681
perature is unknown, let t = 15 C (59 F). 1.40 0.685
The value of F given in this paragraph 1.42 0.688
(i)(2)(i)(A) for insulated shells may only be 1.44 0.691
120
ER01OC08.000</MATH>
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178.276 49 CFR Ch. I (10111 Edition)
(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
(A) Without insulation or sun shield: method must be as prescribed in the
60 C (140 F); ASME Code. Welded attachments to
(B) With sun shield: 55 C (131 F); and pads may be made after postweld heat
(C) With insulation: 50 C (122 F). treatment is made. A portable tank
(3) Filling density means the average used for anhydrous ammonia must be
mass of liquefied compressed gas per postweld heat-treated. The postweld
liter of shell capacity (kg/l). heat treatment must be as prescribed
(4) Maximum allowable working pres- in the ASME Code, but in no event at
sure (MAWP) means a pressure that less than 1050 F tank metal tempera-
must be not less than the highest of ture. Additionally, portable tanks con-
the following pressures measured at structed in accordance with part UHT
the top of the shell while in operating of the ASME Code must conform to the
position, but in no case less than 7 bar following requirements:
(700 kPa): (i) Welding procedure and welder per-
(i) The maximum effective gauge formance tests must be made annually
pressure allowed in the shell during in accordance with Section IX of the
filling or discharge; or ASME Code. In addition to the essen-
(ii) The maximum effective gauge tial variables named therein, the fol-
pressure to which the shell is designed, lowing must be considered to be essen-
which must be: tial variables: number of passes, thick-
(A) Not less than the pressure speci- ness of plate, heat input per pass, and
fied for each liquefied compressed gas manufacturers identification of rod
listed in the UN Portable Tank Table and flux. The number of passes, thick-
for Liquefied Compressed Gases in ness of plate and heat input per pass
173.313; and may not vary more than 25 percent
(B) Not less than the sum of: from the qualified procedure. Records
(1) The absolute vapor pressure (in of the qualification must be retained
bar) of the liquefied compressed gas at for at least 5 years by the portable
the design reference temperature tank manufacturer or his designated
minus 1 bar; and agent and, upon request, made avail-
(2) The partial pressure (in bar) of air able to a representative of the Depart-
or other gases in the ullage space ment of Transportation or the owner of
which is determined by the design ref- the tank.
erence temperature and the liquid (ii) Impact tests must be made on a
phase expansion due to the increase of lot basis. A lot is defined as 100 tons or
the mean bulk temperature of trtf (tf less of the same heat and having a
= filling temperature, usually 15 C, tr = thickness variation no greater than
50 C maximum mean bulk tempera- plus or minus 25 percent. The minimum
ture). impact required for full-sized speci-
(b) General design and construction re- mens shall be 20 foot-pounds (or 10
quirements. (1) Shells must be of seam- foot-pounds for half-sized specimens) at
less or welded steel construction, or 0 F (17.8 F) Charpy V-Notch in both
combination of both, and have a water the longitudinal and transverse direc-
capacity greater than 450 liters (118.9 tion. If the lot test does not pass this
gallons). Shells must be designed, con- requirement, individual plates may be
structed, certified and stamped in ac- accepted if they individually meet this
cordance with the ASME Code, Section impact requirement.
VIII. (3) When the shells intended for the
(2) Portable tanks must be postweld transportation of non-refrigerated liq-
heat-treated and radiographed as pre- uefied compressed gases are equipped
scribed in Section VIII of the ASME with thermal insulation, a device must
Code, except that each portable tank be provided to prevent any dangerous
constructed in accordance with part pressure from developing in the insu-
wreier-aviles on DSK3TPTVN1PROD with CFR
UHT of the ASME Code must be lating layer in the event of a leak,
postweld heat-treated. Where postweld when the protective covering is closed
heat treatment is required, the port- it must be gas tight. The thermal insu-
able tank must be treated as a unit lation must not inhibit access to the
122
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Pipeline and Hazardous Materials Safety Admin., DOT 178.276
fittings and discharge devices. In addi- tation of flammable and/or toxic lique-
tion, the thermal insulation systems fied compressed gases, the internal
must satisfy the following require- stop-valve must be a self-closing safety
ments: device that fully closes automatically
(i) consist of a shield covering not during filling or discharge in the event
less than the upper third, but not more of fire engulfment. The device shall
than the upper half of the surface of fully close within 30 seconds of actu-
the shell, and separated from the shell ation and the thermal means of closure
by an air space of approximately 40 mm must actuate at a temperature of not
(1.7 inches) across; or more than 121 C (250 F). Except for
(ii) consist of a complete cladding of portable tanks having a capacity less
insulating materials. The insulation than 1,000 liters (264.2 gallons), this de-
must be of adequate thickness and con- vice must be operable by remote con-
structed to prevent the ingress of mois- trol.
ture and damage to the insulation. The (5) In addition to filling, discharge
insulation and cladding must have a and gas pressure equalizing orifices,
thermal conductance of not more than shells may have openings in which
0.67 (Wm2K1) under normal condi- gauges, thermometers and manometers
tions of transportation. can be fitted. Connections for such in-
(c) Service equipment. (1) Each opening struments must be made by suitable
with a diameter of more than 1.5 mm welded nozzles or pockets and may not
(0.1 inch) in the shell of a portable be connected by screwed connections
tank, except openings for pressure-re- through the shell.
lief devices, inspection openings and (6) All portable tanks must be fitted
closed bleed holes, must be fitted with with manholes or other inspection
at least three mutually independent openings of suitable size to allow for
shut-off devices in series: the first internal inspection and adequate ac-
being an internal stop-valve, excess
cess for maintenance and repair of the
flow valve, integral excess flow valve,
interior.
or excess flow feature (see 178.337
(7) Inlets and discharge outlets on chlo-
1(g)), the second being an external
stop-valve and the third being a blank rine portable tanks. The inlet and dis-
flange, thread cap, plug or equivalent charge outlets on portable tanks used
tight liquid closure device. to transport chlorine must meet the re-
(2) When a portable tank is fitted quirements of 178.3371(c)(2) and must
with an excess flow valve, the excess be fitted with an internal excess flow
flow valve must be so fitted that its valve. In addition to the internal ex-
seating is inside the shell or inside a cess flow valve, the inlet and discharge
welded flange or, when fitted exter- outlets must be equipped with an ex-
nally, its mountings must be designed ternal stop valve (angle valve). Excess
so that in the event of impact it main- flow valves must conform to the stand-
tains its effectiveness. The excess flow ards of The Chlorine Institute, Inc.
valves must be selected and fitted so as (IBR, see 171.7 of this subchapter) as
to close automatically when the rated follows:
flow, specified by the manufacturer, is (i) A valve conforming to Drawing
reached. Connections and accessories 1017, dated July 1993, must be installed
leading to or from such a valve must under each liquid angle valve.
have a capacity for a flow more than (ii) A valve conforming to Drawing
the excess flow valves rated flow. 1066, dated July 1993, must be installed
(3) For filling and discharge openings under each gas angle valve. For port-
that are located below the liquid level, able tanks used to transport non-re-
the first shut-off device must be an in- frigerated liquefied gases.
ternal stop-valve and the second must (8) External fittings must be grouped
be a stop-valve placed in an accessible together as close as reasonably prac-
position on each discharge and filling ticable. The following openings may be
wreier-aviles on DSK3TPTVN1PROD with CFR
123
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124
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Pipeline and Hazardous Materials Safety Admin., DOT 178.277
125
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178.277 49 CFR Ch. I (10111 Edition)
126
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Pipeline and Hazardous Materials Safety Admin., DOT 178.277
and the third being a blank flange or sures. The pressure relief devices must
equivalent device. The shut-off device be of the type that will resist dynamic
closest to the jacket must be a self- forces including surge.
closing device, which is capable of (2) Except for portable tanks used for
being closed from an accessible posi- oxygen, portable tanks for non-flam-
tion on the portable tank that is re- mable refrigerated liquefied gases (ex-
mote from the valve within 30 seconds cept oxygen) and hydrogen may in ad-
of actuation. This device must actuate dition have frangible discs in parallel
at a temperature of not more than 121 with the reclosing devices as specified
C (250 F). in paragraphs (e)(4)(ii) and (e)(4)(iii) of
(2) Each filling and discharge opening this section.
in portable tanks used for the trans- (3) Pressure relief devices must be de-
port of non-flammable refrigerated liq- signed to prevent the entry of foreign
uefied gases must be fitted with at matter, the leakage of gas and the de-
least two mutually independent shut- velopment of any dangerous excess
off devices in series: the first being a pressure.
stop-valve situated as close as reason- (4) Capacity and setting of pressure re-
ably practicable to the jacket and the lief devices. (i) In the case of the loss of
second a blank flange or equivalent de- vacuum in a vacuum-insulated tank or
vice. of loss of 20% of the insulation of a
(3) For sections of piping which can portable tank insulated with solid ma-
be closed at both ends and where liquid terials, the combined capacity of all
product can be trapped, a method of pressure relief devices installed must
automatic pressure relief must be pro- be sufficient so that the pressure (in-
vided to prevent excess pressure build- cluding accumulation) inside the shell
up within the piping. does not exceed 120% of the MAWP.
(4) Each filling and discharge opening (ii) For non-flammable refrigerated
on a portable tank must be clearly liquefied gases (except oxygen) and hy-
marked to indicate its function. drogen, this capacity may be achieved
(5) When pressure-building units are by the use of frangible discs in parallel
used, the liquid and vapor connections with the required safety-relief devices.
to that unit must be provided with a Frangible discs must rupture at nomi-
valve as close to the jacket as reason- nal pressure equal to the test pressure
ably practicable to prevent the loss of of the shell.
contents in case of damage to the pres- (iii) Under the circumstances de-
sure-building unit. A check valve may scribed in paragraphs (e)(4)(i) and
be used for this purpose if it is located (e)(4)(ii) of this section, together with
on the vapor side of the pressure build- complete fire engulfment, the com-
up coil. bined capacity of all pressure relief de-
(6) The materials of construction of vices installed must be sufficient to
valves and accessories must have satis- limit the pressure in the shell to the
factory properties at the lowest oper- test pressure.
ating temperature of the portable (iv) The required capacity of the re-
tank. lief devices must be calculated in ac-
(7) Vacuum insulated portable tanks cordance with CGA Pamphlet S1.2
are not required to have an inspection (IBR, see 171.7 of this subchapter).
opening. [66 FR 33450, June 21, 2001, as amended at 68
(e) Pressure relief devices. (1) Every FR 75748, 75752, Dec. 31, 2003]
shell must be provided with not less
than two independent reclosing pres-
sure relief devices. The pressure relief Subpart I [Reserved]
devices must open automatically at a
pressure not less than the MAWP and Subpart JSpecifications for Con-
be fully open at a pressure equal to tainers for Motor Vehicle
110% of the MAWP. These devices Transportation
wreier-aviles on DSK3TPTVN1PROD with CFR
127
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178.318 49 CFR Ch. I (10111 Edition)
128
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Pipeline and Hazardous Materials Safety Admin., DOT 178.320
(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 re- the carriage of liquids, gases, solids, or
129
EC02MR91.076</GPH>
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178.320 49 CFR Ch. I (10111 Edition)
130
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Pipeline and Hazardous Materials Safety Admin., DOT 178.320
131
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178.337 49 CFR Ch. I (10111 Edition)
or closures, but excludes any appur- (c) Exceptions to the ASME Code. Un-
tenances, reinforcements, fittings, or less otherwise specified, when excep-
closures. tions are provided in this subpart from
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. 17889, 55 FR 37055, Sept. 7, 1990, as
bility of a material to absorb energy amended by Amdt. 17898, 58 FR 33306, June
represented by the area under a stress 16, 1993; Amdt. 178118, 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; 76 FR
up to the point of rupture. 43532, July 20, 2011]
Vacuum cargo tank means a cargo
tank that is loaded by reducing the 178.337 Specification MC 331; cargo
tank motor vehicle primarily for
pressure in the cargo tank to below at- transportation of compressed gases
mospheric pressure. as defined in subpart G of part 173
Variable specification cargo tank of this subchapter.
means a cargo tank that is constructed
in accordance with one specification, 178.3371 General requirements.
but that may be altered to meet an- (a) ASME Code construction. Tanks
other specification by changing relief must be
device, closures, lading discharge de- (1) Seamless or welded construction,
vices, and other lading retention de- or a combination of both;
vices. (2) Designed, constructed, certified,
Void means the space between tank and stamped in accordance with Sec-
heads or bulkheads and a connecting tion VIII of the ASME Code (IBR, see
structure. 171.7 of this subchapter);
Welded flange means a flange at- (3) Made of steel or aluminum; how-
tached to the tank by a weld joining ever, if aluminum is used, the cargo
the tank shell to the cylindrical outer tank must be insulated and the haz-
surface of the flange, or by a fillet weld ardous material to be transported must
joining the tank shell to a flange be compatible with the aluminum (see
shaped to fit the shell contour. 178.3371(e)(2), 173.315(a) table, and
(b) Design certification. (1) Each cargo 178.3372(a)(1) of this subchapter); and
tank or cargo tank motor vehicle de- (4) Covered with a steel jacket if the
sign type, including its required acci- cargo tank is insulated and used to
dent damage protection device, must transport a flammable gas (see
be certified to conform to the specifica- 173.315(a) table Note 11 of this sub-
tion requirements by a Design Certi- chapter).
fying Engineer who is registered in ac- (b) Design pressure. The design pres-
cordance with subpart F of part 107 of sure of a cargo tank authorized under
this title. An accident damage protec- this specification shall be not less than
tion device is a rear-end protection, the vapor pressure of the commodity
overturn protection, or piping protec- contained therein at 115 F. or as pre-
tion device. scribed for a particular commodity in
(2) The Design Certifying Engineer 173.315(a) of this subchapter, except
shall furnish to the manufacturer a that in no case shall the design pres-
certificate to indicate compliance with sure of any cargo tank be less than 100
the specification requirements. The p.s.i.g. nor more than 500 p.s.i.g.
certificate must include the sketches,
drawings, and calculations used for cer- NOTE 1: The term design pressure as used in
tification. Each certificate, including this specification, is identical to the term
MAWP as used in the ASME Code.
sketches, drawings, and calculations,
shall be signed by the Design Certi- (c) Openings. (1) Excess pressure relief
fying Engineer. valves shall be located in the top of the
wreier-aviles on DSK3TPTVN1PROD with CFR
132
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Pipeline and Hazardous Materials Safety Admin., DOT 178.3371
shall be fitted with a nozzle that meets provisions in Section VIII of the ASME
the following requirements: Code under which it is constructed.
(i) On a cargo tank manufactured on Where postweld heat treatment is re-
or before December 31, 1974, the nozzle quired, the cargo tank must be treated
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. 1033, dated January 23, 1958, Section VIII of the ASME Code. Welded
or to the standard specified in para- attachments 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. 1034, in no event at less than 1,050 F cargo
dated September 1, 1971. tank metal temperature.
(d) Reflective design. Every (g) Definitions. The following defini-
uninsulated cargo tank permanently tions apply to 178.3371 through
attached to a cargo tank motor vehicle 178.33718:
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 uninten-
painted 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 re- operation. A passive means of emer-
quired to be insulated must conform gency discharge control automatically
with the use and performance require- shuts off the flow of product without
ments contained in 173.315(a) table the need for human intervention with-
and 178.3371 (a)(3) and (e)(2) of this in 20 seconds of an unintentional re-
subchapter. lease caused by a complete separation
(2) Each cargo tank intended for of the liquid delivery hose. An off-
chlorine; carbon dioxide, refrigerated truck remote means of emergency dis-
liquid; or nitrous oxide, refrigerated charge control permits a qualified per-
liquid service must have suitable insu- son attending the unloading operation
lation of such thickness that the over- to close the cargo tanks internal self-
all thermal conductance is not more closing stop valve and shut off all mo-
than 0.08 Btu per square foot per F dif- tive 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 automati-
used 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 ex-
with a minimum thickness of 4 inches, ceeds the rated flow of gas or liquid
or 2 inches minimum thickness of ce- specified by the original valve manu-
ramic 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
wreier-aviles on DSK3TPTVN1PROD with CFR
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134
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135
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178.3373 49 CFR Ch. I (10111 Edition)
static weight of the fully loaded cargo (C) The lateral shear stress generated
tank motor vehicle, all structural ele- by a normal operating lateral accelera-
ments, equipment and appurtenances tive force equal to 0.2 times the
supported by the cargo tank wall. The vertical reaction at each suspension as-
following loadings must be included: sembly of a trailer, applied at the road
(1) The axial load generated by a surface, and as transmitted to the
decelerative force; cargo tank wall through the suspension
(2) The bending moment generated by assembly of a trailer, and the hori-
a decelerative force; zontal pivot of the upper coupler (fifth
(3) The axial load generated by an ac- wheel) or turntable; or anchoring and
support members of a truck, as applica-
celerative 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 re- and 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 gen-
the vertical reaction at the suspension erated by the same lateral forces as de-
assembly 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 fol-
members 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 ap- point) must be determined by the fol-
purtenances supported by the cargo lowing formula:
tank wall.
S = 0.5(Sy + Sx) [0.25(Sy Sx)2 + Ss2]0.5
(iv) Ss = 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 sus- occur at the same time, in psi.
pension assembly of a trailer, and the (ii) Sy = circumferential stress gen-
horizontal 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 ap- psi.
plicable. The vertical reaction must be (iii) Sx = the following net longitu-
calculated 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, equip- conditions, in psi:
ment and appurtenances supported by (A) The longitudinal stresses result-
the cargo tank wall; ing from the MAWP and external pres-
(B) The vertical shear stress gen- sure, when applicable, plus static head,
erated by a normal operating accelera- in 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 as- fully 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
wreier-aviles on DSK3TPTVN1PROD with CFR
loaded cargo tank motor vehicle, all case the forces applied must be 0.7
structural elements, equipment and ap- times the vertical reaction at the sus-
purtenances supported by the cargo pension assembly, applied at the road
tank wall; surface, and as transmitted to the
136
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Pipeline and Hazardous Materials Safety Admin., DOT 178.3373
cargo tank wall through the suspension or turntable; or anchoring and support
assembly of a trailer during decelera- members of a truck, as applicable. The
tion; or the horizontal pivot of the vertical reaction must be calculated
truck tractor or converter dolly fifth based on the static weight of the fully
wheel, or the drawbar hinge on the loaded cargo tank motor vehicle, all
fixed dolly during acceleration; or the structural elements, equipment and ap-
anchoring and support members of a purtenances supported by the cargo
truck during acceleration and decelera- tank 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 re-
tank motor vehicle, all structural ele- action 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 ac- vertical 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 re- tank wall; and
sulting from an extreme vertical accel-
(D) The torsional shear stress gen-
erative force equal to 0.7 times the
erated by the same lateral forces as de-
vertical reaction at the suspension as-
scribed in paragraph (c)(2)(iv)(C) of this
sembly of a trailer, and the horizontal
section.
pivot of the upper coupler (fifth wheel)
or turntable; or the anchoring and sup- (d) In order to account for stresses
port members of a truck, as applicable. due to impact in an accident, the de-
The vertical reaction must be cal- sign calculations for the cargo tank
culated based on the static weight of shell and heads must include the load
the fully loaded cargo tank motor vehi- resulting from the design pressure in
cle, all structural elements, equipment combination with the dynamic pres-
and appurtenances supported by the sure resulting from a longitudinal de-
cargo tank wall. celeration of 2g. For this loading
(iv) Ss = The following shear stresses condition the stress value used may
generated by static and extreme dy- not exceed the lesser of the yield
namic loading conditions, in psi: strength or 75 percent of the ultimate
(A) The static shear stress resulting tensile strength of the material of con-
from the vertical reaction at the sus- struction. For cargo tanks constructed
pension assembly of a trailer, and the of stainless steel the maximum design
horizontal pivot of the upper coupler stress may not exceed 75 percent of the
(fifth wheel) or turntable; or anchoring ultimate tensile strength of the type
and support members of a truck, as ap- steel used.
plicable. The vertical reaction must be (e) The minimum metal thickness for
calculated based on the static weight the shell and heads on tanks with a de-
of the fully loaded cargo tank motor sign pressure of 100 psig or more must
vehicle, all structural elements, equip- be 4.75 mm (0.187 inch) for steel and 6.86
ment and appurtenances supported by mm (0.270 inch) for aluminum, except
the cargo tank wall; for chlorine and sulfur dioxide tanks.
(B) The vertical shear stress gen- In all cases, the minimum thickness of
erated by an extreme vertical accelera- the tank shell and head shall be deter-
wreier-aviles on DSK3TPTVN1PROD with CFR
tive force equal to 0.7 times the mined using structural design require-
vertical reaction at the suspension as- ments in Section VIII of the ASME
sembly of a trailer, and the horizontal Code or 25% of the tensile strength of
pivot of the upper coupler (fifth wheel) the material used. For a cargo tank
137
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178.3373 49 CFR Ch. I (10111 Edition)
used in chlorine or sulfur dioxide serv- there will be no adverse effect upon the
ice, the cargo tank must be made of lading retention integrity of the cargo
steel. A corrosion allowance of 20 per- tank if any force less than that pre-
cent or 2.54 mm (0.10 inch), whichever scribed in paragraph (b)(1) of this sec-
is less, must be added to the thickness tion is applied from any direction. The
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), includ- not 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 at- minimum 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 tell-
tank wall must meet the requirements
in paragraph (a) of this section. tale holes are used, the pad must be
(g) The design, construction, and in- drilled or punched at the lowest point
stallation of an attachment, appur- before it is welded to the tank. Each
tenance to the cargo tank, structural pad must
support member between the cargo (i) Be fabricated from material deter-
tank and the vehicle or suspension mined to be suitable for welding to
component, or accident protection de- both the cargo tank material and the
vice must conform to the following re- material of the appurtenance or struc-
quirements: tural support member; a Design Certi-
(1) Structural members, the suspen- fying Engineer must make this deter-
sion sub-frame, accident protection mination considering chemical and
structures, and external circumferen- physical properties of the materials
tial reinforcement devices must be and must specify filler material con-
used as sites for attachment of appur- forming to the requirements in Section
tenances and other accessories to the VIII of the ASME Code (IBR, see 171.7
cargo tank, when practicable. of 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
brake line clip, skirting structure,
the cargo tank at the attachment loca-
lamp mounting bracket, or placard
tion.
holder must be of a construction hav-
ing lesser strength than the cargo tank (iii) Extend at least 2 inches in each
wall materials and may not be more direction from any point of attachment
than 72 percent of the thickness of the of an appurtenance or structural sup-
material to which it is attached. The port member. This dimension may be
lightweight attachment may be se- measured from the center of the at-
cured directly to the cargo tank wall if tached structural member.
the device is designed and installed in (iv) Have rounded corners, or other-
such a manner that, if damaged, it will wise be shaped in a manner to mini-
not affect the lading retention integ- mize stress concentrations on the shell
rity of the tank. A lightweight attach- or head.
ment must be secured to the cargo (v) Be attached by continuous fillet
tank shell or head by a continuous welding. Any fillet weld discontinuity
weld or in such a manner as to preclude may only be for the purpose of pre-
formation of pockets which may be- venting an intersection between the fil-
come sites for corrosion. Attachments let weld and a tank or jacket seam
meeting the requirements of this para- weld.
graph are not authorized for cargo
tanks constructed under part UHT in [Amdt. 17889, 55 FR 37056, Sept. 7, 1990, as
Section VIII of the ASME Code. amended by Amdt. 178104, 59 FR 49135, Sept.
(3) Except as prescribed in para- 26, 1994; Amdt. 178105, 60 FR 17401, Apr. 5,
wreier-aviles on DSK3TPTVN1PROD with CFR
graphs (g)(1) and (g)(2) of this section, 1995; Amdt. 178118, 61 FR 51340, Oct. 1, 1996;
the welding of any appurtenance to the 65 FR 58631, Sept. 29, 2000; 68 FR 19279, Apr.
18, 2003; 68 FR 52370, Sept. 3, 2003; 68 FR 75753,
cargo tank wall must be made by at-
Dec. 31, 2003]
tachment of a mounting pad so that
138
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Pipeline and Hazardous Materials Safety Admin., DOT 178.3378
tations affecting 178.3374, see the List of mometer wells, pressure relief valves,
CFR Sections Affected which appears in the manhole openings, product inlet open-
Finding Aids section of the printed volume ings, and product discharge openings,
and at www.fdsys.gov. each opening in a cargo tank must be
139
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178.3378 49 CFR Ch. I (10111 Edition)
closed with a plug, cap, or bolted ing connection area. The loading/un-
flange. loading connection area is where hoses
(3) Except as provided in paragraph or hose reels are connected to the per-
(b) of this section, each product inlet manent metal piping. Linkages be-
opening, including vapor return lines, tween closures and remote operators
must be fitted with a back flow check must be corrosion resistant and effec-
valve or an internal self-closing stop tive in all types of environmental con-
valve located inside the cargo tank or ditions incident to discharge of prod-
inside a welded nozzle that is an inte- uct.
gral part of the cargo tank. The valve (iii) All parts of a valve inside a
seat must be located inside the cargo cargo tank or within a welded flange
tank or within 2.54 cm (one inch) of the must be made of material that will not
external face of the welded flange.
corrode or deteriorate in the presence
Damage to parts exterior to the cargo
of the lading.
tank or mating flange must not pre-
vent effective seating of the valve. All (iv) An excess flow valve, integral ex-
parts of a valve inside a cargo tank or cess flow valve, or excess flow feature
welded flange must be made of mate- must 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 con- excess flow valve, integral excess flow
trol system as defined in 178.3371(g). valve, or excess flow feature.
Thermal remote operators must acti- (v) An integral excess flow valve or
vate at a temperature of 121.11C (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 corro- with 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 clo- are located inside the cargo tank or
sure must be installed at the ends of within 2.54 cm (one inch) of the exter-
the cargo tank in at least two diago- nal 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 effec-
is 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 sys-
sentence of this paragraph (a)(4)(i), ad- tem is not required on the following:
ditional means of thermal remote clo-
(i) A vapor or liquid discharge open-
sure must be installed so that heat
ing of less than 114 NPT equipped with
from a fire in the loading/unloading
connection area or the discharge pump an excess flow valve together with a
will activate the primary discharge manually operated external stop valve
control system. The loading/unloading in place of an internal self-closing stop
connection area is where hoses or hose valve.
reels are connected to the permanent (ii) An engine fuel line on a truck-
metal piping. mounted cargo tank of not more than
34 NPT equipped with a valve having an
(ii) On a cargo tank of 13,247.5 L (3,500
gallons) water capacity or less, a ther- integral excess flow valve or excess
mal means of remote closure must be flow feature.
installed at or near the internal self- (iii) A cargo tank motor vehicle used
wreier-aviles on DSK3TPTVN1PROD with CFR
140
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Pipeline and Hazardous Materials Safety Admin., DOT 178.3379
(6) In addition to the internal self- lief devices, must be at least 4 times
closing stop valve, each filling and dis- the design pressure of the cargo tank.
charge line must be fitted with a stop Additionally, the burst pressure may
valve located in the line between the not be less than 4 times any higher
internal self-closing stop valve and the pressure to which each pipe, pipe fit-
hose connection. A back flow check ting, hose or other pressure part may
valve or excess flow valve may not be be subjected to in service. For chlorine
used to satisfy this requirement. service, see paragraph (b)(7) of this sec-
(7) An excess flow valve may be de- tion.
signed with a bypass, not to exceed a (2) Pipe joints must be threaded,
0.1016 centimeter (0.040 inch) diameter welded, or flanged. If threaded pipe is
opening, to allow equalization of pres-
used, the pipe and fittings must be
sure.
Schedule 80 weight or heavier, except
(b) Inlets and discharge outlets on chlo-
for sacrificial devices. Malleable metal,
rine tanks. The inlet and discharge out-
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 178.3371(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 Chlo- union type. The melting point of the
rine Institute, Inc., Dwg. 1017 (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 Chlo- strength of the tubing.
rine Institute, Inc., Dwg. 1066 (IBR, (3) Each hose coupling must be de-
see 171.7 of this subchapter), must be signed for a pressure of at least 120 per-
installed 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 con-
refrigerated liquid, cargo tanks. A dis- nected.
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
[64 FR 28049, May 24, 1999, as amended at 66 purpose.
FR 45387, Aug. 28, 2001; 68 FR 19279, Apr. 18, (5) [Reserved]
2003; 68 FR 75753, Dec. 31, 2003] (6) Cargo tank manufacturers and
178.3379 Pressure relief devices, fabricators must demonstrate that all
piping, valves, hoses, and fittings. piping, valves, and fittings on a cargo
tank are free from leaks. To meet this
(a) Pressure relief devices. (1) See
requirement, the piping, valves, and
173.315(i) of this subchapter.
fittings must be tested after installa-
(2) On cargo tanks for carbon dioxide
or nitrous oxide see 173.315 (i) (9) and tion at not less than 80 percent of the
(10) of this subchapter. design pressure marked on the cargo
(3) Each valve must be designed, con- tank.
structed, and marked for a rated pres- (7) A hose assembler must:
sure not less than the cargo tank de- (i) Permanently mark each hose as-
sign pressure at the temperature ex- sembly with a unique identification
pected to be encountered. number.
wreier-aviles on DSK3TPTVN1PROD with CFR
(b) Piping, valves, hose, and fittings. (1) (ii) Demonstrate that each hose as-
The burst pressure of all piping, pipe sembly is free from leaks by per-
fittings, hose and other pressure parts, forming the tests and inspections in
except for pump seals and pressure re- 180.416(f) of this subchapter.
141
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178.33710 49 CFR Ch. I (10111 Edition)
(iii) Mark each hose assembly with 178.33710 Accident damage protec-
the month and year of its original pres- tion.
sure test. (a) All valves, fittings, pressure relief
(8) Chlorine cargo tanks. Angle valves devices, and other accessories to the
on cargo tanks intended for chlorine tank proper shall be protected in ac-
service must conform to the standards cordance with paragraph (b) of this sec-
of the Chlorine Institute, Inc., Dwg. tion against such damage as could be
1048 or Section 3, Pamphlet 166, caused by collision with other vehicles
Angle Valve Guidelines for Chlorine or objects, jack-knifing and over-
Bulk Transportation. (IBR, see 171.7 turning. In addition, pressure relief
of this subchapter). Before installation, valves shall be so protected that in the
each angle valve must be tested for event of overturn of the vehicle onto a
leakage at not less than 225 psig using hard surface, their opening will not be
dry air or inert gas. prevented and their discharge will not
(c) Marking inlets and outlets. Except be restricted.
for gauging devices, thermometer (b) The protective devices or housing
wells, and pressure relief valves, each must be designed to withstand static
cargo tank inlet and outlet must be loading in any direction equal to twice
marked liquid or vapor to des- the weight of the tank and attach-
ignate whether it communicates with ments when filled with the lading,
liquid or vapor when the cargo tank is using a safety factor of not less than
filled to the maximum permitted fill- four, based on the ultimate strength of
ing density. A filling line that commu- the material to be used, without dam-
nicates with vapor may be marked age to the fittings protected, and must
spray-fill instead of vapor. be made of metal at least 316-inch
(d) Refrigeration and heating coils. (1) thick.
Refrigeration and heating coils must (c) Rear-end tank protection. Rear-end
be securely anchored with provisions tank protection devices must:
for thermal expansion. The coils must (1) Consist of at least one rear bump-
be pressure tested externally to at er designed to protect the cargo tank
least the cargo tank test pressure, and and all valves, piping and fittings lo-
internally to either the tank test pres- cated at the rear of the cargo tank
sure or twice the working pressure of from damage that could result in loss
the heating/refrigeration system, of lading in the event of a rear end col-
whichever is higher. A cargo tank may lision. The bumper design must trans-
not be placed in service if any leakage mit the force of the collision directly
occurs or other evidence of damage is to the chassis of the vehicle. The rear
found. The refrigerant or heating me- bumper and its attachments to the
dium to be circulated through the coils chassis must be designed to withstand
must not be capable of causing any ad- a load equal to twice the weight of the
verse chemical reaction with the cargo loaded cargo tank motor vehicle and
tank lading in the event of leakage. attachments, using a safety factor of
The unit furnishing refrigeration may four based on the tensile strength of
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 refrigera- meet the requirements of 393.86 of this
tion, the heating or refrigeration sys- title; or
tem shall be arranged to permit com-
(2) Conform to the requirements of
plete drainage. 178.3458(d).
[Order 59B, 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 ci- housing and a manway cover to permit
wreier-aviles on DSK3TPTVN1PROD with CFR
tations affecting 178.3379, 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. For tanks manufac-
and at www.fdsys.gov. tured on or after October 1, 2009, the
142
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Pipeline and Hazardous Materials Safety Admin., DOT 178.33714
more than 34 NPT equipped with a [Amdt. 17829, 38 FR 27599, Oct. 5, 1973, as
valve having an integral excess flow amended by Amdt. 17889, 54 FR 25018, June
valve or excess flow feature. 12, 1989; Amdt. 178118, 61 FR 51340, Oct. 1,
[64 FR 28050, May 24, 1999] 1996]
143
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178.33715 49 CFR Ch. I (10111 Edition)
144
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Pipeline and Hazardous Materials Safety Admin., DOT 178.33718
(4) The specification plate may be at- specification plate in accordance with
tached to the cargo tank motor vehicle this section:
chassis rail by brazing, welding, or (1) Cargo tank motor vehicle manu-
other suitable means on the left side facturer (CTMV mfr.).
near the front head, in a place acces- (2) Cargo tank motor vehicle certifi-
sible for inspection. If the specification cation date (CTMV cert. date).
plate is attached to the chassis rail, (3) Cargo tank manufacturer (CT
then the cargo tank serial number as- mfr.).
signed by the cargo tank manufacturer (4) Cargo tank date of manufacture
must be included on the plate. (CT date of mfr.), month and year.
(b) Name plate. The following infor- (5) Maximum weight of lading (Max.
mation must be marked on the name Payload), in pounds
plate in accordance with this section:
(6) Lining materials (Lining), if ap-
(1) DOT-specification number MC 331
plicable.
(DOT MC 331).
(7) Heating system design pressure
(2) Original test date (Orig. Test
(Heating sys. press.), in psig, if applica-
Date).
ble.
(3) MAWP in psig.
(8) Heating system design tempera-
(4) Cargo tank design temperature
ture (Heating sys. temp.), in F, if ap-
(Design Temp. Range) lll F to
plicable.
lll F.
(5) Nominal capacity (Water Cap.), in (9) Cargo tank serial number, as-
pounds. signed by cargo tank manufacturer (CT
(6) Maximum design density of lading serial), if applicable.
(Max. Lading density), in pounds per NOTE 1 TO PARAGRAPH (c): See 173.315(a) of
gallon. this chapter regarding water capacity.
(7) Material specification number NOTE 2 TO PARAGRAPH (c): When the shell
shell (Shell matl, yyy***), where yyy and head materials are the same thickness,
is replaced by the alloy designation they may be combined (Shell & head matl,
yyy***).
and *** is replaced by the alloy type.
(8) Material specification number (d) The design weight of lading used
heads (Head matl. yyy***), where in determining the loading in 178.337
yyy is replaced by the alloy designa- 3(b), 178.33710(b) and (c), and 178.337
tion and *** by the alloy type. 13(a) and (b), must be shown as the
(9) Minimum Thicknessshell (Min. maximum weight of lading marking re-
Shell-thick), in inches. When minimum quired by paragraph (c) of this section.
shell thicknesses are not the same for
different areas, show (topll, sidell, [68 FR 19280, Apr. 18, 2003; 68 FR 52370, Sept.
3, 2003, as amended at 68 FR 57633, Oct. 6,
bottomll, in inches). 2003]
(10) Minimum thicknessheads (Min.
heads thick.), in inches. 178.33718 Certification.
(11) Manufactured thicknessshell
(Mfd. Shell thick.), topll, sidell, (a) At or before the time of delivery,
bottomll, in inches. (Required when the cargo tank motor vehicle manufac-
additional thickness is provided for turer must supply and the owner must
corrosion allowance.) obtain, a cargo tank motor vehicle
(12) Manufactured thicknessheads manufacturers data report as required
(Mfd. Heads thick.), in inches. (Re- by Section VIII of the ASME Code
quired when additional thickness is (IBR, see 171.7 of this subchapter), and
provided for corrosion allowance.) a certificate stating that the com-
(13) Exposed surface area, in square pleted cargo tank motor vehicle con-
feet. forms in all respects to Specification
MC 331 and the ASME Code. The reg-
NOTE TO PARAGRAPH (b): When the shell and istration numbers of the manufacturer,
head materials are the same thickness, they the Design Certifying Engineer, and
wreier-aviles on DSK3TPTVN1PROD with CFR
145
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178.338 49 CFR Ch. I (10111 Edition)
(1) For each design type, the certifi- certificate, or certificates, will include
cate must be signed by a responsible of- sufficient sketches, drawings, and
ficial of the manufacturer and a Design other information to indicate the loca-
Certifying Engineer; and tion, make, model, and size of each
(2) For each cargo tank motor vehi- valve and the arrangement of all piping
cle, the certificate must be signed by a associated with the cargo tank.
responsible official of the manufac- (6) The certificate must contain a
turer and a Registered Inspector. statement indicating whether or not
(3) When a cargo tank motor vehicle the cargo tank was postweld heat
is manufactured in two or more stages, treated for anhydrous ammonia as
each manufacturer who performs a specified in 178.3371(f).
manufacturing function or portion (b) The owner shall retain the copy of
thereof on the incomplete cargo tank the data report and certificates and re-
motor vehicle must provide to the suc- lated papers in his files throughout his
ceeding manufacturer, at or before the ownership of the cargo tank motor ve-
time of delivery, a certificate that hicle and for at least one year there-
states the function performed by the after; and in the event of change in
manufacturer, including any certifi- ownership, retention by the prior
cates received from previous manufac- owner of nonfading photographically
turers, Registered Inspectors, and De- reproduced copies will be deemed to
sign Certifying Engineers. satisfy this requirement. Each motor
(4) Specification shortages. When a carrier using the cargo tank motor ve-
cargo tank motor vehicle is manufac- hicle, if not the owner thereof, shall
tured in two or more stages, the manu- obtain 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 178.33717(a) and (b) motor vehicle and for at least one year
without the original date of certifi- thereafter.
cation stamped on the specification [Order 59B, 30 FR 583, Jan. 16, 1965. Redesig-
plate. Prior manufacturers must list nated at 32 FR 5606, Apr. 5, 1967]
the specification requirements that are
not completed on the Certificate of EDITORIAL NOTE: For FEDERAL REGISTER ci-
tations affecting 178.33718, see the List of
Compliance. When the cargo tank
CFR Sections Affected which appears in the
motor vehicle is brought into full com- Finding Aids section of the printed volume
pliance with the applicable specifica- and at www.fdsys.gov.
tion, the cargo tank motor vehicle
manufacturer must have a Registered 178.338 Specification MC338; insu-
Inspector stamp the date of certifi- lated cargo tank motor vehicle.
cation on the specification plate and
issue a Certificate of Compliance to the 178.3381 General requirements.
owner of the cargo tank motor vehicle. (a) For the purposes of this section
The Certificate of Compliance must (1) Design pressure means the
list the actions taken to bring the MAWP as used in Section VIII of the
cargo tank motor vehicle into full ASME Code (IBR, see 171.7 of this sub-
compliance. In addition, the certificate chapter), and is the gauge pressure at
must include the date of certification the top of the tank.
and the person (manufacturer, carrier (2) Design service temperature means
or repair organization) accomplishing the coldest temperature for which the
compliance. tank is suitable (see 173.318 (a)(1) and
(5) The certificate must state wheth- (f) of this subchapter).
er or not it includes certification that (b) Each cargo tank must consist of a
all valves, piping, and protective de- suitably supported welded inner vessel
vices conform to the requirements of enclosed within an outer shell or jack-
the specification. If it does not so cer- et, with insulation between the inner
tify, the installer of any such valve, vessel and outer shell or jacket, and
wreier-aviles on DSK3TPTVN1PROD with CFR
piping, or device shall supply and the having piping, valves, supports and
owner shall obtain a certificate assert- other appurtenances as specified in this
ing complete compliance with these subchapter. For the purpose of this
specifications for such devices. The specification, tank means inner vessel
146
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Pipeline and Hazardous Materials Safety Admin., DOT 178.3382
and jacket means either the outer shell 178.3383(b), may not exceed 25 percent
or insulation cover. of the minimum specified tensile
(c) Each tank must be designed, con- strength.
structed, certified, and stamped in ac- [Amdt. 17877, 48 FR 27703, June 16, 1983, as
cordance with Section VIII of the amended at 49 FR 24316, June 12, 1984; Amdt.
ASME Code. 178104, 59 FR 49135, Sept. 26, 1994; 66 FR
(d) The exterior surface of the tank 45387, Aug. 28, 2001; 68 FR 75754, Dec. 31, 2003]
must be insulated with a material com-
patible with the lading. 178.3382 Material.
(1) Each cargo tank must have an in- (a) All material used in the construc-
sulation system that will prevent the tion of a tank and its appurtenances
tank pressure from exceeding the pres- that may come in contact with the lad-
sure relief valve set pressure within the ing must be compatible with the lading
specified holding time when the tank is to be transported. All material used for
loaded with the specific cryogenic liq- tank pressure parts must conform to
uid at the design conditions of the requirements in Section II of the
(i) The specified temperature and ASME Code (IBR, see 171.7 of this sub-
pressure of the cryogenic liquid, and chapter). All material used for evacu-
(ii) The exposure of the filled cargo ated jacket pressure parts must con-
tank to an average ambient tempera- form to the chemistry and steelmaking
ture of 85 F. practices of one of the material speci-
(2) For a cargo tank used to transport fications of Section II of the ASME
oxygen, the insulation may not sustain Code or the following ASTM Specifica-
combustion in a 99.5 percent oxygen at- tions (IBR, see 171.7 of this sub-
mosphere at atmospheric pressure chapter): A 242, A 441, A 514, A 572, A
when contacted with a continuously
588, A 606, A 633, A 715, A 1008/A 1008M,
heated glowing platinum wire. The
A 1011/A 1011M.
cargo tank must be marked in accord- (b) All tie-rods, mountings, and other
ance with 178.33818(b)(7). appurtenances within the jacket and
(3) Each vacuum-insulated cargo
all piping, fittings and valves must be
tank must be provided with a connec-
of material suitable for use at the low-
tion for a vacuum gauge to indicate the
est temperature to be encountered.
absolute pressure within the insulation (c) Impact tests are required on all
space. tank materials, except materials that
(e) The insulation must be com-
are excepted from impact testing by
pletely covered by a metal jacket. The
the ASME Code, and must be per-
jacket or the insulation must be so
formed using the procedure prescribed
constructed and sealed as to prevent
in Section VIII of the ASME Code.
moisture from coming into contact (d) The direction of final rolling of
with the insulation (see 173.318(a)(3) of the shell material must be the circum-
this subchapter). Minimum metal ferential orientation of the tank shell.
thicknesses are as follows: (e) Each tank constructed in accord-
Jacket evacu- Jacket not ance with part UHT in Section VIII of
ated evacuated the ASME Code must be postweld heat
Type metal
Gauge Inches Gauge Inches treated as a unit after completion of
all welds to the shell and heads. Other
Stainless steel .............. 18 0.0428 22 0.0269
Low carbon mild steel .. 12 0.0946 14 0.0677 tanks must be postweld heat treated as
Aluminum ..................... ........... 0.125 ........... 0.1000 required in Section VIII of the ASME
Code. For all tanks the method must
(f) An evacuated jacket must be in be as prescribed in the ASME Code.
compliance with the following require- Welded attachments to pads may be
ments: made after postweld heat treatment.
(1) The jacket must be designed to (f) The fabricator shall record the
sustain a minimum critical collapsing heat and slab numbers and the certified
pressure of 30 psig. Charpy impact values of each plate
wreier-aviles on DSK3TPTVN1PROD with CFR
(2) If the jacket also supports addi- used in the tank on a sketch showing
tional loads, such as the weight of the the location of each plate in the shell
tank and lading, the combined stress, and heads of the tank. A copy of the
computed according to the formula in sketch must be provided to the owner
147
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178.3383 49 CFR Ch. I (10111 Edition)
of the cargo tank and a copy must be ture gradients resulting from lading
retained by the fabricator for at least and ambient temperature extremes.
five years and made available, upon re- When dissimilar materials are used,
quest, to any duly identified represent- their thermal coefficients must be used
ative of the Department. in calculation of the thermal stresses.
(Approved by the Office of Management and (2) Stress concentrations in tension,
Budget under control number 21370017) bending, and torsion which occur at
pads, cradles, or other supports must
[Amdt. 17877, 48 FR 27703 and 27713, June 16,
1983, as amended at 49 FR 24316, June 12, 1984; be considered in accordance with ap-
68 FR 19281, Apr. 18, 2003; 68 FR 75754, Dec. 31, pendix G in Section VIII of the ASME
2003; 70 FR 34076, June 13, 2005] Code.
(c) Stresses resulting from static and
178.3383 Structural integrity. dynamic loadings, or a combination
(a) General requirements and accept- thereof, are not uniform throughout
ance criteria. (1) Except as permitted in the cargo tank motor vehicle. The fol-
paragraph (d) of this section, the max- lowing is a simplified procedure for cal-
imum 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 max-
value 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
S = 0.5 (Sy + Sx) (0.25(Sy Sx)2 + Ss2) 0.5
of the materials used in each tank may
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 combina-
case, 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 gen-
ultimate tensile strength specified in erated by internal and external pres-
either 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
(3) The maximum design stress at conditions:
any point in the tank must be cal- (i) The longitudinal tensile stress
culated separately for the loading con- generated by internal pressure;
ditions described in paragraphs (b), (c), (ii) The tensile or compressive stress
and (d) of this section. Alternate test generated by the axial load resulting
or analytical methods, or a combina- from a decelerative force applied inde-
tion thereof, may be used in lieu of the pendently to each suspension assembly
procedures described in paragraphs (b), at the road surface using applicable
(c), and (d) of this section, if the meth- static loadings specified in 178.33813
ods are accurate and verifiable. (b);
(4) Corrosion allowance material may (iii) The tensile or compressive stress
not be included to satisfy any of the generated by the bending moment re-
design calculation requirements of this sulting from a decelerative force ap-
section. plied independently to each suspension
(b) Static design and construction. (1) assembly at the road surface using ap-
The static design and construction of plicable static loadings specified in
each tank must be in accordance with 178.33813 (b);
appendix G in Section VIII of the (iv) The tensile or compressive stress
ASME Code (IBR, see 171.7 of this sub- generated by the axial load resulting
chapter). The tank design must include from an accelerative force applied to
wreier-aviles on DSK3TPTVN1PROD with CFR
calculation of stress due to the design the horizontal pivot of the fifth wheel
pressure, the weight of lading, the supporting the vehicle using applicable
weight of structures supported by the static loadings specified in 178.33813
tank wall, and the effect of tempera- (b);
148
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Pipeline and Hazardous Materials Safety Admin., DOT 178.3383
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178.3384 49 CFR Ch. I (10111 Edition)
supports other than load rings and control valve, full trycock or gas phase
stiffening rings. manual vent valve, would permit loss
(d) Substructures must be properly of flammable material, an additional
fitted before attachment and the weld- closure that is leak tight at the tank
150
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Pipeline and Hazardous Materials Safety Admin., DOT 178.3389
design pressure must be provided out- (7) All fittings must be rated for the
board of such valve. maximum tank pressure and suitable
[Amdt. 17877, 48 FR 27704, June 16, 1983]
for the coldest temperature to which
they will be subjected in actual serv-
178.3388 Pressure relief devices, ice.
piping, valves, and fittings. (8) All piping, valves, and fittings
(a) Pressure relief devices. Each tank must be grouped in the smallest prac-
pressure relief device must be designed, ticable space and protected from dam-
constructed, and marked in accordance age as required by 178.33810.
with 173.318(b) of this subchapter. (9) When a pressure-building coil is
(b) Piping, valves, and fittings. (1) The used on a tank designed to handle oxy-
burst pressure of all piping, pipe fit- gen or flammable ladings, the vapor
tings, hoses and other pressure parts, connection to that coil must be pro-
except for pump seals and pressure re- vided with a valve or check valve as
lief devices, must be at least 4 times close to the tank shell as practicable to
the design pressure of the tank. Addi- prevent the loss of vapor from the tank
tionally, the burst pressure may not be in case of damage to the coil. The liq-
less than 4 times any higher pressure uid 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 [Amdt. 17877, 48 FR 27704, June 16, 1983, as
to in service. amended by Amdt. 17889, 54 FR 25019, June
(2) Pipe joints must be threaded, 12, 1989]
welded or flanged. If threaded pipe is
used, the pipe and fittings must be 178.3389 Holding time.
Schedule 80 weight or heavier. Malle- (a) Holding time is the time, as de-
able metals must be used in the con- termined by testing, that will elapse
struction of valves and fittings. Where from loading until the pressure of the
copper tubing is permitted, joints shall contents, under equilibrium conditions,
be brazed or be of equally strong metal reaches the level of the lowest pressure
union type. The melting point of the control valve or pressure relief valve
brazing materials may not be lower setting.
than 1000 F. The method of joining (b) Holding time test. (1) The test to
tubing may not reduce the strength of determine holding time must be per-
the tubing, such as by the cutting of formed by charging the tank with a
threads. cryogenic liquid having a boiling point,
(3) Each hose coupling must be de- at a pressure of one atmosphere, abso-
signed for a pressure of at least 120 per- lute, no lower than the design service
cent of the hose design pressure and so temperature of the tank. The tank
that there will be no leakage when con- must be charged to its maximum per-
nected. mitted filling density with that liquid
(4) Piping must be protected from and stabilized to the lowest practical
damage due to thermal expansion and pressure, which must be equal to or
contraction, jarring, and vibration. less than the pressure to be used for
Slip joints are not authorized for this 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-dis-
or 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 appli- lowest 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
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151
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178.33810 49 CFR Ch. I (10111 Edition)
152
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Pipeline and Hazardous Materials Safety Admin., DOT 178.33812
(1) Consist of at least one rear bump- such pressure into the cargo tank. If
er designed to protect the cargo tank the jacket is not evacuated, the seat of
and piping in the event of a rear-end the valve must be inside the tank, in
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 re-
of the vehicle. The rear-end tank pro- motely controlled valve must be lo-
tection device and its attachments to cated as close to the tank as prac-
the chassis must be designed to with- ticable.
stand a load equal to twice the weight (2) Each remotely controlled shut off
of the loaded cargo tank and attach- valve 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 rear- linkage 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 environ-
of this title and extend vertically to a ment and weather. The thermal means
height adequate to protect all valves must consist of fusible elements actu-
and 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
178.3458(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 assem- over 3,500 gallons water capacity, re-
blies), must be at least 14 inches above mote means of automatic closure must
level ground. be installed at the ends of the cargo
tank in at least two diagonally oppo-
[Amdt. 17877, 48 FR 27705, June 16, 1983, as
amended at 49 FR 24316, June 12, 1984; Amdt. site locations. If the loading/unloading
17899, 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 lo-
cations, at least one additional ther-
178.33811 Discharge control devices. mal device must be installed so that
(a) Excess-flow valves are not re- heat from a fire in the loading/unload-
quired. ing connection area will activate the
(b) Each liquid filling and liquid dis- emergency 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 in-
used to transport argon, carbon diox- stalled 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 sys-
filling and liquid discharge line must tem.
be provided with an on-vehicle re- [Amdt. 17877, 48 FR 27705, June 16, 1983, as
motely controlled self-closing shutoff amended by Amdt. 178105, 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]
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153
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178.33813 49 CFR Ch. I (10111 Edition)
154
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Pipeline and Hazardous Materials Safety Admin., DOT 178.33816
(2) The design pressure of each liquid 178.33816 Inspection and testing.
level gauging device must be at least (a) General. The material of construc-
that of the tank. tion of a tank and its appurtenances
(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 hydro-
near the jacket and extending into the static or pneumatic test. The test pres-
cargo 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 vacu-
uid reaches the maximum level per- um, 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 pres-
must be designed and installed to accu- sure.
rately indicate the maximum filling (b) Additional requirements for pneu-
level 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 per-
must be provided with a suitable pres- sonnel should be taken because of the
sure gauge indicating the lading pres- potential hazard involved in a pneu-
sure and located on the front of the matic test. The pneumatic test pres-
jacket so it can be read by the driver in sure in the tank must be reached by
the rear view mirror. Each gauge must gradually increasing the pressure to
have a reference mark at the cargo one-half of the test pressure. There-
tank design pressure or the set pres- after, the test pressure must be in-
sure of the pressure relief valve or pres- creased in steps of approximately one-
tenth of the test pressure until the re-
sure control valve, whichever is lowest.
quired test pressure has been reached.
(c) Orifices. All openings for dip tube Then the pressure must be reduced to a
gauging devices and pressure gauges in value equal to four-fifths of the test
flammable cryogenic liquid service pressure and held for a sufficient time
must be restricted at or inside the to permit inspection of the cargo tank
jacket by orifices no larger than 0.060- for leaks.
inch diameter. Trycock lines, if pro- (c) Weld inspection. All tank shell or
vided, may not be greater than 12-inch head welds subject to pressure shall be
nominal pipe size. radiographed in accordance with Sec-
[Amdt. 17877, 48 FR 27706, June 16, 1983, as tion VIII of the ASME Code. A tank
amended at 49 FR 24317, June 12, 1984] which has been subjected to inspection
by the magnetic particle method, the
178.33815 Cleanliness. liquid penetrant method, or any meth-
A cargo tank constructed for oxygen od involving a material deposit on the
service must be thoroughly cleaned to interior tank surface, must be cleaned
remove all foreign material in accord- to remove any such residue by scrub-
ance with CGA G4.1 (IBR, see 171.7 of bing or equally effective means, and all
this subchapter). All loose particles such residue and cleaning solution
from fabrication, such as weld beads, must be removed from the tank prior
dirt, grinding wheel debris, and other to final closure of the tank.
(d) Defect repair. All cracks and other
loose materials, must be removed prior
defects must be repaired as prescribed
to the final closure of the manhole of
in Section VIII of the ASME Code. The
the tank. Chemical or solvent cleaning
welder and the welding procedure must
with a material compatible with the
be qualified in accordance with Section
intending lading must be performed to
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178.33817 49 CFR Ch. I (10111 Edition)
performed, and the repaired areas must quired by Section VIII of the ASME
be retested. Code (IBR, see 171.7 of this sub-
(e) Verification must be made of the chapter), in characters at least 3/16
interior cleanliness of a tank con- inch high (parenthetical abbreviations
structed for oxygen service by means may be used). All plates must be main-
that 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
[Amdt. 17877, 48 FR 27706, June 16, 1983, as specified unless the specification plate
amended at 49 FR 24317, June 12, 1984; 49 FR is attached to the chassis and has the
42736, Oct. 24, 1984; 68 FR 75755, Dec. 31, 2003] information required in paragraphs (b)
and (c) of this section.
178.33817 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, ade- be displayed on a single plate. If the in-
quately 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 infor-
power 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 at-
shall be equipped with suitable pres- tached to the cargo tank motor vehicle
sure actuated by-pass valves permit- chassis rail by brazing, welding, or
ting flow from discharge to suction to other suitable means on the left side
the tank. near the front head, in a place acces-
(b) A valve or fitting made of alu- sible for inspection. If the specification
minum with internal rubbing or abrad- plate is attached to the chassis rail,
ing aluminum parts that may come in then the cargo tank serial number as-
contact 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 infor-
liquid) unless the parts are anodized in mation must be marked on the name
accordance with ASTM B 580 (IBR, see plate in accordance with this section:
171.7 of this subchapter).
(1) DOT-specification number MC 338
[Amdt. 17889, 54 FR 25020, June 12, 1989, as (DOT MC 338).
amended at 55 FR 37058, Sept. 7, 1990; 67 FR (2) Original test date (Orig, Test
61016, Sept. 27, 2002; 68 FR 75755, Dec. 31, 2003] Date).
178.33818 Marking. (3) MAWP in psig.
(4) Cargo tank test pressure (Test P),
(a) General. Each cargo tank certified
in psig.
after October 1, 2004 must have a corro-
sion-resistant metal name plate (5) Cargo tank design temperature
(ASME Plate) and specification plate (Design Temp. Range) ll F to ll
permanently attached to the cargo F.
tank by brazing, welding, or other suit- (6) Nominal capacity (Water Cap.), in
able means on the left side near the pounds.
front, in a place accessible for inspec- (7) Maximum design density of lading
tion. If the specification plate is at- (Max. Lading density), in pounds per
tached directly to the cargo tank wall gallon.
by welding, it must be welded to the (8) Material specification number
tank before the cargo tank is postweld shell (Shell matl, yyy * * *), where
heat treated. yyy is replaced by the alloy designa-
(1) The plates must be legibly marked tion and * * * is replaced by the
by stamping, embossing, or other alloy type.
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156
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Pipeline and Hazardous Materials Safety Admin., DOT 178.33819
NOTE: When the shell and heads materials NOTE 2 TO PARAGRAPH (c): When the shell
are the same thickness, they may be com- and head materials are the same thickness,
bined, (Shell & head matl, yyy * * *). they may be combined (Shell & head matl,
yyy***).
(10) Weld material (Weld matl.).
(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), 178.33810 (b) and (c), and 178.338
different areas, show (top ll, side 13 (b), must be shown as the maximum
ll, bottom ll, 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 ll, side ll, 2003]
bottom ll, in inches. (Required when
additional thickness is provided for 178.33819 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. (Re- motor vehicle shall furnish to the
quired when additional thickness is owner of the completed vehicle the fol-
provided for corrosion allowance.) lowing:
(15) Exposed surface area, in square (1) The tank manufacturers data re-
feet. 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 manufactur-
specification plate in accordance with ers vehicle serial number stating that
this section: the completed cargo tank motor vehi-
(1) Cargo tank motor vehicle manu- cle conforms to all applicable require-
facturer (CTMV mfr.). ments of Specification MC 338, includ-
(2) Cargo tank motor vehicle certifi- ing 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 cer-
mfr.). tification. The registration numbers of
(4) Cargo tank date of manufacture the manufacturer, the Design Certi-
(CT date of mfr.), month and year. fying Engineer, and the Registered In-
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 gal-
paragraphs (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 ap- manufactured 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 ll hrs, name of cryogenic liq- turer, and any certificates received
uid). Marked rated holding marking for from previous manufacturers, Reg-
additional cryogenic liquids may be istered Inspectors, and Design Certi-
displayed on or adjacent to the speci- fying Engineers. The certificates must
fication plate. include sufficient sketches, drawings,
(11) Cargo tank serial number (CT se- and other information to indicate the
wreier-aviles on DSK3TPTVN1PROD with CFR
rial), as assigned by cargo tank manu- location, make, model and size of each
facturer, if applicable. valve and the arrangement of all piping
NOTE 1 TO PARAGRAPH (c): See 173.315(a) of associated with the tank. Each certifi-
this chapter regarding water capacity. cate must be signed by an official of
157
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178.340178.343 49 CFR Ch. I (10111 Edition)
accessory attachment that has no lad- inside 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
158
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Pipeline and Hazardous Materials Safety Admin., DOT 178.3451
external face of the welded flange or under a load in order to prevent dam-
sump of the cargo tank. age to any lading retention part or de-
Lading means the hazardous material vice. The device must break under
contained in a cargo tank. strain at no more than 70 percent of
Loading/unloading connection means the strength of the weakest piping ele-
the fitting in the loading/unloading ment between the cargo tank and the
line farthest from the loading/unload- sacrificial device. Operation of the sac-
ing outlet to which the loading/unload- rificial 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 load- lading.
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 exter-
the loading/unloading connection is at-
nal force and which closes when the ex-
tached.
ternal force is removed.
MAWP. See 178.320(a).
Multi-specification cargo tank motor ve- Shear section means a sacrificial de-
hicle means a cargo tank motor vehicle vice fabricated in such a manner as to
equipped with two or more cargo tanks abruptly reduce the wall thickness of
fabricated to more than one cargo tank the adjacent piping or valve material
specification. by at least 30 percent.
Normal operating loading means the Shell means the circumferential por-
loading a cargo tank motor vehicle tion of a cargo tank defined by the
may be expected to experience rou- basic design radius or radii excluding
tinely in operation. the closing heads.
Nozzle means the subassembly con- Stop-valve means a valve that stops
sisting of a pipe or tubular section with the flow of lading.
or without a welded or forged flange on Sump means a protrusion from the
one end. bottom of a cargo tank shell designed
Outlet means any opening in the shell to facilitate complete loading and un-
or head of a cargo tank, (including the loading of lading.
means for attaching a closure), except Tank means a container, consisting
that the following are not outlets: A of a shell and heads, that forms a pres-
threaded opening securely closed dur- sure tight vessel having openings de-
ing transportation with a threaded signed to accept pressure tight fittings
plug or a threaded cap, a flanged open- or closures, but excludes any appur-
ing securely closed during transpor- tenances, reinforcements, fittings, or
tation with a bolted or welded blank closures.
flange, a manhole, or gauging devices, Test pressure means the pressure to
thermometer wells, and safety relief which a tank is subjected to determine
devices.
pressure integrity.
Outlet stop-valve means the stop-valve
Toughness of material means the capa-
at the cargo tank loading/unloading
outlet. bility of a material to absorb the en-
Pipe coupling means a fitting with in- ergy represented by the area under the
ternal threads on both ends. stress strain curve (indicating the en-
Rear bumper means the structure de- ergy absorbed per unit volume of the
signed to prevent a vehicle or object material) up to the point of rupture.
from under-riding the rear of a motor Vacuum cargo tank means a cargo
vehicle. See 393.86 of this title. tank that is loaded by reducing the
Rear-end tank protection device means pressure in the cargo tank to below at-
the structure designed to protect a mospheric pressure.
cargo tank and any lading retention Variable specification cargo tank
wreier-aviles on DSK3TPTVN1PROD with CFR
piping or devices in case of a rear end means a cargo tank that is constructed
collision. in accordance with one specification,
Sacrificial device means an element, but which may be altered to meet an-
such as a shear section, designed to fail other specification by changing relief
159
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178.3452 49 CFR Ch. I (10111 Edition)
device, closures, lading discharge de- (2) The strength of the connecting
vices, and other lading retention de- structure joining multiple cargo tanks
vices. in a cargo tank motor vehicle must
Void means the space between tank meet the structural design require-
heads or bulkheads and a connecting ments in 178.3453. Any void within
structure. the connecting structure must be
Welded flange means a flange at- equipped with a drain located on the
tached to the tank by a weld joining bottom centerline that is accessible
the tank shell to the cylindrical outer and kept open at all times. For carbon
surface of the flange, or by a fillet weld steel, self-supporting cargo tanks, the
joining the tank shell to a flange drain configuration may consist of a
shaped to fit the shell contour. single drain of at least 1.0 inch diame-
(d) A manufacturer of a cargo tank ter, or two or more drains of at least
must hold a current ASME certificate 0.5 inch diameter, 6.0 inches apart, one
of authorization and must be registered of which is located as close to the bot-
with the Department in accordance tom centerline as practicable. Vapors
with part 107, subpart F of this chapter. trapped in a void within the connecting
(e) All construction must be certified structure must be allowed to escape to
by an Authorized Inspector or by a the atmosphere either through the
Registered Inspector as applicable to drain or a separate vent.
the cargo tank. (j) Variable specification cargo tank. A
(f) Each cargo tank must be designed cargo tank that may be physically al-
and constructed in conformance with tered to conform to another cargo tank
the requirements of the applicable specification must have the required
cargo tank specification. Each DOT 412 physical alterations to convert from
cargo tank with a MAWP greater one specification to another clearly in-
than 15 psig, and each DOT 407 cargo dicated on the variable specification
tank with a maximum allowable work- plate.
ing pressure greater than 35 psig must
[Amdt. 17889, 54 FR 25020, June 12, 1989, as
be constructed and certified in con- amended at 55 FR 37058, Sept. 7, 1990; Amdt.
formance with Section VIII of the 178105, 59 FR 55173, Nov. 3, 1994; Amdt. 178
ASME Code (IBR, see 171.7 of this 118, 61 FR 51340, Oct. 1, 1996; 66 FR 45387,
subchapter) except as limited or modi- 45389, Aug. 28, 2001; 68 FR 19283, Apr. 18, 2003;
fied by the applicable cargo tank speci- 68 FR 52371, Sept. 3, 2003; 68 FR 75755, Dec. 31,
fication. Other cargo tanks must be 2003; 70 FR 56099, Sept. 23, 2005; 76 FR 43532,
constructed in accordance with Sec- July 20, 2011]
tion VIII of the ASME Code, except as
178.3452 Material and material
limited or modified by the applicable thickness.
cargo tank specification.
(g) Requirements relating to parts (a) All material for shell, heads,
and accessories on motor vehicles, bulkheads, and baffles must conform to
which are contained in part 393 of the Section II of the ASME Code (IBR, see
Federal Motor Carrier Safety Regula- 171.7 of this subchapter) except as fol-
tions of this title, are incorporated lows:
into these specifications. (1) The following steels are also au-
(h) Any additional requirements pre- thorized for cargo tanks constructed
scribed in part 173 of this subchapter in accordance with the ASME Code,
that pertain to the transportation of a Section VIII.
specific lading are incorporated into ASTM A 569
these specifications. ASTM A 570
(i) Cargo tank motor vehicle composed ASTM A 572
of multiple cargo tanks. (1) A cargo tank ASTM A 622
motor vehicle composed of more than ASTM A 656
one cargo tank may be constructed ASTM A 715
ASTM A 1008/ A 1008M, ASTM A 1011/A 1011M
with the cargo tanks made to the same
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160
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161
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178.3453 49 CFR Ch. I (10111 Edition)
pads, cradles, or other supports must (A) The longitudinal stresses result-
be considered in accordance with ap- ing from the MAWP and external pres-
pendix G in Section VIII of the ASME sure, when applicable, plus static head,
Code. in combination with the bending stress
(2) Longitudinal compressive buck- generated by the static weight of the
ling stress for ASME certified vessels fully loaded cargo tank motor vehicle,
must be calculated using paragraph all structural elements, equipment and
UG23(b) in Section VIII of the ASME appurtenances supported by the cargo
Code. For cargo tanks not required to tank wall;
be certified in accordance with the (B) The tensile or compressive stress
ASME Code, compressive buckling resulting from normal operating longi-
stress may be calculated using alter- tudinal acceleration or deceleration. In
native analysis methods which are ac- each 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 decelera-
section. tion; or the horizontal pivot of the
(3) Cargo tank designers and manu- truck tractor or converter dolly fifth
facturers must consider all of the con- wheel, or the drawbar hinge on the
ditions specified in 173.33(c) of this fixed dolly during acceleration; or an-
subchapter when matching a cargo choring and support members of a
tanks performance characteristic to truck during acceleration and decelera-
the characteristic of each lading trans- tion, as applicable. The vertical reac-
ported. tion must be calculated based on the
(c) Shell design. Shell stresses result- static weight of the fully loaded cargo
ing from static or dynamic loadings, or tank motor vehicle, all structural ele-
combinations thereof, are not uniform ments, equipment and appurtenances
throughout the cargo tank motor vehi-
supported by the cargo tank wall. The
cle. The vertical, longitudinal, and lat-
following loadings must be included:
eral normal operating loadings can
(1) The axial load generated by a
occur simultaneously and must be
combined. The vertical, longitudinal decelerative force;
and lateral extreme dynamic loadings (2) The bending moment generated by
occur separately and need not be com- a decelerative force;
bined. (3) The axial load generated by an ac-
(1) Normal operating loadings. The fol- celerative force; and
lowing procedure addresses stress in (4) The bending moment generated by
the cargo tank shell resulting from an accelerative force; and
normal operating loadings. The effec- (C) The tensile or compressive stress
tive stress (the maximum principal generated by the bending moment re-
stress at any point) must be deter- sulting from normal operating vertical
mined by the following formula: accelerative force equal to 0.35 times
the vertical reaction at the suspension
S = 0.5(Sy + Sx) [0.25(SySx)2 + SS2]0.5
assembly of a trailer; or the horizontal
Where: pivot of the upper coupler (fifth wheel)
(i) S = effective stress at any given or turntable; or anchoring and support
point under the combination of static members of a truck, as applicable. The
and normal operating loadings that can vertical reaction must be calculated
occur at the same time, in psi. based on the static weight of the fully
(ii) Sy = circumferential stress gen- loaded cargo tank motor vehicle, all
erated by the MAWP and external pres- structural elements, equipment and ap-
sure, when applicable, plus static head, purtenances supported by the cargo
in psi. tank wall.
wreier-aviles on DSK3TPTVN1PROD with CFR
(iii) Sx = The following net longitu- (iv) SS = The following shear stresses
dinal stress generated by the following generated by the following static and
static and normal operating loading normal operating loading conditions,
conditions, in psi: in psi:
162
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Pipeline and Hazardous Materials Safety Admin., DOT 178.3453
(A) The static shear stress resulting and extreme dynamic loadings that can
from the vertical reaction at the sus- occur at the same time, in psi.
pension assembly of a trailer, and the (ii) Sy = circumferential stress gen-
horizontal 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 ap- psi.
plicable. The vertical reaction must be (iii) Sx = the following net longitu-
calculated 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, equip- conditions, in psi:
ment and appurtenances supported by
(A) The longitudinal stresses result-
the cargo tank wall;
ing from the MAWP and external pres-
(B) The vertical shear stress gen-
sure, when applicable, plus static head,
erated by a normal operating accelera-
in combination with the bending stress
tive force equal to 0.35 times the
vertical reaction at the suspension as- generated by the static weight of the
sembly of a trailer; or the horizontal fully loaded cargo tank motor vehicle,
pivot of the upper coupler (fifth wheel) all structural elements, equipment and
or turntable; or anchoring and support appurtenances supported by the tank
members of a truck, as applicable. The wall;
vertical reaction must be calculated (B) The tensile or compressive stress
based on the static weight of the fully resulting from extreme longitudinal
loaded cargo tank motor vehicle, all acceleration or deceleration. In each
structural elements, equipment and ap- case the forces applied must be 0.7
purtenances supported by the cargo times the vertical reaction at the sus-
tank wall; pension assembly, applied at the road
(C) The lateral shear stress generated surface, and as transmitted to the
by a normal operating lateral accelera- cargo tank wall through the suspension
tive force equal to 0.2 times the assembly of a trailer during decelera-
vertical reaction at each suspension as- tion; or the horizontal pivot of the
sembly of a trailer, applied at the road truck tractor or converter dolly fifth
surface, and as transmitted to the wheel, or the drawbar hinge on the
cargo tank wall through the suspension fixed dolly during acceleration; or the
assembly of a trailer, and the hori- anchoring and support members of a
zontal pivot of the upper coupler (fifth truck during acceleration and decelera-
wheel) or turntable; or anchoring and tion, as applicable. The vertical reac-
support members of a truck, as applica- tion must be calculated based on the
ble. The vertical reaction must be cal- static weight of the fully loaded cargo
culated based on the static weight of tank motor vehicle, all structural ele-
the fully loaded cargo tank motor vehi- ments, equipment and appurtenances
cle, all structural elements, equipment supported by the cargo tank wall. The
and appurtenances supported by the following loadings must be included:
cargo tank wall; and (1) The axial load generated by a
(D) The torsional shear stress gen- decelerative force;
erated by the same lateral forces as de- (2) The bending moment generated by
scribed in paragraph (c)(1)(iv)(C) of this a decelerative force;
section. (3) The axial load generated by an ac-
(2) Extreme dynamic loadings. The fol- celerative force; and
lowing procedure addresses stress in (4) The bending moment generated by
the cargo tank shell resulting from ex- an accelerative force; and
treme dynamic loadings. The effective (C) The tensile or compressive stress
stress (the maximum principal stress generated by the bending moment re-
at any point) must be determined by sulting from an extreme vertical accel-
the following formula: erative force equal to 0.7 times the
S = 0.5(Sy + Sx) [0.25(Sy Sx)2 + SS2]0.5 vertical reaction at the suspension as-
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178.3453 49 CFR Ch. I (10111 Edition)
164
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Pipeline and Hazardous Materials Safety Admin., DOT 178.3455
thickness of 0.187 inch may be used (b) Where practical all welds must be
when the shell or head thickness is easily accessible for inspection.
over 0.187 inch. If weep holes or tell- [Amdt. 17889, 54 FR 25022, June 12, 1989, as
tale holes are used, the pad must be amended by Amdt. 178118, 61 FR 51341, Oct.
drilled or punched at the lowest point 1, 1996; 68 FR 75756, Dec. 31, 2003]
before it is welded to the tank. Each
pad must: 178.3455 Manhole assemblies.
(i) Be fabricated from material deter- (a) Each cargo tank with capacity
mined to be suitable for welding to greater than 400 gallons must be acces-
both the cargo tank material and the sible through a manhole at least 15
material of the appurtenance or struc- inches in diameter.
tural support member; a Design Certi- (b) Each manhole, fill opening and
fying Engineer must make this deter- washout assembly must be structurally
mination considering chemical and capable of withstanding, without leak-
physical properties of the materials age or permanent deformation that
and must specify filler material con- would affect its structural integrity, a
forming to the requirements of the static internal fluid pressure of at least
ASME Code (incorporated by reference; 36 psig, or cargo tank test pressure,
see 171.7 of this subchapter). whichever is greater. The manhole as-
(ii) Be preformed to an inside radius sembly manufacturer shall verify com-
no greater than the outside radius of pliance with this requirement by
the cargo tank at the attachment loca- hydrostatically testing at least one
tion. percent (or one manhole closure,
whichever is greater) of all manhole
(iii) Extend at least 2 inches in each
closures of each type produced each 3
direction from any point of attachment months, as follows:
of an appurtenance or structural sup-
(1) The manhole, fill opening, or
port member. This dimension may be washout assembly must be tested with
measured from the center of the struc- the venting devices blocked. Any leak-
tural member attached. age or deformation that would affect
(iv) Have rounded corners, or other- the product retention capability of the
wise be shaped in a manner to mini- assembly shall constitute a failure.
mize stress concentrations on the shell (2) If the manhole, fill opening, or
or head. washout assembly tested fails, then
(v) Be attached by continuous fillet five more covers from the same lot
welding. Any fillet weld discontinuity must be tested. If one of these five cov-
may only be for the purpose of pre- ers fails, then all covers in the lot from
venting an intersection between the fil- which the tested covers were selected
let weld and the tank or jacket seam are to be 100% tested or rejected for
weld. service.
(c) Each manhole, filler and washout
[Amdt. 17889, 55 FR 37059, Sept. 7, 1990, as
cover must be fitted with a safety de-
amended by Amdt. 17889, 56 FR 27876, June
17, 1991; Amdt. 178104, 59 FR 49135, Sept. 26,
vice that prevents the cover from open-
1994; Amdt. 178105, 59 FR 55173, 55174 and ing fully when internal pressure is
55175, Nov. 3, 1994; 60 FR 17402, Apr. 5, 1995; present.
Amdt. 178118, 61 FR 51341, Oct. 1, 1996; 65 FR (d) Each manhole and fill cover must
58631, Sept. 29, 2000; 68 FR 19283, Apr. 18, 2003; be secured with fastenings that will
68 FR 75755, Dec. 31, 2003; 74 FR 16143, Apr. 9, prevent opening of the covers as a re-
2009] sult of vibration under normal trans-
portation conditions or shock impact
178.3454 Joints. due to a rollover accident on the road-
(a) All joints between the cargo tank way or shoulder where the fill cover is
shell, heads, baffles, baffle attaching not struck by a substantial obstacle.
rings, and bulkheads must be welded in (e) On cargo tank motor vehicles
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165
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178.3456 49 CFR Ch. I (10111 Edition)
amended by Amdt. 178105, 59 FR 55175, Nov. portion may not be less than 50 percent
3, 1994; Amdt. 178118, 61 FR 51341, Oct. 1, of the total circumference of the cargo
1996] tank and the length of any unwelded
space on the joint may not exceed 40
166
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Pipeline and Hazardous Materials Safety Admin., DOT 178.3458
times the shell thickness unless rein- (5) Hat shaped or open channel ring
forced external to the cargo tank. stiffeners which prevent visual inspec-
(d) When a ring stiffener is used as a tion of the cargo tank shell are prohib-
circumferential reinforcement mem- ited on cargo tank motor vehicles con-
ber, whether internal or external, rein- structed of carbon steel.
forcement must be continuous around
[Amdt. 17889, 55 FR 37060, Sept. 7, 1990, as
the circumference of the cargo tank
amended by Amdt. 17889, 56 FR 27876, June
shell and must be in accordance with 17, 1991; 56 FR 46354, Sept. 11, 1991; Amdt. 178
the following: 104, 59 FR 49135, Sept. 26, 1994; Amdt. 178118,
(1) The section modulus about the 61 FR 51341, Oct. 1, 1996; 68 FR 75756, Dec. 31,
neutral axis of the ring section parallel 2003]
to the shell must be at least equal to
that derived from the applicable for- 178.3458 Accident damage protec-
mula: tion.
I/C = 0.00027WL, for MS, HSLA and SS; (a) General. Each cargo tank motor
or vehicle must be designed and con-
I/C = 0.000467WL, for aluminum alloys; structed in accordance with the re-
quirements of this section and the ap-
Where:
plicable individual specification to
I/C = Section modulus in inches 3
W = Tank width, or diameter, inches
minimize the potential for the loss of
L = Spacing of ring stiffener, inches; i.e., the lading due to an accident.
maximum longitudinal distance from the (1) Any dome, sump, or washout
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
(2) If a ring stiffener is welded to the have a thickness at least equal to that
cargo tank shell, a portion of the shell specified by the appropriate cargo tank
may be considered as part of the ring specification. Any such projection lo-
section for purposes of computing the cated in the lower 13 of the tank cir-
ring section modulus. This portion of cumference (or cross section perimeter
the shell may be used provided at least for non-circular cargo tanks) that ex-
50 percent of the total circumference of tends more than half its diameter at
the cargo tank is welded and the length the point of attachment to the tank or
of any unwelded space on the joint does more than 4 inches from the cargo tank
not exceed 40 times the shell thickness. wall, or located in the upper 23 of the
The maximum portion of the shell to tank circumference (or cross section
be used in these calculations is as fol- perimeter for non-circular cargo tanks)
lows: that extends more than 14 its diameter
or more than 2 inches from the point of
Number of circum- Shell sec- attachment to the tank must have ac-
ferential ring stiffener- J1 tion
to-shell welds cident damage protection devices that
1 .................................. ..................................... 20t are:
2 .................................. Less than 20t ............. 20t+J (i) As specified in this section;
2 .................................. 20t or more ................. 40t
(ii) 125 percent as strong as the other-
1 where:
wise required accident damage protec-
t=Shell thickness, inches;
J=Longitudinal distance between parallel circumferential tion device; or
ring stiffener-to-shell welds. (iii) Attached to the cargo tank in
(3) When used to meet the vacuum re- accordance with the requirements of
quirements of this section, ring stiff- paragraph (a)(3) of this section.
eners must be as prescribed in Section (2) Outlets, valves, closures, piping,
VIII of the ASME Code. or any devices that if damaged in an
(4) If configuration of internal or ex- accident could result in a loss of lading
ternal ring stiffener encloses an air from the cargo tank must be protected
wreier-aviles on DSK3TPTVN1PROD with CFR
space, this air space must be arranged by accident damage protection devices
for venting and be equipped with drain- as specified in this section.
age facilities which must be kept oper- (3) Accident damage protection de-
ative at all times. vices attached to the wall of a cargo
167
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178.3458 49 CFR Ch. I (10111 Edition)
tank must be able to withstand or de- tank circumference (or cross section
flect away from the cargo tank the perimeter for non-circular cargo tanks)
loads specified in this section. They that could be damaged in an accident
must be designed, constructed and in- that may result in the loss of lading
stalled so as to maximize the distribu- must be protected by a bottom damage
tion of loads to the cargo tank wall and protection device, except as provided
to minimize the possibility of ad- by paragraph (a)(1) of this section and
versely affecting the lading retention 173.33(e) of this subchapter. Outlets,
integrity of the cargo tank. Accident projections and piping may be grouped
induced stresses resulting from the ap- or clustered together and protected by
propriate accident damage protection a single protection device.
device requirements in combination (1) Any bottom damage protection
with the stresses from the cargo tank device must be able to withstand a
operating at the MAWP may not result force of 155,000 pounds (based on the ul-
in a cargo tank wall stress greater timate strength of the material) from
than the ultimate strength of the ma- the front, side, or rear, uniformly dis-
terial of construction using a safety tributed over each surface of the de-
factor of 1.3. Deformation of the pro- vice, over an area not to exceed 6
tection device is acceptable provided square feet, and a width not to exceed
the devices being protected are not 6 feet. Suspension components and
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 lo- equipped with an internal self-closing
cated in the piping system outboard of stop-valve need not conform to para-
the stop-valve and within the accident graph (b)(1) of this section provided it
damage protection device to prevent is protected so as to reasonably assure
any accidental loss of lading. The de- against 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 re- sacrificial device located outboard of
quired to cause the failure of the pro- each 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 sac- of 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 attach- than 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 min- that would be required to cause the
imum road clearance of any cargo tank failure of the protected lading reten-
motor 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 com- must leave the protected lading reten-
bination 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 capa-
or device from the nearest axle of the ble of retaining product.
adjacent pair, but in no case less than (c) Each closure for openings, includ-
twelve (12) inches, except that the min- ing 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 23
be calculated at the gross vehicle of a cargo tank circumference (or cross
wreier-aviles on DSK3TPTVN1PROD with CFR
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 roll-
located in the lower 13 of the cargo over damage protection devices, or by
168
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Pipeline and Hazardous Materials Safety Admin., DOT 178.3458
being 125 percent of the strength that (2) The dimensions of the rear-end
would be provided by the otherwise re- cargo tank protection device shall con-
quired damage protection device. form to the following:
(1) A rollover damage protection de- (i) The bottom surface of the rear-end
vice on a cargo tank motor vehicle protection device must be at least 4
must be designed and installed to with- inches below the lower surface of any
stand loads equal to twice the weight part at the rear of the cargo tank
of the loaded cargo tank motor vehicle motor vehicle which contains lading
applied as follows: normal to the cargo during transit and not more than 60
tank shell (perpendicular to the cargo inches from the ground when the vehi-
tank surface); and tangential (perpen- cle is empty.
dicular to the normal load) from any (ii) The maximum width of a notch,
direction. The stresses shall not exceed indentation, or separation between sec-
the ultimate strength of the material tions of a rear-end cargo tank protec-
of construction. These design loads tion device may not exceed 24 inches. A
may be considered to be uniformly dis- notched, indented, or separated rear-
tributed and independently applied. If end protection device may be used only
more than one rollover protection de- when the piping at the rear of the
vice is used, each device must be capa- cargo tank is equipped with a sacrifi-
ble of carrying its proportionate share cial device outboard of a shut-off valve.
of the required loads and in each case
(iii) The widest part of the motor ve-
at least one-fourth the total tangential
hicle at the rear may not extend more
load. The design must be proven capa-
than 18 inches beyond the outermost
ble of carrying the required loads by
ends of the device or (if separated) de-
calculations, tests or a combination of
tests and calculations. vices on either side of the vehicle.
(2) A rollover damage protection de- (3) The structure of the rear-end pro-
vice that would otherwise allow the ac- tection device and its attachment to
cumulation of liquid on the top of the the vehicle must be designed to satisfy
cargo tank, must be provided with a the conditions specified in paragraph
drain that directs the liquid to a safe (d)(1) of this section when subjected to
point of discharge away from any an impact of the cargo tank motor ve-
structural component of the cargo hicle at rated payload, at a decelera-
tank motor vehicle. tion of 2 g. Such impact must be
(d) Rear-end tank protection. Each considered as being uniformly applied
cargo tank motor vehicle must be pro- in the horizontal plane at an angle of
vided with a rear-end tank protection 10 degrees or less to the longitudinal
device to protect the cargo tank and axis of the vehicle.
piping in the event of a rear-end colli- (e) Longitudinal deceleration protec-
sion and reduce the likelihood of dam- tion. In order to account for stresses
age that could result in the loss of lad- due to longitudinal impact in an acci-
ing. Nothing in this paragraph relieves dent, the cargo tank shell and heads
the manufacturer of responsibility for must be able to withstand the load re-
complying with the requirements of sulting from the design pressure in
393.86 of this title and, if applicable, combination with the dynamic pres-
paragraph (b) of this section. The rear- sure resulting from a longitudinal de-
end tank protection device must con- celeration of 2 g. For this loading
form to the following requirements: condition, the allowable stress value
(1) The rear-end cargo tank protec- used may not exceed the ultimate
tion device must be designed so that it strength of the material of construc-
can deflect at least 6 inches hori- tion using a safety factor of 1.3. Per-
zontally forward with no contact be- formance testing, analytical methods,
tween any part of the cargo tank or a combination thereof, may be used
motor vehicle which contains lading to prove this capability provided the
wreier-aviles on DSK3TPTVN1PROD with CFR
during transit and with any part of the methods are accurate and verifiable.
rear-end protection device, or with a For cargo tanks with internal baffles,
vertical plane passing through the out- the decelerative force may be reduced
board surface of the protection device. by 0.25 g for each baffle assembly,
169
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178.3459 49 CFR Ch. I (10111 Edition)
but in no case may the total reduction ment is located outboard of the lading
in decelerative force exceed 1.0 g. retention system.
[Amdt. 17889, 54 FR 25023, June 12, 1989, as [Amdt. 17889, 54 FR 25025, June 12, 1989, as
amended at 55 FR 37061, Sept. 7, 1990; Amdt. amended at 55 FR 37061, Sept. 7, 1990, Amdt.
178105, 59 FR 55175, Nov. 3, 1994; Amdt. 178 17889, 56 FR 27877, June 17, 1991; Amdt. 178
118, 61 FR 51341, Oct. 1, 1996; 68 FR 19284, Apr. 118, 61 FR 51341, Oct. 1, 1996]
18, 2003]
178.34510 Pressure relief.
178.3459 Pumps, piping, hoses and (a) Each cargo tank must be equipped
connections.
to relieve pressure and vacuum condi-
(a) Suitable means must be provided tions in conformance with this section
during loading or unloading operations and the applicable individual specifica-
to ensure that pressure within a cargo tion. The pressure and vacuum relief
tank does not exceed test pressure. system must be designed to operate
(b) Each hose, piping, stop-valve, lad- and have sufficient capacity to prevent
ing retention fitting and closure must cargo tank rupture or collapse due to
be designed for a bursting pressure of over-pressurization or vacuum result-
the greater of 100 psig or four times the ing from loading, unloading, or from
MAWP. heating and cooling of lading. Pressure
(c) Each hose coupling must be de- relief systems are not required to con-
signed for a bursting pressure of the form to the ASME Code.
greater of 120 psig or 4.8 times the (b) Type and construction of relief sys-
MAWP of the cargo tank, and must be tems and devices. (1) Each cargo tank
designed so that there will be no leak- must be provided with a primary pres-
age when connected. sure relief system consisting of one or
(d) Suitable provision must be made more reclosing pressure relief valves. A
to allow for and prevent damage due to secondary pressure relief system con-
expansion, contraction, jarring, and vi- sisting of another pressure relief valve
bration. Slip joints may not be used for in parallel with the primary pressure
this purpose in the lading retention relief system may be used to augment
system. the total venting capacity of the cargo
(e) Any heating device, when in- tank. Non-reclosing pressure relief de-
stalled, must be so constructed that vices are not authorized in any cargo
tank except when in series with a re-
the breaking of its external connec-
closing pressure relief device. Gravity
tions will not cause leakage of the
actuated reclosing valves are not au-
cargo tank lading.
thorized on any cargo tank.
(f) Any gauging, loading or charging
(2) When provided by 173.33(c)(1)(iii)
device, including associated valves,
of this subchapter, cargo tanks may be
must be provided with an adequate
equipped with a normal vent. Such
means of secure closure to prevent
vents must be set to open at not less
leakage. than 1 psig and must be designed to
(g) The attachment and construction prevent loss of lading through the de-
of each loading/unloading or charging vice in case of vehicle overturn.
line must be of sufficient strength, or (3) Each pressure relief system must
be protected by a sacrificial device, be designed to withstand dynamic pres-
such that any load applied by loading/ sure surges in excess of the design set
unloading or charging lines connected pressure as specified in paragraphs
to the cargo tank cannot cause damage (b)(3) (i) and (ii) of this section. Set
resulting in loss of lading from the pressure is a function of MAWP as set
cargo tank. forth in paragraph (d) of this section.
(h) Use of a nonmetallic pipe, valve (i) Each pressure relief device must
or connection that is not as strong and be able to withstand dynamic pressure
wreier-aviles on DSK3TPTVN1PROD with CFR
heat resistant as the cargo tank mate- surge reaching 30 psig above the design
rial is authorized only if such attach- set pressure and sustained above the
set pressure for at least 60 milliseconds
with a total volume of liquid released
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Pipeline and Hazardous Materials Safety Admin., DOT 178.34510
not exceeding one gallon before the re- the required vent capacity is main-
lief device recloses to a leak-tight con- tained.
dition. This requirement must be met (d) Settings of pressure relief system.
regardless of vehicle orientation. This The set pressure of the pressure relief
capability must be demonstrated by system is the pressure at which it
testing. An acceptable method is out- starts to open, allowing discharge.
lined in TTMA RP No. 8197 Perform- (1) Primary pressure relief system. The
ance of Spring Loaded Pressure Relief set pressure of each primary relief
Valves on MC 306, MC 307, MC 312, DOT valve must be no less than 120 percent
406, DOT 407, and DOT 412 Tanks (in- of the MAWP, and no more than 132
corporated by reference; see 171.7 of percent of the MAWP. The valve must
this subchapter). reclose at not less than 108 percent of
(ii) After August 31, 1995, each pres- the MAWP and remain closed at lower
sure relief device must be able to with- pressures.
stand a dynamic pressure surge reach- (2) Secondary pressure relief system.
ing 30 psig above the design set pres- The set pressure of each pressure relief
sure and sustained above the design set valve used as a secondary relief device
pressure for at least 60 milliseconds must be not less than 120 percent of the
with a total volume of liquid released MAWP.
not exceeding 1 L before the relief (e) Venting capacity of pressure relief
valve recloses to a leak-tight condi- systems. The pressure relief system (pri-
tion. This requirement must be met re- mary and secondary, including piping)
gardless of vehicle orientation. This must have sufficient venting capacity
capability must be demonstrated by to limit the cargo tank internal pres-
testing. TTMA RP No. 81, cited in para- sure to not more than the cargo tank
graph (b)(3)(i) of this section, is an ac- test pressure. The total venting capac-
ity, rated at not more than the cargo
ceptable test procedure.
tank test pressure, must be at least
(4) Each reclosing pressure relief
that specified in table I, except as pro-
valve must be constructed and in-
vided in 178.3484.
stalled in such a manner as to prevent
unauthorized adjustment of the relief TABLE IMINIMUM EMERGENCY VENT CAPACITY
valve setting. [In cubic feet 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
pressure relief system may be installed hour
in a pressure relief system. 20 ....................................................................... 15,800
(6) The pressure relief system must 30 ....................................................................... 23,700
be mounted, shielded and drainable so 40 ....................................................................... 31,600
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
350 ..................................................................... 245,700
a level attitude, the device should be 400 ..................................................................... 265,000
positioned at the horizontal and trans- 450 ..................................................................... 283,200
verse center of the cargo tank; on 500 ..................................................................... 300,600
550 ..................................................................... 317,300
cargo tanks sloped to the rear, the de- 600 ..................................................................... 333,300
vice should be located in the forward 650 ..................................................................... 348,800
wreier-aviles on DSK3TPTVN1PROD with CFR
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178.34511 49 CFR Ch. I (10111 Edition)
TABLE IMINIMUM EMERGENCY VENT percent of the average value for the de-
CAPACITYContinued vices tested.
[In cubic feet free air/hour at 60 F and 1 atm.] (3) The rated flow capacity derived
for each device model must be certified
Cubic feet
Exposed area in square feet free air per by a responsible official of the device
hour manufacturer.
950 ..................................................................... 432,300 (h) Marking of pressure relief devices.
1,000 .................................................................. 445,000 Each pressure relief device must be
NOTE 1: Interpolate for intermediate sizes. permanently marked with the fol-
lowing:
(1) Primary pressure relief system. Un- (1) Manufacturers name;
less otherwise specified in the applica-
(2) Model number;
ble individual specification, the pri-
(3) Set pressure, in psig; and
mary relief system must have a min-
imum venting capacity of 12,000 SCFH (4) Rated flow capacity, in SCFH at
per 350 square feet of exposed cargo the rating pressure, in psig.
tank area, but in any case at least one [Amdt. 17889, 54 FR 25025, June 12, 1989, as
fourth the required total venting ca- amended at 55 FR 21038, May 22, 1990; 55 FR
pacity for the cargo tank. 37062, Sept. 7, 1990; Amdt. 17889, 56 FR 27877,
(2) Secondary pressure relief system. If June 17, 1991; Amdt. 178105, 59 FR 55175, Nov.
the primary pressure relief system does 3, 1994; Amdt. 178118, 61 FR 51341, Oct. 1,
not provide the required total venting 1996; 65 FR 58631, Sept. 29, 2000; 66 FR 45389,
capacity, additional capacity must be Aug. 28, 2001; 68 FR 19284, Apr. 18, 2003]
provided by a secondary pressure relief
178.34511 Tank outlets.
system.
(f) Certification of pressure relief de- (a) General. As used in this section,
vices. The manufacturer of any pressure loading/unloading outlet means any
relief device, including valves, fran- opening in the cargo tank wall used for
gible (rupture) disks, vacuum vents and loading or unloading of lading, as dis-
combination devices must certify that tinguished from outlets such as man-
the device model was designed and hole covers, vents, vapor recovery de-
tested in accordance with this section vices, and similar closures. Cargo tank
and the appropriate cargo tank speci- outlets, closures and associated piping
fication. The certificate must contain must be protected in accordance with
sufficient information to describe the 178.3458.
device and its performance. The certifi- (b) Each cargo tank loading/unload-
cate must be signed by a responsible of- ing outlet must be equipped with an in-
ficial of the manufacturer who ap- ternal self-closing stop-valve, or alter-
proved the flow capacity certification. natively, with an external stop-valve
(g) Rated flow capacity certification located as close as practicable to the
test. Each pressure relief device model cargo tank wall. Each cargo tank load-
must be successfully flow capacity cer- ing/unloading outlet must be in accord-
tification tested prior to first use. De- ance with the following provisions:
vices having one design, size and set (1) Each loading/unloading outlet
pressure are considered to be one
must be fitted with a self-closing sys-
model. The testing requirements are as
tem capable of closing all such outlets
follows:
in an emergency within 30 seconds of
(1) At least 3 devices of each specific
actuation. During normal operations
model must be tested for flow capacity
the outlets may be closed manually.
at a pressure not greater than the test
pressure of the cargo tank. For a de- The self-closing system must be de-
vice model to be certified, the capac- signed according to the following:
ities of the devices tested must fall (i) Each self-closing system must in-
within a range of plus or minus 5 per- clude a remotely actuated means of
wreier-aviles on DSK3TPTVN1PROD with CFR
cent of the average for the devices test- closure located more than 10 feet from
ed. the loading/unloading outlet where ve-
(2) The rated flow capacity of a de- hicle length allows, or on the end of
vice model may not be greater than 90 the cargo tank farthest away from the
172
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Pipeline and Hazardous Materials Safety Admin., DOT 178.34513
loading/unloading outlet. The actu- liquid level. Gauge glasses are not per-
ating mechanism must be corrosion-re- mitted.
sistant and effective in all types of en- [Amdt. 17889, 55 FR 37062, Sept. 7, 1990, as
vironment and weather. amended by Amdt. 178118, 61 FR 51342, Oct.
(ii) If the actuating system is acci- 1, 1996]
dentally damaged or sheared off during
transportation, each loading/unloading 178.34513 Pressure and leakage
outlet must remain securely closed and tests.
capable of retaining lading. (a) Each cargo tank must be pressure
(iii) When required by part 173 of this and leakage tested in accordance with
subchapter for materials which are this section and 178.3465, 178.3475, or
flammable, pyrophoric, oxidizing, or 178.3485.
Division 6.1 (poisonous liquid) mate- (b) Pressure test. Each cargo tank or
rials, the remote means of closure cargo tank compartment must be test-
must be capable of thermal activation. ed hydrostatically or pneumatically.
The means by which the self-closing Each cargo tank of a multi-cargo tank
motor vehicle must be tested with the
system is thermally activated must be
adjacent cargo tanks empty and at at-
located as close as practicable to the
mospheric pressure. Each closure, ex-
primary loading/unloading connection
cept pressure relief devices and load-
and must actuate the system at a tem-
ing/unloading venting devices rated at
perature not over 250 F. In addition,
less than the prescribed test pressure,
outlets on these cargo tanks must be
must be in place during the test. If the
capable of being remotely closed manu- venting device is not removed during
ally or mechanically. the test, such device must be rendered
(2) Bottom loading outlets which dis- inoperative by a clamp, plug or other
charge lading into the cargo tank equally effective restraining device,
through fixed internal piping above the which may not prevent the detection of
maximum liquid level of the cargo leaks, or damage the device. Restrain-
tank need not be equipped with a self- ing devices must be removed imme-
closing system. diately after the test is completed.
(c) Any loading/unloading outlet ex- (1) Hydrostatic method. Each cargo
tending beyond an internal self-closing tank, including its domes, must be
stop-valve, or beyond the innermost ex- filled with water or other liquid having
ternal stop-valve which is part of a similar viscosity, the temperature of
self-closing system, must be fitted with which may not exceed 100 F. The cargo
another stop-valve or other leak-tight tank must then be pressurized as pre-
closure at the end of such connection. scribed in the applicable specification.
(d) Each cargo tank outlet that is not The pressure must be gauged at the top
a loading/unloading outlet must be of the cargo tank. The prescribed test
equipped with a stop-valve or other pressure must be maintained for at
leak-tight closure located as close as least 10 minutes during which time the
practicable to the cargo tank outlet. cargo tank must be inspected for leak-
Any connection extending beyond this age, bulging, or other defect.
closure must be fitted with another (2) Pneumatic method. A pneumatic
stop-valve or other leak-tight closure test may be used in place of the hydro-
at the end of such connection. static test. However, pneumatic pres-
sure testing may involve higher risk
[Amdt. 17889, 56 FR 27877, June 17, 1991, as than hydrostatic testing. Therefore,
amended by Amdt. 17897, 57 FR 45465, Oct. 1, suitable safeguards must be provided to
1992; Amdt. 178118, 61 FR 51341, Oct. 1, 1996] protect personnel and facilities should
failure occur during the test. The cargo
178.34512 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
wreier-aviles on DSK3TPTVN1PROD with CFR
equipped with a gauging device that in- pressure to one half of test pressure.
dicates the maximum permitted liquid Thereafter, the pressure must be in-
level to within 0.5 percent of the nomi- creased in steps of approximately one
nal capacity as measured by volume or tenth of the test pressure until test
173
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178.34514 49 CFR Ch. I (10111 Edition)
pressure is reached. Test pressure must ing, embossing or other means in char-
be held for at least 5 minutes. The pres- acters at least 316 inch high. The infor-
sure must then be reduced to the in- mation required by paragraphs (b) and
spection pressure which must be main- (c) of this section may be combined on
tained while the entire cargo tank sur- one specification plate.
face is inspected for leakage and other (b) Nameplate. Each cargo tank must
sign of defects. The inspection method have a corrosion resistant nameplate
must consist of coating all joints and permanently attached to it. The fol-
fittings with a solution of soap and lowing information, in addition to any
water or other equally sensitive meth- applicable information required by the
od. ASME Code, must be marked on the
(c) Leakage test. The cargo tank with tank nameplate (parenthetical abbre-
all its accessories in place and operable viations may be used):
must be leak tested at not less than 80 (1) DOT-specification number DOT
percent of tanks MAWP with the pres- XXX (DOT XXX) where XXX is re-
sure maintained for at least 5 minutes. placed with the applicable specification
(d) Any cargo tank that leaks, bulges number. For cargo tanks having a vari-
or shows any other sign of defect must able specification plate, the DOT-speci-
be rejected. Rejected cargo tanks must fication number is replaced with the
be suitably repaired and retested suc- words See variable specification
cessfully prior to being returned to plate.
service. The retest after any repair (2) Original test date, month and
must use the same method of test year (Orig. Test Date).
under which the cargo tank was origi- (3) Tank MAWP in psig.
nally rejected. (4) Cargo tank test pressure (Test P),
[Amdt. 17889, 54 FR 25026, June 12, 1989, as in psig.
amended at 55 FR 37063, Sept. 7, 1990; Amdt. (5) Cargo tank design temperature
178105, 59 FR 55176, Nov. 3, 1994; Amdt. 178 range (Design temp. range),l F to l
118, 61 FR 51342, Oct. 1, 1996; 65 FR 58631, F.
Sept. 29, 2000; 68 FR 19284, Apr. 18, 2003] (6) Nominal capacity (Water cap.), in
gallons.
178.34514 Marking.
(7) Maximum design density of lading
(a) General. The manufacturer shall (Max. lading density), in pounds per
certify that each cargo tank motor ve- gallon.
hicle has been designed, constructed (8) Material specification number
and tested in accordance with the ap- shell (Shell matl, yyy***), where yyy
plicable Specification DOT 406, DOT 407 is replaced by the alloy designation
or DOT 412 ( 178.345, 178.346, 178.347, and *** by the alloy type.
178.348) cargo tank requirements and, (9) Material specification number
when applicable, with Section VIII of heads (Head matl, yyy***), where
the ASME Code (IBR, see 171.7 of this yyy is replaced by the alloy designa-
subchapter). The certification shall be tion and *** by the alloy type.
accomplished by marking the cargo
tank as prescribed in paragraphs (b) NOTE: When the shell and heads materials
are the same thickness, they may be com-
and (c) of this section, and by pre-
bined, (Shell&head matl, yyy***).
paring the certificate prescribed in
178.34515. Metal plates prescribed by (10) Weld material (Weld matl.).
paragraphs (b), (c), (d) and (e) of this (11) Minimum thicknessshell (Min.
section, must be permanently attached shell-thick), in inches. When minimum
to the cargo tank or its integral sup- shell thicknesses are not the same for
porting structure, by brazing, welding different areas, show (top l, side l,
or other suitable means. These plates bottom l, in inches).
must be affixed on the left side of the (12) Minimum thicknessheads (Min.
vehicle near the front of the cargo tank heads thick.), in inches.
(or the frontmost cargo tank of a (13) Manufactured thicknessshell
wreier-aviles on DSK3TPTVN1PROD with CFR
multi-cargo tank motor vehicle), in a (Mfd. shell thick.), top l, side l, bot-
place readily accessible for inspection. tom l, in inches. (Required when addi-
The plates must be permanently and tional thickness is provided for corro-
plainly marked in English by stamp- sion allowance.)
174
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Pipeline and Hazardous Materials Safety Admin., DOT 178.34514
ble. specification.
(10) Heating system design tempera- (2) If no change of information in the
ture (Heating sys. temp.), in F, if ap- specification plate is required, the let-
plicable. ters NC must follow the rating re-
(d) Multi-cargo tank motor vehicle. For quired. If the cargo tank is not so
a multi-cargo tank motor vehicle hav- equipped, the word None must be in-
ing all its cargo tanks not separated by serted.
any void, the information required by (3) Those parts to be changed or
paragraphs (b) and (c) of this section added must be stamped with the appro-
may be combined on one specification priate MC or DOT Specification mark-
plate. When separated by a void, each ings.
cargo tank must have an individual (4) The alterations that must be
nameplate as required in paragraph (b) made in order for the tank to be modi-
of this section, unless all cargo tanks fied from one specification to another
are made by the same manufacturer must be clearly indicated on the manu-
with the same materials, manufactured facturers certificate and on the vari-
thickness, minimum thickness and to able specification plate.
the same specification. The cargo tank
motor vehicle may have a combined [Amdt. 17889, 54 FR 25027, June 12, 1989, as
nameplate and specification plate. amended at 55 FR 37063, Sept. 7, 1990; Amdt.
When only one plate is used, the plate 17899, 58 FR 51534, Oct. 1, 1993; Amdt. 178104,
59 FR 49135, Sept. 26, 1994; Amdt. 178105, 59
must be visible and not covered by in-
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175
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178.34515 49 CFR Ch. I (10111 Edition)
stages, each manufacturer who per- eral design and construction require-
forms 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.
176
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Pipeline and Hazardous Materials Safety Admin., DOT 178.3462
(b) MAWP: The MAWP of each cargo cated farther from the top and bottom
tank must be no lower than 2.65 psig centerline than 16 percent of the shells
and no higher than 4 psig. circumference.
(c) Vacuum loaded cargo tanks must (ii) For a self-supporting cargo tank,
not be constructed to this specifica- no more than two such joints may be
tion. used on the top of the tank. They may
(d) Each cargo tank must be con- not be located farther from the top
structed in accordance with Section centerline than 12.5 percent of the
VIII of the ASME Code (IBR, see shells circumference.
171.7 of this subchapter) except as (iii) Compliance test. Two test speci-
modified herein: mens of the material to be used in the
(1) The record-keeping requirements manufacture of a cargo tank must be
contained in the ASME Code Section tested to failure in tension. The test
VIII do not apply. Parts UG90 through specimens must be of the same
94 in Section VIII do not apply. Inspec- thicknesses and joint configuration as
tion and certification must be made by the cargo tank, and joined by the same
an inspector registered in accordance welding procedures. The test specimens
with subpart F of part 107. may represent all the tanks that are
(2) Loadings must be as prescribed in made of the same materials and weld-
178.3453. ing procedures, have the same joint
(3) The knuckle radius of flanged configuration, and are made in the
heads must be at least three times the same facility within 6 months after the
material thickness, and in no case less tests are completed. Before welding,
than 0.5 inch. Stuffed (inserted) heads the fit-up of the joints on the test
may be attached to the shell by a fillet specimens must represent production
weld. The knuckle radius and dish ra- conditions that would result in the
dius versus diameter limitations of least joint strength. Evidence of joint
UG32 do not apply. Shell sections of
fit-up and test results must be retained
cargo tanks designed with a non-cir-
at the manufacturers facility.
cular cross section need not be given a
(iv) Weld joint efficiency. The lower
preliminary curvature, as prescribed in
UG79(b). value of stress at failure attained in
(4) Marking, certification, data re- the two tensile test specimens shall be
ports, and nameplates must be as pre- used to compute the efficiency of the
scribed in 178.34514 and 178.34515. joint as follows: Determine the failure
(5) Manhole closure assemblies must ratio by dividing the stress at failure
conform to 178.3455 and 178.3465. by the mechanical properties of the ad-
(6) Pressure relief devices must be as jacent metal; this value, when multi-
prescribed in 178.3463. plied by 0.75, is the design weld joint ef-
(7) The hydrostatic or pneumatic test ficiency.
must be as prescribed in 178.3465. (10) The requirements of paragraph
(8) The following paragraphs in parts UW9(d) in Section VIII of the ASME
UG and UW in Section VIII of the Code do not apply.
ASME Code do not apply: UG11, UG [Amdt. 17889, 54 FR 25028, June 12, 1989, as
12, UG22(g), UG32(e), UG34, UG35, amended at 55 FR 37063, Sept. 7, 1990; Amdt.
UG44, UG76, UG77, UG80, UG81, 17889, 56 FR 27877, June 17, 1991; Amdt. 178
UG96, UG97, UW13(b)(2), UW13.1(f) 105, 59 FR 55176, Nov. 3, 1994; 65 FR 58631,
and the dimensional requirements Sept. 29, 2000; 66 FR 45387, Aug. 28, 2001; 68 FR
found in Figure UW13.1. 19285, Apr. 18, 2003; 68 FR 75756, Dec. 31, 2003]
(9) Single full fillet lap joints with-
out plug welds may be used for arc or 178.3462 Material and thickness of
gas welded longitudinal seams without material.
radiographic examination under the The type and thickness of material
following conditions: for DOT 406 specification cargo tanks
(i) For a truck-mounted cargo tank, must conform to 178.3452, but in no
wreier-aviles on DSK3TPTVN1PROD with CFR
no more than two such joints may be case may the thickness be less than
used on the top half of the tank and no that determined by the minimum
more than two joints may be used on thickness requirements in 178.320(a).
the bottom half. They may not be lo- The following Tables I and II identify
177
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178.3463 49 CFR Ch. I (10111 Edition)
Thickness .............................................. .100 .100 .160 .115 .115 .173 .129 .129 .187
TABLE IISPECIFIED 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
[Amdt. 17889, 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
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Pipeline and Hazardous Materials Safety Admin., DOT 178.3471
psig above the MAWP. The venting ca- mination of Vapor Tightness of Gaso-
pacity required in 178.34510(e) may be line Delivery Tank Using Pressure-
rated at these same pressures. Vacuum Test) may not be used to sat-
(2) Each vacuum relief system must isfy the leakage test requirements of
have sufficient capacity to limit the this paragraph. A cargo tank tested in
vacuum to 1 psig. accordance with 40 CFR 63.425(e) may
(3) If pressure loading or unloading be marked as specified in 180.415 of
devices are provided, the relief system this subchapter.
must have adequate vapor and liquid
[Amdt. 17889, 54 FR 25029, June 12, 1989, as
capacity to limit the tank pressure to
amended at 55 FR 37064, Sept. 7, 1990; Amdt.
the cargo tank test pressure at max- 178105, 59 FR 55176, Nov. 3, 1994. Redesig-
imum loading or unloading rate. The nated by Amdt. 178112, 61 FR 18934, Apr. 29,
maximum loading and unloading rates 1996; 68 FR 19285, Apr. 18, 2003]
must be included on the metal speci-
fication plate. 178.347 Specification DOT 407; cargo
tank motor vehicle.
[Amdt. 17889, 54 FR 25029, June 12, 1989, as
amended at 55 FR 37064, Sept. 7, 1990; Amdt. 178.3471 General requirements.
178105, 59 FR 55176, Nov. 3, 1994. Redesig-
nated by Amdt. 178112, 61 FR 18934, Apr. 29, (a) Each specification DOT 407 cargo
1996; 66 FR 45389, Aug. 28, 2001; 68 FR 75756, tank motor vehicle must conform to
Dec. 31, 2003] the general design and construction re-
quirements in 178.345 in addition to
178.3464 Outlets. the specific requirements contained in
(a) All outlets on each tank must this section.
conform to 178.34511 and this section. (b) Each tank must be of a circular
(b) External self-closing stop-valves cross-section and have an MAWP of at
are not authorized as an alternative to least 25 psig.
internal self-closing stop-valves on (c) Any cargo tank motor vehicle
loading/unloading outlets. built to this specification with a
[Amdt. 17889, 54 FR 25029, June 12, 1989. Re- MAWP greater than 35 psig or any
designated by Amdt. 178112, 61 FR 18934, cargo tank motor vehicle built to this
Apr. 29, 1996] specification designed to be loaded by
vacuum must be constructed and cer-
178.3465 Pressure and leakage tests. tified in accordance with Section VIII
(a) Each cargo tank must be tested in of the ASME Code (IBR, see 171.7 of
accordance with 178.34513 and this this subchapter). The external design
section. pressure for a cargo tank loaded by
(b) Pressure test. Test pressure must vacuum must be at least 15 psi.
be as follows: (d) Any cargo tank motor vehicle
(1) Using the hydrostatic test meth- built to this specification with a
od, the test pressure must be the great- MAWP of 35 psig or less or any cargo
er of 5.0 psig or 1.5 times the cargo tank motor vehicle built to this speci-
tank MAWP. fication designed to withstand full vac-
(2) Using the pneumatic test method, uum but not equipped to be loaded by
the test pressure must be the greater of vacuum must be constructed in accord-
5.0 psig or 1.5 times the cargo tank ance with Section VIII of the ASME
MAWP, and the inspection pressure Code.
must be the cargo tank MAWP. (1) The record-keeping requirements
(c) Leakage test. A cargo tank used to contained in Section VIII of the ASME
transport a petroleum distillate fuel Code do not apply. The inspection re-
that is equipped with vapor recovery quirements of parts UG90 through 94
equipment may be leakage tested in do not apply. Inspection and certifi-
accordance with 40 CFR 63.425(e). To cation must be made by an inspector
satisfy the leakage test requirements registered in accordance with subpart
of this paragraph, the test specified in F of part 107.
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179
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178.3472 49 CFR Ch. I (10111 Edition)
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
wreier-aviles on DSK3TPTVN1PROD with CFR
180
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Pipeline and Hazardous Materials Safety Admin., DOT 178.3481
TABLE IISPECIFIED 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
10 or Over 10 Over 14 Over 18 Over 22 Over 26
Volume capacity in gallons per inch Over 30
less to 14 to 18 to 22 to 26 to 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. 17889, 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]
capacity to limit the tank pressure to (b) The MAWP of each cargo tank
the cargo tank test pressure at max- must be at least 5 psig.
imum loading or unloading rate. The (c) The MAWP for each cargo tank
maximum loading or unloading rate designed to be loaded by vacuum must
181
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178.3482 49 CFR Ch. I (10111 Edition)
be at least 25 psig internal and 15 psig tion need not be given a preliminary
external. curvature, as prescribed in UG79(b).
(d) Each cargo tank having a MAWP (iv) Marking, certification, data re-
greater than 15 psig must be of circular ports, and nameplates must be as pre-
cross-section. scribed in 178.34514 and 178.34515.
(e) Each cargo tank having a (v) Manhole closure assemblies must
(1) MAWP greater than 15 psig must conform to 178.3455.
be constructed and certified in con- (vi) Pressure relief devices must be as
formance with Section VIII of the prescribed in 178.3484.
ASME Code (IBR, see 171.7 of this (vii) The hydrostatic or pneumatic
subchapter); or test must be as prescribed in 178.3485.
(2) MAWP of 15 psig or less must be (viii) The following paragraphs in
parts UG and UW in Section VIII of the
constructed in accordance with Sec-
ASME Code do not apply: UG11, UG
tion VIII of the ASME Code, except as
12, UG22(g), UG32(e), UG34, UG35,
modified herein:
UG44, UG76, UG77, UG80, UG81,
(i) The recordkeeping requirements UG96, UG97, UW13(b)(2), UW13.1(f),
contained in Section VIII of the ASME and the dimensional requirements
Code do not apply. Parts UG90 found in Figure UW13.1.
through 94 in Section VIII do not
apply. Inspection and certification [Amdt. 17889, 54 FR 25031, June 12, 1989, as
must be made by an inspector reg- amended at 55 FR 37065, Sept. 7, 1990; Amdt.
17889, 56 FR 27877, June 17, 1991; 65 FR 58632,
istered in accordance with subpart F of Sept. 29, 2000; 68 FR 19285, Apr. 18, 2003; 68 fR
part 107. 75756, Dec. 31, 2003]
(ii) Loadings must be as prescribed in
178.3453. 178.3482 Material and thickness of
(iii) The knuckle radius of flanged material.
heads must be at least three times the (a) The type and thickness of mate-
material thickness, and in no case less rial for DOT 412 specification cargo
than 0.5 inch. Stuffed (inserted) heads tanks must conform to 178.3452, but
may be attached to the shell by a fillet in no case may the thickness be less
weld. The knuckle radius and dish ra- than that determined by the minimum
dius versus diameter limitations of thickness requirements in 178.320(a).
UG32 do not apply for cargo tank The following Tables I and II identify
motor vehicles with a MAWP of 15 psig the Specified Minimum Thickness
or less. Shell sections of cargo tanks values to be employed in that deter-
designed with a non-circular cross sec- mination.
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182
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VerDate Mar<15>2010
TABLE ISPECIFIED 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
Jkt 223216
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
PO 00000
TABLE IISPECIFIED 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
Frm 00195
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
Fmt 8010
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
183
Thickness (steel):
Distances between heads (and bulkheads baffles and ring
stiffeners when used as tank reinforcement):
Sfmt 8010
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):
Pipeline and Hazardous Materials Safety Admin., DOT
Y:\SGML\223216.XXX
223216
178.3482
178.3483 49 CFR Ch. I (10111 Edition)
(b) [Reserved]
[Amdt. 17889, 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]
184
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Pipeline and Hazardous Materials Safety Admin., DOT 178.3562
178.3561 General requirements. [Amdt. 17835, 39 FR 45247, Dec. 31, 1974. Re-
designated by Amdt. 17897, 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 178.3562 Materials of construction
and its contents, must not exceed the and other requirements.
following: (a) Phenolic foam insulation must be
(1) Specification 20PF1138 kg (300 fire-resistant and fabricated in accord-
pounds). ance with USDOE Material and Equip-
(2) Specification 20PF2320 kg (700 ment Specification SP9, Rev. 1 and
pounds). Supplement (IBR, see 171.7 of this sub-
(3) Specification 20PF3455 kg (1000 chapter), which is a part of this speci-
pounds). fication. (Note: Packagings manufac-
(c) The general configuration of the tured under USAEC Specification SP9
overpack must be a right cylinder, con- and 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 sec- cm (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-in- foam; 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
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185
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178.3563 49 CFR Ch. I (10111 Edition)
screws in inner liner flange assembly. including any vent hole, must be sealed
Average density of insulation must be with waterproofing material as pre-
0.13 g/cc (8 pounds per cubic foot (pcf)) scribed in USDOE Material and Equip-
minimum for bottom section and 0.16 g/ ment Specification SP9, Rev. 1 and
cc (10 pcf) minimum for top section, ex- Supplement, or equivalent.
cept 0.1 g/cc (6.5 pcf) for the specifica-
[Amdt. 17835, 39 FR 45247, Dec. 31, 1974, as
tion 20PF1 top section.
amended by Amdt. 17856, 44 FR 49458, Aug.
(b) Gaskets must be as follows: 23, 1979. Redesignated by Amdt. 17897, 55 FR
(1) Inner liner flangeNeoprene rub- 52716, Dec. 21, 1990; 66 FR 45387, Aug. 28, 2001;
ber of 30 to 60 type A durometer hard- 68 FR 75757, Dec. 31, 2003]
ness or other equivalent gasket mate-
rial which is compatible with the spe- 178.3563 Tests.
cific contents.
(a) Leakage testEach inner liner
(2) Outer shellSynthetic rubber
assembly must be tested for leakage
conforming to MIL-R-6855 (available
prior to installation. Seam welds of the
from the Naval Publications Forms
liner must be covered for a distance of
Center, 5801 Tabor Avenue, Philadel-
at least 15 cm (6 inches) on either side
phia, Pennsylvania 19120) class 2, grade
of the seam with soapsuds, heavy oil,
60.
or equivalent material, and interior air
(3) Support and pressure pads for
pressure applied to at least 776 mm Hg
inner liner top and bottom must be
(15 p.s.i.g.) above atmospheric pressure
sponge rubber or equivalent.
must be held for at least 30 seconds.
(c) Alternate top section (specifica-
Liners failing to pass this test may not
tion 20PF1 only). Average insulation
be used until repairs are made, and
density must be 0.16 g/cc (10 pcf min-
retests successfully passed.
imum). Thickness of plug must be 11
cm (4.3 inches) minimum, except thick- (b) [Reserved]
ness may be reduced to 10 cm (4 inches) [Amdt. 17835, 39 FR 45247, Dec. 31, 1974. Re-
to clear bolt heads. A flush mounted designated by Amdt. 17897, 55 FR 52716, Dec.
top lifting device must be securely fas- 21, 1990; 66 FR 45387, Aug. 28, 2001; 67 FR 61016,
tened to a wood block encapsulated by Sept. 27, 2002]
the foam.
(d) Vent holes 5 mm (0.2-inch) diame- 178.3564 Required markings.
ter must be drilled in the outer shell to (a) Marking must be as prescribed in
provide pressure relief during the insu- 178.3.
lation foaming and in the event of a (b) Marking on the outside of each
fire. These holes, which must be drilled overpack must be as follows:
in all areas of the shell that mate with (1) USA-DOT-20PF-1 or 2, as ap-
the foam insulation, must be spaced in propriate, and if the entire liner is
accordance with DOE CAPE1662, Rev. made of stainless steel, additional
1 and Supplement 1 (IBR, see 171.7 of marking such as 3041SS to indicate
this subchapter). the type of stainless steel used.
(e) Welding must be by a fusion weld-
(2) TARE WT: xxx lbs. where xxx is
ing process in accordance with Amer-
the tare weight of the assembled over-
ican Welding Society Codes B3.0 and
pack without the inner container.
D1.0 (IBR, see 171.7 of this sub-
chapter). Body seams and joints for the (3) Year of manufacture.
liner or shell must be continuous [Amdt. 17835, 39 FR 45247, Dec. 31, 1974. Re-
welds. designated by Amdt. 17897, 55 FR 52716, Dec.
(f) Waterproofing. Each screw hole in 21, 1990, as amended at 63 FR 37462, July 10,
the outer shell must be sealed with ap- 1998]
propriate resin-type sealing material,
or equivalent, during installation of 178.3565 Typical assembly detail.
the screw. All exposed foam surfaces, (a) Specifications 20PF1.
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186
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Pipeline and Hazardous Materials Safety Admin., DOT 178.3565
187
EC02MR91.077</GPH>
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178.3565 49 CFR Ch. I (10111 Edition)
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188
EC02MR91.078</GPH>
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Pipeline and Hazardous Materials Safety Admin., DOT 178.3565
[Amdt. 17835, 39 FR 45247, Dec. 31, 1974. Redesignated by Amdt. 17897, 55 FR 52716, Dec. 21,
1990]
wreier-aviles on DSK3TPTVN1PROD with CFR
189
EC02MR91.079</GPH>
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178.358 49 CFR Ch. I (10111 Edition)
ening from vibration. Outer steel brac- fied in DOE CAPE1662, 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.
190
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Pipeline and Hazardous Materials Safety Admin., DOT 178.3583
(1) Drill out or otherwise clean the pack must be marked USA-DOT-21PF-
plug material from the vent holes
originally provided for foam expansion.
See drawing S1E31536J1D of CAPE
191
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178.3584 49 CFR Ch. I (10111 Edition)
1A. See the marking requirements of (2) For Specification 21PF1 and
178.3585. 21PF2 only, TARE WT: * * * lbs.
[Amdt. 17890, 53 FR 36551, Sept. 20, 1988. (* * * kg) where * * * is the tare
Redesigntated by Amdt. 17897, 55 FR 52716, weight in pounds and kilograms, re-
Dec. 21, 1990; Amdt. 178110, 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 21PF1A and
21PF1B only: TARE WT. of Cover:
178.3584 Construction of Specifica-
tion 21PF1B overpacks. * * * lbs (* * * kg) TARE WT. of BOT-
TOM: * * * lbs (* * * kg) where
(a) Each Specification 21PF1 over- * * * is the tare weight in pounds and
pack for which construction began kilograms, respectively, of the sepa-
after March 31, 1989, must meet the re-
rate halves of the overpack without the
quirements of Specification 21PF1B,
inner product container. For Specifica-
in conformance with drawings E-S-
tion 21PF1A overpacks, the previous
31536-J-P, and S1E31536J2B of DOE
CAPE1662, 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 21PF1B must be of stain- the 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 sec- party certifying compliance with speci-
tion. fication requirements. A symbol, if
used, must be registered with the Asso-
[Amdt. 17890, 53 FR 36551, Sept. 20, 1988.
Redesigntated by Amdt. 17897, 55 FR 52716, ciate Administrator.
Dec. 21, 1990; 68 FR 75757, Dec. 31, 2003] (c) For Specification 21PF1A and 1B
only, the markings required by this
178.3585 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 15
(b) Specification marking on the out- inches long (28 cm 38 cm), fabricated
side of each overpack must be as fol- of 16 to 20 gauge stainless steel sheet,
lows: USA-DOT-21PF-1, 1A, 1B, ASTM A240/A 240M (IBR, see 171.7 of
or 2, as appropriate. this subchapter), Type 304L.
(1) For Specifications 21PF1 and
[Amdt. 17890, 53 FR 36552, Sept. 20, 1988.
21PF2 only, if the inner shell is con-
Redesigntated by Amdt. 17897, 55 FR 52716,
structed of stainless steel, additional Dec. 21, 1990, and amended at Amdt. 17897, 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]
192
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Pipeline and Hazardous Materials Safety Admin., DOT 178.3586
193
EC02MR91.080</GPH>
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178.3586 49 CFR Ch. I (10111 Edition)
194
EC02MR91.081</GPH>
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Pipeline and Hazardous Materials Safety Admin., DOT 178.3586
[Amdt. 17890, 53 FR 36552, Sept. 20, 1988. Redesignated by Amdt. 17897, 55 FR 52716, Dec. 21,
1990]
wreier-aviles on DSK3TPTVN1PROD with CFR
195
EC02MR91.082</GPH>
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178.360 49 CFR Ch. I (10111 Edition)
2 5
3 32 2.5 Not less than that prescribed for schedule 40 pipe ................. 16 41
6 15 18 3.2 ................................................................................................... 72 183
12 30 14 6.5 ................................................................................................... 72 183
(b) [Reserved]
[Amdt. 17835, 39 FR 45245, Dec. 31, 1974. Redesignated by Amdt. 17897, 55 FR 52716, Dec. 21,
1990; 66 FR 45387, Aug. 28, 2001]
ket. Each flange must be welded or and 12 inches, AWWA Standard C20755,
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 C20755, section 10 (IBR, see (a)(2)(i) of this section.
196
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Pipeline and Hazardous Materials Safety Admin., DOT 178.503
(iii) Sizes under 6 inches, nominal AWWA C20755, 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. Bolt circle diameter Diameter of bolts Flange thickness
Number
of bolts
Inches Cm Inches Cm Inches Cm Inches Cm Inches Cm
2 5 6 15 4 434 11.8
12 1.2
58 1.6
212 6.2 7 17.5 4 512 13.8 12 ............... 58 ...............
3 7.5 712 18.8 4 6 15 12 ............... 58 ...............
312 8.8 812 21.3 8 7 17.5 12 ............... 58 ...............
4 10 9 22.5 8 7 2
1 18.8 12 ............... 58 ...............
5 12.6 10 25.4 8 8 2
1 21.3 12 ............... 58 ...............
197
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178.503 49 CFR Ch. I (10111 Edition)
markings must be durable, legible and (i) For packagings without inner
placed in a location and of such a size packagings intended to contain liquids,
relative to the packaging as to be read- the designation shall be the specific
ily visible, as specified in 178.3(a). Ex- gravity rounded down to the first dec-
cept as otherwise provided in this sec- imal but may be omitted when the spe-
tion, every reusable packaging liable cific gravity does not exceed 1.2; and
to undergo a reconditioning process (ii) For packagings intended to con-
which might obliterate the packaging tain solids or inner packagings, the
marks must bear the marks specified designation shall be the maximum
in paragraphs (a)(1) through (a)(6) and gross mass in kilograms;
(a)(9) of this section in a permanent (5)(i) For single and composite pack-
form (e.g. embossed) able to withstand agings intended to contain liquids, the
the reconditioning process. A marking test pressure in kilopascals rounded
may be applied in a single line or in down to the nearest 10 kPa of the hy-
multiple lines provided the correct se- drostatic pressure test that the pack-
quence is used. As illustrated by the aging design type has successfully
examples in paragraph (e) of this sec- passed;
tion, the following information must (ii) For packagings intended to con-
be presented in the correct sequence. tain solids or inner packagings, the let-
Slash marks should be used to separate ter S;
this information. A packaging con- (6) The last two digits of the year of
forming to a UN standard must be manufacture. Packagings of types 1H
marked as follows: and 3H shall also be marked with the
(1) Except as provided in paragraph month of manufacture in any appro-
(e)(1)(ii) of this section, the United Na- priate manner; this may be marked on
tions symbol as illustrated in para- the packaging in a different place from
graph (e)(1)(i) of this section (for em- the remainder of the markings;
bossed metal receptacles, the letters (7) The state authorizing allocation
UN) may be applied in place of the of the mark. The letters USA indicate
symbol;; that the packaging is manufactured
and marked in the United States in
(2) A packaging identification code
compliance with the provisions of this
designating the type of packaging, the
subchapter;
material of construction and, when ap-
(8) The name and address or symbol
propriate, the category of packaging
of the manufacturer or the approval
under 178.504 through 178.523 of this
agency certifying compliance with sub-
subpart within the type to which the
part L and subpart M of this part.
packaging belongs. The letter V
Symbols, if used, must be registered
must follow the packaging identifica-
with the Associate Administrator;
tion code on packagings tested in ac-
(9) For metal or plastic drums or
cordance with 178.601(g)(2); for exam-
jerricans intended for reuse or recondi-
ple, 4GV. The letter W must fol-
tioning as single packagings or the
low the packaging identification code
outer packagings of a composite pack-
on packagings when required by an ap-
aging, the thickness of the packaging
proval under the provisions of
material, expressed in mm (rounded to
178.601(h) of this part;
the nearest 0.1 mm), as follows:
(3) A letter identifying the perform- (i) Metal drums or jerricans must be
ance standard under which the pack- marked with the nominal thickness of
aging design type has been successfully the metal used in the body. The
tested, as follows: marked nominal thickness must not
(i) Xfor packagings meeting Pack- exceed the minimum thickness of the
ing Group I, II and III tests; steel used by more than the thickness
(ii) Yfor packagings meeting Pack- tolerance stated in ISO 3574 (IBR, see
ing Group II and III tests; or 171.7 of this subchapter). (See appen-
(iii) Zfor packagings only meeting dix C of this part.) The unit of measure
wreier-aviles on DSK3TPTVN1PROD with CFR
198
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Pipeline and Hazardous Materials Safety Admin., DOT 178.503
head, body, and bottom head must be (ii) The name and address or symbol
marked (e.g., 1.01.21.0 or 0.91.0 of the reconditioner. Symbols, if used,
1.0). must be registered with the Associate
(ii) Plastic drums or jerricans must Administrator;
be marked with the minimum thick- (iii) The last two digits of the year of
ness of the packaging material. Min- reconditioning;
imum thicknesses of plastic must be as (iv) The letter R; and
determined in accordance with
(v) For every packaging successfully
173.28(b)(4). The unit of measure is not
required to be marked; passing a leakproofness test, the addi-
(10) In addition to the markings pre- tional letter L.
scribed in paragraphs (a)(1) through (2) When, after reconditioning, the
(a)(9) of this section, every new metal markings required by paragraph (a)(1)
drum having a capacity greater than through (a)(5) of this section no longer
100 L must bear the marks described in appear on the top head or the side of
paragraphs (a)(1) through (a)(6), and the metal drum, the reconditioner
(a)(9)(i) of this section, in a permanent must apply them in a durable form fol-
form, on the bottom. The markings on lowed by the markings in paragraph
the top head or side of these pack- (c)(1) of this section. These markings
agings need not be permanent, and may identify a different performance
need not include the thickness mark capability than that for which the
described in paragraph (a)(9) of this original design type had been tested
section. This marking indicates a and marked, but may not identify a
drums characteristics at the time it greater performance capability. The
was manufactured, and the information markings applied in accordance with
in paragraphs (a)(1) through (a)(6) of this paragraph may be different from
this section that is marked on the top those which are permanently marked
head or side must be the same as the on the bottom of a drum in accordance
information in paragraphs (a)(1) with paragraph (a)(10) of this section.
through (a)(6) of this section perma- (d) Marking of remanufactured pack-
nently marked by the original manu- agings. For remanufactured metal
facturer on the bottom of the drum;
drums, if there is no change to the
and
packaging type and no replacement or
(11) Rated capacity of the packaging
removal of integral structural compo-
expressed in liters may be marked.
nents, the required markings need not
(b) For a packaging with a removable
head, the markings may not be applied be permanent (e.g., embossed). Every
only to the removable head. other remanufactured drum must bear
(c) Marking of reconditioned pack- the marks required in paragraphs (a)(1)
agings. (1) If a packaging is recondi- through (a)(6) of this section in a per-
tioned, it shall be marked by the re- manent form (e.g., embossed) on the
conditioner near the marks required in top head or side. If the metal thickness
paragraphs (a)(1) through (6) of this marking required in paragraph (a)(9)(i)
section with the following additional of this section does not appear on the
information: bottom of the drum, or if it is no
(i) The name of the country in which longer valid, the remanufacturer also
the reconditioning was performed (in must mark this information in perma-
the United States, use the letters nent form.
USA); (1)(i) The United Nations symbol is:
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199
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178.503 49 CFR Ch. I (10111 Edition)
EC02MR91.090</GPH>
(3) Examples of markings for recondi-
tioned packagings are as follows:
EC02MR91.089</GPH>
(as in 178.503(c)(1)).
(f) A manufacturer must mark every
UN specification package represented
wreier-aviles on DSK3TPTVN1PROD with CFR
200
er02fe10.002</GPH>
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Pipeline and Hazardous Materials Safety Admin., DOT 178.504
must be durable, legible, and must be drum. Minimum thickness and mark-
readily visible, as specified in 178.3(a). ing requirements in 173.28(b)(4) and
An infectious substance packaging that 178.503(a)(9) of this subchapter apply to
successfully passes the tests con- drums intended for reuse.
forming to the UN standard must be (2) Body seams must be welded on
marked as follows: drums designed to contain more than
(1) The United Nations symbol as il- 40 L (11 gallons) of liquids. Body seams
lustrated in paragraph (e) of this sec- must be mechanically seamed or weld-
tion.
ed on drums intended to contain only
(2) The code designating the type of
packaging and material of construc- solids or 40 L (11 gallons) or less of liq-
tion according to the identification uids.
codes for packagings specified in (3) Chimes must be mechanically
178.502. seamed or welded. Separate reinforcing
(3) The text CLASS 6.2. rings may be applied.
(4) The last two digits of the year of (4) The body of a drum of a capacity
manufacture of the packaging. greater than 60 L (16 gallons) may have
(5) The country authorizing the allo- at least two expanded rolling hoops or
cation of the mark. The letters USA two separate rolling hoops. If there are
indicate the packaging is manufac- separate rolling hoops, they must be
tured and marked in the United States fitted tightly on the body and so se-
in compliance with the provisions of cured that they cannot shift. Rolling
this subchapter. hoops may not be spot-welded.
(6) The name and address or symbol
(5) Openings for filling, emptying and
of the manufacturer or the approval
venting in the bodies or heads of non-
agency certifying compliance with sub-
parts L and M of this part. Symbols, if removable head (1A1) drums may not
used, must be registered with the Asso- exceed 7.0 cm (3 inches) in diameter.
ciate Administrator for Hazardous Ma- Drums with larger openings are consid-
terials Safety. ered to be of the removable head type
(7) For packagings meeting the re- (1A2). Closures for openings in the bod-
quirements of 178.609(i)(3), the letter ies and heads of drums must be so de-
U must be inserted immediately fol- signed and applied that they will re-
lowing the marking designating the main secure and leakproof under nor-
type of packaging and material re- mal conditions of transport. Closure
quired in paragraph (f)(2) of this sec- flanges may be mechanically seamed or
tion. welded in place. Gaskets or other seal-
[Amdt. 17897, 55 FR 52717, Dec. 21, 1990, as ing elements must be used with clo-
amended at 56 FR 66284, Dec. 20, 1991; Amdt. sures unless the closure is inherently
178102, 59 FR 28493, June 2, 1994; Amdt. 178 leakproof.
106, 59 FR 67520, 67521, Dec. 29, 1994; Amdt. (6) Closure devices for removable
178107, 60 FR 26806, May 18, 1995; 62 FR 51561,
Oct. 1, 1997; 66 FR 45386, Aug. 28, 2001; 67 FR
head drums must be so designed and
61016, Sept. 27, 2002; 67 FR 53143, Aug. 14, 2002; applied that they will remain secure
68 FR 75757, Dec. 31, 2003; 75 FR 5395, Feb 2, and drums will remain leakproof under
2010; 75 FR 60339, Sept. 30, 2010] normal conditions of transport. Gas-
kets or other sealing elements must be
178.504 Standards for steel drums. used with all removable heads.
(a) The following are identification (7) If materials used for body, heads,
codes for steel drums: closures, and fittings are not in them-
(1) 1A1 for a non-removable head selves compatible with the contents to
steel drum; and be transported, suitable internal pro-
(2) 1A2 for a removable head steel tective coatings or treatments must be
drum. applied. These coatings or treatments
(b) Construction requirements for
must retain their protective properties
steel drums are as follows:
wreier-aviles on DSK3TPTVN1PROD with CFR
(1) Body and heads must be con- under normal conditions of transport.
structed of steel sheet of suitable type (8) Maximum capacity of drum: 450 L
and adequate thickness in relation to (119 gallons).
the capacity and intended use of the
201
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178.505 49 CFR Ch. I (10111 Edition)
(9) Maximum net mass: 400 kg (882 other sealing elements must be used
pounds). with all removable heads.
(6) Maximum capacity of drum: 450 L
[Amdt. 17897, 55 FR 52717, Dec. 21, 1990, as
amended at 56 FR 66284, Dec. 20, 1991; Amdt. (119 gallons).
178110, 60 FR 49111, Sept. 21, 1995] (7) Maximum net mass: 400 kg (882
pounds).
178.505 Standards for aluminum [Amdt. 17897, 55 FR 52717, Dec. 21, 1990, as
drums. amended at 56 FR 66284, Dec. 20, 1991; Amdt.
(a) The following are the identifica- 178102, 59 FR 28494, June 2, 1994]
tion codes for aluminum drums:
(1) 1B1 for a non-removable head alu- 178.506 Standards for metal drums
minum drum; and other than steel or aluminum.
(2) 1B2 for a removable head alu- (a) The following are the identifica-
minum drum. tion codes for metal drums other than
(b) Construction requirements for steel or aluminum:
aluminum drums are as follows: (1) 1N1 for a non-removable head
(1) Body and heads must be con- metal drum; and
structed of aluminum at least 99 per- (2) 1N2 for a removable head metal
cent pure or an aluminum base alloy. drum.
Material must be of suitable type and (b) Construction requirements for
adequate thickness in relation to the metal drums other than steel or alu-
capacity and the intended use of the minum are as follows:
drum. Minimum thickness and mark- (1) Body and heads must be con-
ing requirements in 173.28(b)(4) and structed of metal (other than steel or
178.503(a)(9) of this subchapter apply to aluminum) of suitable type and ade-
drums intended for reuse. quate thickness in relation to the ca-
(2) All seams must be welded. Chime pacity and the intended use of the
seams, if any, must be reinforced by drum. Minimum thickness and mark-
the application of separate reinforcing ing requirements in 173.28(b)(4) and
rings. 178.503(a)(9) of this subchapter apply to
(3) The body of a drum of a capacity drums intended for reuse.
greater than 60 L (16 gallons) may have (2) All seams must be welded. Chime
at least two expanded rolling hoops or seams, if any, must be reinforced by
two separate rolling hoops. If there are the application of separate reinforcing
separate rolling hoops, the hoops must rings.
be fitted tightly on the body and so se- (3) The body of a drum of a capacity
cured that they cannot shift. Rolling greater than 60 L (16 gallons) may have
hoops may not be spot-welded. at least two expanded rolling hoops or
(4) Openings for filling, emptying, or two separate rolling hoops. If there are
venting in the bodies or heads of non- separate rolling hoops, the hoops must
removable head (1B1) drums may not be fitted tightly on the body and so se-
exceed 7.0 cm (3 inches) in diameter. cured that they cannot shift. Rolling
Drums with larger openings are consid- hoops may not be spot-welded.
ered to be of the removable head type (4) Openings for filling, emptying, or
(1B2). Closures for openings in the bod- venting in the bodies or heads of non-
ies and heads of drums must be so de- removable head (1N1) drums may not
signed and applied that they will re- exceed 7.0 cm (3 inches) in diameter.
main secure and leakproof under nor- Drums with larger openings are consid-
mal conditions of transport. Closure ered to be of the removable head type
flanges may be welded in place so that (1N2). Closures for openings in the bod-
the weld provides a leakproof seam. ies and heads of drums must be so de-
Gaskets or other sealing elements signed and applied that they will re-
must be used with closures unless the main secure and leakproof under nor-
closure is inherently leakproof. mal conditions of transport. Closure
(5) Closure devices for removable flanges may be welded in place so that
wreier-aviles on DSK3TPTVN1PROD with CFR
head drums must be so designed and the weld provides a leakproof seam.
applied that they remain secure and Gaskets or other sealing elements
drums remain leakproof under normal must be used with closures unless the
conditions of transport. Gaskets or closure is inherently leakproof.
202
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Pipeline and Hazardous Materials Safety Admin., DOT 178.509
(5) Closure devices for removable tions) firmly glued or laminated to-
head drums must be so designed and gether and may include one or more
applied that they remain secure and protective layers of bitumen, waxed
drums remain leakproof under normal kraft paper, metal foil, plastic mate-
conditions of transport. Gaskets or rial, or similar materials.
other sealing elements must be used (2) Heads must be of natural wood, fi-
with all removable heads. berboard, metal, plywood, plastics, or
(6) Maximum capacity of drum: 450 L other suitable material and may in-
(119 gallons). clude one or more protective layers of
(7) Maximum net mass: 400 kg (882 bitumen, waxed kraft paper, metal foil,
pounds). plastic material, or similar material.
[Amdt. 17897, 55 FR 52717, Dec. 21, 1990, as (3) The body and heads of the drum
amended at 56 FR 66285, Dec. 20, 1991; Amdt. and their joints must be of a design ap-
178102, 59 FR 28494, June 2, 1994] propriate to the capacity and intended
178.507 Standards for plywood use of the drum.
drums. (4) The assembled packaging must be
sufficiently water-resistant so as not
(a) The identification code for a ply-
to delaminate under normal conditions
wood drum is 1D.
(b) Construction requirements for of transport.
plywood drums are as follows: (5) Maximum capacity of drum: 450 L
(1) The wood used must be well-sea- (119 gallons).
soned, commercially dry and free from (6) Maximum net mass: 400 kg (882
any defect likely to lessen the effec- pounds).
tiveness of the drum for the purpose in- [Amdt. 17897, 55 FR 52717, Dec. 21, 1990, as
tended. A material other than plywood, amended by Amdt. 178106, 59 FR 67521, Dec.
of at least equivalent strength and du- 29, 1994]
rability, may be used for the manufac-
ture of the heads. 178.509 Standards for plastic drums
(2) At least two-ply plywood must be and jerricans.
used for the body and at least three-ply (a) The following are identification
plywood for the heads; the plies must codes for plastic drums and jerricans:
be firmly glued together, with their
(1) 1H1 for a non-removable head
grains crosswise.
(3) The body and heads of the drum plastic drum;
and their joints must be of a design ap- (2) 1H2 for a removable head plastic
propriate to the capacity of the drum drum;
and its intended use. (3) 3H1 for a non-removable head
(4) In order to prevent sifting of the jerrican; and
contents, lids must be lined with kraft (4) 3H2 for a removable head jerrican.
paper or some other equivalent mate- (b) Construction requirements for
rial which must be securely fastened to plastic drums and jerricans are as fol-
the lid and extend to the outside along lows:
its full circumference. (1) The packaging must be manufac-
(5) Maximum capacity of drum: 250 L tured from suitable plastic material
(66 gallons). and be of adequate strength in relation
(6) Maximum net mass: 400 kg (882 to its capacity and intended use. No
pounds). used material other than production
[Amdt. 17897, 55 FR 52717, Dec. 21, 1990, as residues or regrind from the same man-
amended at 57 FR 45465, Oct. 1, 1992] ufacturing process may be used unless
approved by the Associate Adminis-
178.508 Standards for fiber drums. trator. The packaging must be ade-
(a) The identification code for a fiber quately resistant to aging and to deg-
drum is 1G. radation caused either by the sub-
(b) Construction requirements for stance contained or by ultra-violet ra-
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203
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178.510 49 CFR Ch. I (10111 Edition)
the drum or jerrican design is such (2) 3A2 for a removable head steel
that when the removable head is prop- jerrican;
erly secured, the drum or jerrican is in- (3) 3B1 for a non-removable head alu-
herently leakproof. minum jerrican; and
204
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Pipeline and Hazardous Materials Safety Admin., DOT 178.513
(4) 3B2 for a removable head alu- 178.512 Standards for steel or alu-
minum jerrican. minum boxes.
(b) Construction requirements for (a) The following are identification
aluminum and steel jerricans are as codes for steel or aluminum boxes:
follows: (1) 4A for a steel box; and
(1) For steel jerricans the body and (2) 4B for an aluminum box.
heads must be constructed of steel (b) Construction requirements for
sheet of suitable type and adequate steel or aluminum boxes are as follows:
thickness in relation to the capacity of (1) The strength of the metal and the
the jerrican and its intended use. Min- construction of the box must be appro-
imum thickness and marking require- priate to the capacity and intended use
ments in 173.28(b)(4) and 178.503(a)(9) of the box.
of this subchapter apply to jerricans (2) Boxes must be lined with fiber-
intended for reuse. board or felt packing pieces or must
(2) For aluminum jerricans the body have an inner liner or coating of suit-
and heads must be constructed of alu- able material in accordance with sub-
minum at least 99% pure or of an alu- part C of part 173 of this subchapter. If
minum base alloy. Material must be of a double seamed metal liner is used,
a type and of adequate thickness in re- steps must be taken to prevent the in-
lation to the capacity of the jerrican gress of materials, particularly explo-
and to its intended use. sives, into the recesses of the seams.
(3) Chimes of all jerricans must be (3) Closures may be of any suitable
mechanically seamed or welded. Body type, and must remain secure under
seams of jerricans intended to carry normal conditions of transport.
more than 40 L (11 gallons) of liquid (4) Maximum net mass: 400 kg (882
must be welded. Body seams of pounds).
jerricans intended to carry 40 L (11 gal- [Amdt. 17897, 55 FR 52717, Dec. 21, 1990, as
lons) or less must be mechanically amended by Amdt. 178106, 59 FR 67521, Dec.
seamed or welded. 29, 1994]
(4) Openings in jerricans (3A1) may
not exceed 7.0 cm (3 inches) in diame- 178.513 Standards for boxes of nat-
ural wood.
ter. Jerricans with larger openings are
considered to be of the removable head (a) The following are the identifica-
type. Closures must be so designed that tion codes for boxes of natural wood:
they remain secure and leakproof (1) 4C1 for an ordinary box; and
under normal conditions of transport. (2) 4C2 for a box with sift-proof walls.
Gaskets or other sealing elements (b) Construction requirements for
must be used with closures, unless the boxes of natural wood are as follows:
closure is inherently leakproof. (1) The wood used must be well-sea-
(5) If materials used for body, heads, soned, commercially dry and free from
closures and fittings are not in them- defects that would materially lessen
selves compatible with the contents to the strength of any part of the box. The
be transported, suitable internal pro- strength of the material used and the
tective coatings or treatments must be method of construction must be appro-
applied. These coatings or treatments priate to the capacity and intended use
must retain their protective properties of the box. The tops and bottoms may
under normal conditions of transport. be made of water-resistant reconsti-
tuted wood such as hard board, particle
(6) Maximum capacity of jerrican: 60
board or other suitable type.
L (16 gallons).
(2) Fastenings must be resistant to
(7) Maximum net mass: 120 kg (265
vibration experienced under normal
pounds). conditions of transportation. End grain
[Amdt. 17897, 55 FR 52717, Dec. 21, 1990, as nailing must be avoided whenever prac-
wreier-aviles on DSK3TPTVN1PROD with CFR
amended by Amdt. 178102, 59 FR 28494, June ticable. Joints which are likely to be
2, 1994; Amdt. 178119, 62 FR 24742, May 6, highly stressed must be made using
1997] clenched or annular ring nails or equiv-
alent fastenings.
205
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178.514 49 CFR Ch. I (10111 Edition)
(3) Each part of the 4C2 box must be 178.516 Standards for fiberboard
one piece or equivalent. Parts are con- boxes.
sidered equivalent to one piece when (a) The identification code for a fi-
one of the following methods of glued berboard box is 4G.
assembly is used: Linderman joint, (b) Construction requirements for fi-
tongue and groove joint, ship lap or berboard boxes are as follows:
rabbet joint, or butt joint with at least (1) Strong, solid or double-faced cor-
two corrugated metal fasteners at each rugated fiberboard (single or multi-
joint. wall) must be used, appropriate to the
(4) Maximum net mass: 400 kg (882 capacity and intended use of the box.
pounds). The water resistance of the outer sur-
[Amdt. 17897, 55 FR 52717, Dec. 21, 1990, as face must be such that the increase in
amended by Amdt. 178106, 59 FR 67521, Dec. mass, as determined in a test carried
29, 1994] out over a period of 30 minutes by the
Cobb method of determining water ab-
178.514 Standards for plywood boxes. sorption, is not greater than 155 g per
(a) The identification code for a ply- square meter (0.0316 pounds per square
wood box is 4D. foot)see ISO 535 (IBR, see 171.7 of
(b) Construction requirements for this subchapter). Fiberboard must have
plywood boxes are as follows: proper bending qualities. Fiberboard
(1) Plywood used must be at least 3 must be cut, creased without cutting
ply. It shall be made from well-sea- through any thickness of fiberboard,
soned rotary cut, sliced or sawn veneer, and slotted so as to permit assembly
commercially dry and free from defects without cracking, surface breaks, or
that would materially lessen the undue bending. The fluting of cor-
strength of the box. The strength of the rugated fiberboard must be firmly
material used and the method of con- glued to the facings.
struction must be appropriate to the (2) The ends of boxes may have a
capacity and intended use of the box. wooden frame or be entirely of wood or
All adjacent plies must be glued with other suitable material. Reinforce-
water-resistant adhesive. Other suit- ments of wooden battens or other suit-
able materials may be used together able material may be used.
with plywood in the construction of (3) Manufacturing joints. (i) Manu-
boxes. Boxes must be nailed or secured facturing joints in the bodies of boxes
to corner posts or ends or assembled must be
with other equally suitable devices. (A) Taped;
(2) Maximum net mass: 400 kg (882 (B) Lapped and glued; or
pounds). (C) Lapped and stitched with metal
staples.
178.515 Standards for reconstituted (ii) Lapped joints must have an ap-
wood boxes. propriate overlap.
(a) The identification code for a re- (4) Where closing is effected by glu-
constituted wood box is 4F. ing or taping, a water resistant adhe-
(b) Construction requirements for re- sive must be used.
constituted wood boxes are as follows: (5) Boxes must be designed so as to
(1) The walls of boxes must be made provide a snug fit to the contents.
of water-resistant, reconstituted wood (6) Maximum net mass: 400 kg (882
such as hardboard, particle board, or pounds).
other suitable type. The strength of [Amdt. 17897, 55 FR 52717, Dec. 21, 1990, and
the material used and the method of amended by Amdt. 17899, 58 FR 51534, Oct. 1,
construction must be appropriate to 1993; Amdt. 178106, 59 FR 67521, Dec. 29, 1994;
the capacity of the boxes and their in- 68 FR 75758, Dec. 31, 2003]
tended use.
(2) Other parts of the box may be 178.517 Standards for plastic boxes.
made of other suitable materials. (a) The following are identification
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206
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Pipeline and Hazardous Materials Safety Admin., DOT 178.519
(b) Construction requirements for signed as to prevent the box from unin-
plastic boxes are as follows: tentionally opening.
(1) The box must be manufactured (7) Maximum net mass 4H1: 60 kg (132
from suitable plastic material and be pounds); 4H2: 400 kg (882 pounds).
of adequate strength in relation to its
capacity and intended use. The box 178.518 Standards for woven plastic
bags.
must be adequately resistant to aging
and to degradation caused either by (a) The following are identification
the substance contained or by ultra- codes for woven plastic bags:
violet radiation. (1) 5H1 for an unlined or non-coated
(2) An expanded plastic box must con- woven plastic bag;
sist of two parts made of a molded ex- (2) 5H2 for a sift-proof woven plastic
panded plastic material: a bottom sec- bag; and
tion containing cavities for the inner (3) 5H3 for a water-resistant woven
receptacles, and a top section covering plastic bag.
and interlocking with the bottom sec- (b) Construction requirements for
woven plastic fabric bags are as fol-
tion. The top and bottom sections must
lows:
be so designed that the inner recep-
(1) Bags must be made from stretched
tacles fit snugly. The closure cap for
tapes or monofilaments of a suitable
any inner receptacle may not be in
plastic material. The strength of the
contact with the inside of the top sec-
material used and the construction of
tion of the box.
the bag must be appropriate to the ca-
(3) For transportation, an expanded pacity and intended use of the bag.
plastic box must be closed with a self- (2) If the fabric is woven flat, the
adhesive tape having sufficient tensile bags must be made by sewing or some
strength to prevent the box from open- other method ensuring closure of the
ing. The adhesive tape must be weath- bottom and one side. If the fabric is tu-
er-resistant and its adhesive compat- bular, the bag must be closed by sew-
ible with the expanded plastic material ing, weaving, or some other equally
of the box. Other closing devices at strong method of closure.
least equally effective may be used. (3) Bags, sift-proof, 5H2 must be made
(4) For solid plastic boxes, protection sift-proof by appropriate means such as
against ultra-violet radiation, if re- use of paper or a plastic film bonded to
quired, must be provided by the addi- the inner surface of the bag or one or
tion of carbon black or other suitable more separate inner liners made of
pigments or inhibitors. These additives paper or plastic material.
must be compatible with the contents (4) Bags, water-resistant, 5H3: To pre-
and remain effective throughout the vent the entry of moisture, the bag
life of the box. Where use is made of must be made waterproof by appro-
carbon black pigment or inhibitors priate means, such as separate inner
other than those used in the manufac- liners of water-resistant paper (e.g.,
ture of the tested design type, re- waxed kraft paper, double-tarred kraft
testing may be waived if the carbon paper or plastic-coated kraft paper), or
black content does not exceed 2 percent plastic film bonded to the inner or
by mass or if the pigment content does outer surface of the bag, or one or more
not exceed 3 percent by mass; the con- inner plastic liners.
tent of inhibitors of ultra-violet radi- (5) Maximum net mass: 50 kg (110
ation is not limited. pounds).
(5) Additives serving purposes other [Amdt. 17897, 55 FR 52717, Dec. 21, 1990, and
than protection against ultra-violet ra- amended by Amdt. 17899, 58 FR 51534, Oct. 1,
diation may be included in the com- 1993]
position of the plastic material if they
do not adversely affect the material of 178.519 Standards for plastic film
the box. Addition of these additives bags.
wreier-aviles on DSK3TPTVN1PROD with CFR
does not change the design type. (a) The identification code for a plas-
(6) Solid plastic boxes must have clo- tic film bag is 5H4.
sure devices made of a suitable mate- (b) Construction requirements for
rial of adequate strength and so de- plastic film bags are as follows:
207
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178.520 49 CFR Ch. I (10111 Edition)
(1) Bags must be made of a suitable (2) 5M2 for a multi-wall water-resist-
plastic material. The strength of the ant paper bag.
material used and the construction of (b) Construction requirements for
the bag must be appropriate to the ca- paper bags are as follows:
pacity and the intended use of the bag. (1) Bags must be made of a suitable
Joints and closures must be capable of kraft paper, or of an equivalent paper
withstanding pressures and impacts with at least three plies. The strength
liable to occur under normal conditions of the paper and the construction of
of transportation. the bag must be appropriate to the ca-
(2) Maximum net mass: 50 kg (110 pacity and intended use of the bag.
pounds). Seams and closures must be sift-proof.
(2) Paper bags 5M2: To prevent the
178.520 Standards for textile bags. entry of moisture, a bag of four plies or
(a) The following are identification more must be made waterproof by the
codes for textile bags: use of either a water-resistant ply as
(1) 5L1 for an unlined or non-coated one of the two outermost plies or a
textile bag; water-resistant barrier made of a suit-
(2) 5L2 for a sift-proof textile bag; able protective material between the
and two outermost plies. A 5M2 bag of
(3) 5L3 for a water-resistant textile three plies must be made waterproof by
bag. the use of a water-resistant ply as the
(b) Construction requirements for outermost ply. When there is danger of
textile bags are as follows: the lading reacting with moisture, or
(1) The textiles used must be of good when it is packed damp, a waterproof
quality. The strength of the fabric and ply or barrier, such as double-tarred
the construction of the bag must be ap- kraft paper, plastics-coated kraft
propriate to the capacity and intended paper, plastics film bonded to the inner
use of the bag. surface of the bag, or one or more inner
plastics liners, must also be placed
(2) Bags, sift-proof, 5L2: The bag
next to the substance. Seams and clo-
must be made sift-proof, by appropriate
sures must be waterproof.
means, such as by the use of paper
(3) Maximum net mass: 50 kg (110
bonded to the inner surface of the bag
pounds).
by a water-resistant adhesive such as
bitumen, plastic film bonded to the [Amdt. 17897, 55 FR 52717, Dec. 21, 1990, as
inner surface of the bag, or one or more amended at 56 FR 66285, Dec. 20, 1991; Amdt.
inner liners made of paper or plastic 178106, 59 FR 67521, Dec. 29, 1994]
material.
178.522 Standards for composite
(3) Bags, water-resistant, 5L3: To pre- packagings with inner plastic re-
vent entry of moisture, the bag must ceptacles.
be made waterproof by appropriate
means, such as by the use of separate (a) The following are the identifica-
inner liners of water-resistant paper tion codes for composite packagings
(e.g., waxed kraft paper, tarred paper, with inner plastic receptacles:
or plastic-coated kraft paper), or plas- (1) 6HA1 for a plastic receptacle with-
tic film bonded to the inner surface of in a protective steel drum;
the bag, or one or more inner liners (2) 6HA2 for a plastic receptacle with-
made of plastic material or metalized in a protective steel crate or box;
(3) 6HB1 for a plastic receptacle with-
film or foil.
in a protective aluminum drum.
(4) Maximum net mass: 50 kg (110
(4) 6HB2 for a plastic receptacle with-
pounds).
in a protective aluminum crate or box.
[Amdt. 17897, 55 FR 52717, Dec. 21, 1990, as (5) 6HC for a plastic receptacle within
amended at 56 FR 66285, Dec. 20, 1991] a protective wooden box.
(6) 6HD1 for a plastic receptacle with-
178.521 Standards for paper bags. in a protective plywood drum;
wreier-aviles on DSK3TPTVN1PROD with CFR
(a) The following are identification (7) 6HD2 for a plastic receptacle with-
codes for paper bags: in a protective plywood box;
(1) 5M1 for a multi-wall paper bag; (8) 6HG1 for a plastic receptacle with-
and in a protective fiber drum;
208
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Pipeline and Hazardous Materials Safety Admin., DOT 178.523
(9) 6HG2 for a plastic receptacle with- (5) Maximum net mass is as follows:
in a protective fiberboard box; 6HA1, 6HB1, 6HD1, 6HG1, 6HH1400kg
(10) 6HH1 for a plastic receptacle (882 pounds); 6HB2, 6HC, 6HD2, 6HG2,
within a protective plastic drum; and 6HH275 kg (165 pounds).
(11) 6HH2 for a plastic receptacle
[Amdt. 17897, 55 FR 52717, Dec. 21, 1990, as
within a protective plastic box. amended by Amdt. 178106, 59 FR 67521, Dec.
(b) Construction requirements for 29, 1994]
composite packagings with inner re-
ceptacles of plastic are as follows: 178.523 Standards for composite
(1) Inner receptacles must be con- packagings with inner glass, por-
structed under the applicable construc- celain, or stoneware receptacles.
tion requirements prescribed in (a) The following are identification
178.509(b) (1) through (7) of this sub- codes for composite packagings with
part. inner receptacles of glass, porcelain, or
(2) The inner plastic receptacle must stoneware:
fit snugly inside the outer packaging, (1) 6PA1 for glass, porcelain, or stone-
which must be free of any projections ware receptacles within a protective
which may abrade the plastic material. steel drum;
(3) Outer packagings must be con- (2) 6PA2 for glass, porcelain, or stone-
structed as follows: ware receptacles within a protective
(i) 6HA1 or 6HB1: Protective pack- steel crate or box;
aging must conform to the require- (3) 6PB1 for glass, porcelain, or stone-
ments for steel drums in 178.504(b) of ware receptacles within a protective
this subpart, or aluminum drums in aluminum drum;
178.505(b) of this subpart.
(4) 6PB2 for glass, porcelain, or stone-
(ii) 6HA2 or 6HB2: Protective pack-
ware receptacles within a protective
agings with steel or aluminum crate
aluminum crate or box;
must conform to the requirements for
(5) 6PC for glass, porcelain, or stone-
steel or aluminum boxes found in
ware receptacles within a protective
178.512(b) of this subpart.
wooden box;
(iii) 6HC protective packaging must
conform to the requirements for wood- (6) 6PD1 for glass, porcelain, or stone-
en boxes in 178.513(b) of this subpart. ware receptacles within a protective
(iv) 6HD1: Protective packaging must plywood drum;
conform to the requirements for ply- (7) 6PD2 for glass, porcelain, or stone-
wood drums, in 178.507(b) of this sub- ware receptacles within a protective
part. wickerwork hamper;
(v) 6HD2: Protective packaging must (8) 6PG1 for glass, porcelain, or stone-
conform to the requirements of ply- ware receptacles within a protective
wood boxes, in 178.514(b) of this sub- fiber drum;
part. (9) 6PG2 for glass, porcelain, or stone-
(vi) 6HG1: Protective packaging must ware receptacles within a protective fi-
conform to the requirements for fiber berboard box;
drums, in 178.508(b) of this subpart. (10) 6PH1 for glass, porcelain, or
(vii) 6HG2: protective packaging stoneware receptacles within a protec-
must conform to the requirements for tive expanded plastic packaging; and
fiberboard boxes, in 178.516(b) of this (11) 6PH2 for glass, porcelain, or
subpart. stoneware receptacles within a protec-
(viii) 6HH1: Protective packaging tive solid plastic packaging.
must conform to the requirements for (b) Construction requirements for
plastic drums, in 178.509(b). composite packagings with inner re-
(ix) 6HH2: Protective packaging must ceptacles of glass, porcelain, or stone-
conform 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 recep- the following requirements:
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209
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178.600 49 CFR Ch. I (10111 Edition)
strength, and be firmly secured in the (ix) For receptacles with protective
outer packaging. fiberboard box 6PG2, the requirements
(ii) Any part of a closure likely to of 178.516(b) of this subpart apply to
come into contact with the contents of the protective packaging.
the receptacle must be resistant to (x) For receptacles with protective
those contents. Closures must be fitted solid plastic or expanded plastic pack-
so as to be leakproof and secured to aging 6PH1 or 6PH2, the requirements
prevent any loosening during transpor- of 178.517(b) of this subpart apply to
tation. Vented closures must conform the protective packaging. Solid protec-
to 173.24(f) of this subchapter. tive plastic packaging must be manu-
(2) Protective packagings must con- factured from high-density poly-
form to the following requirements: ethylene from some other comparable
(i) For receptacles with protective plastic material. The removable lid re-
steel drum 6PAl, the drum must com- quired for this type of packaging may
ply with 178.504(b) of this subpart. be a cap.
However, the removable lid required (3) Quantity limitations are as fol-
for this type of packaging may be in lows:
the form of a cap. (i) Maximum net capacity for pack-
(ii) For receptacles with protective aging for liquids: 60 L (16 gallons).
packaging of steel crate or steel box (ii) Maximum net mass for pack-
6PA2, the protective packaging must agings for solids: 75 kg (165 pounds).
conform to the following:
(A) Section 178.512(b) of this subpart. Subpart MTesting of Non-bulk
(B) In the case of cylindrical recep- Packagings and Packages
tacles, the protective packaging must,
when upright, rise above the receptacle
and its closure; and SOURCE: Amdt. 17897, 55 FR 52723, Dec. 21,
1990, unless otherwise noted.
(C) If the protective crate surrounds
a pear-shaped receptacle and is of 178.600 Purpose and scope.
matching shape, the protective pack-
aging must be fitted with a protective This subpart prescribes certain test-
cover (cap). ing requirements for performance-ori-
(iii) For receptacles with protective ented packagings identified in subpart
aluminum drum 6PB1, the require- L of this part.
ments of 178.505(b) of this subpart [Amdt. 17897, 55 FR 52717, Dec. 21, 1990, and
apply to the protective packaging. amended by Amdt. 17899, 58 FR 51534, Oct. 1,
(iv) For receptacles with protective 1993]
aluminum box or crate 6PB2, the re-
quirements of 178.512(b) of this sub- 178.601 General requirements.
part apply to the protective packaging. (a) General. The test procedures pre-
(v) For receptacles with protective scribed in this subpart are intended to
wooden box 6PC, the requirements of ensure that packages containing haz-
178.513(b) of this subpart apply to the ardous materials can withstand normal
protective packaging. conditions of transportation and are
(vi) For receptacles with protective considered minimum requirements.
plywood drum 6PD1, the requirements Each packaging must be manufactured
of 178.507(b) of this subpart apply to and assembled so as to be capable of
the protective packaging. successfully passing the prescribed
(vii) For receptacles with protective tests and of conforming to the require-
wickerwork hamper 6PD2, the ments of 173.24 of this subchapter at
wickerwork hamper must be properly all times while in transportation.
made with material of good quality. (b) Responsibility. It is the responsi-
The hamper must be fitted with a pro- bility 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
wreier-aviles on DSK3TPTVN1PROD with CFR
(viii) For receptacles with protective extent that a package assembly func-
fiber drum 6PG1, the drum must con- tion, including final closure, is per-
form to the requirements of 178.508(b) formed by the person who offers a haz-
of this subpart. ardous material for transportation,
210
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Pipeline and Hazardous Materials Safety Admin., DOT 178.601
that person is responsible for per- stitute a different design type under
forming the function in accordance the provisions of paragraph (g)(8) of
with 173.22 and 178.2 of this sub- this section.
chapter. (d) Design qualification testing. The
(c) Definitions. For the purpose of this packaging manufacturer shall achieve
subpart: successful test results for the design
(1) Design qualification testing is the qualification testing at the start of
performance of the tests prescribed in production of each new or different
178.603, 178.604, 178.605, 178.606, packaging.
178.607, 178.608, or 178.609, as applica- (e) Periodic retesting. The packaging
ble, for each new or different pack- manufacturer must achieve successful
aging, at the start of production of test results for the periodic retesting
that packaging. at intervals established by the manu-
(2) Periodic retesting is the perform- facturer of sufficient frequency to en-
ance of the drop, leakproofness, hydro- sure that each packaging produced by
static pressure, and stacking tests, as the manufacturer is capable of passing
applicable, as prescribed in 178.603, the design qualification tests. Changes
178.604, 178.605, or 178.606, respec- in retest frequency are subject to the
tively, at the frequency specified in approval of the Associate Adminis-
paragraph (e) of this section. For infec- trator for Hazardous Materials Safety.
tious substances packagings required For single or composite packagings,
to meet the requirements of 178.609, the periodic retests must be conducted
periodic retesting is the performance of at least once every 12 months. For
the tests specified in 178.609 at the fre- combination packagings, the periodic
quency specified in paragraph (e) of retests must be conducted at least once
this section. every 24 months. For infectious sub-
(3) Production testing is the perform- stances packagings, the periodic
ance of the leakproofness test pre-
retests must be conducted at least once
scribed in 178.604 of this subpart on
every 24 months.
each single or composite packaging in-
(f) Test samples. The manufacturer
tended to contain a liquid.
(4) A different packaging is one that shall conduct the design qualification
differs (i.e. is not identical) from a pre- and periodic tests prescribed in this
viously produced packaging in struc- subpart using random samples of pack-
tural design, size, material of construc- agings, in the numbers specified in the
tion, wall thickness or manner of con- appropriate test section. In addition,
struction but does not include: the leakproofness test, when required,
(i) A packaging which differs only in shall be performed on each packaging
surface treatment; produced by the manufacturer, and
(ii) A combination packaging which each packaging prior to reuse under
differs only in that the outer pack- 173.28 of this subchapter, by the re-
aging has been successfully tested with conditioner.
different inner packagings. A variety of (g) Selective testing. The selective
such inner packagings may be assem- testing of packagings that differ only
bled in this outer packaging without in minor respects from a tested type is
further testing; permitted as described in this section.
(iii) A plastic packaging which differs For air transport, packagings must
only with regard to additives which comply with 173.27(c)(1) and (c)(2) of
conform to 178.509(b)(3) or 178.517(b) this subchapter.
(4) or (5) of this part; (1) Selective testing of combination
(iv) A combination packaging with packagings. Variation 1. Variations are
inner packagings conforming to the permitted in inner packagings of a
provisions of paragraph (g) of this sec- tested combination package, without
tion; further testing of the package, pro-
(v) Packagings which differ from the vided an equivalent level of perform-
wreier-aviles on DSK3TPTVN1PROD with CFR
design type only in their lesser design ance is maintained and, when a pack-
height; or age is altered under Variation 1 after
(vi) For a steel drum, variations in October 1, 2010, the methodology used
design elements which do not con- to determine that the inner packaging,
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178.601 49 CFR Ch. I (10111 Edition)
including closure, maintains an equiva- side of the packaging may not be re-
lent level of performance is docu- duced below the corresponding thick-
mented in writing by the person certi- ness in the originally tested packaging;
fying compliance with this paragraph and when a single inner packaging was
and retained in accordance with para- used in the original test, the thickness
graph (l) of this section. Permitted of cushioning between inner pack-
variations are as follows: agings may not be less than the thick-
(i) Inner packagings of equivalent or ness of cushioning between the outside
smaller size may be used provided of the packaging and the inner pack-
(A) The inner packagings are of simi- aging in the original test. When either
lar design to the tested inner pack- fewer or smaller inner packagings are
agings (i.e. shaperound, rectangular,
used (as compared to the inner pack-
etc.);
agings used in the drop test), sufficient
(B) The material of construction of
the inner packagings (glass, plastic, additional cushioning material must be
metal, etc.) offers resistance to impact used to take up void spaces.
and stacking forces equal to or greater (iv) The outer packaging must have
than that of the originally tested inner successfully passed the stacking test
packaging; set forth in 178.606 of this subpart
(C) The inner packagings have the when empty, i.e., without either inner
same or smaller openings and the clo- packagings or cushioning materials.
sure is of similar design (e.g., screw The total mass of identical packages
cap, friction lid, etc.); must be based on the combined mass of
(D) Sufficient additional cushioning inner packagings used for the drop
material is used to take up void spaces test;
and to prevent significant moving of (v) Inner packagings containing liq-
the inner packagings; uids must be completely surrounded
(E) Inner packagings are oriented with a sufficient quantity of absorbent
within the outer packaging in the same material to absorb the entire liquid
manner as in the tested package; and, contents of the inner packagings;
(F) The gross mass of the package (vi) When the outer packaging is in-
does not exceed that originally tested.
tended to contain inner packagings for
(ii) A lesser number of the tested
liquids and is not leakproof, or is in-
inner packagings, or of the alternative
types of inner packagings identified in tended to contain inner packagings for
paragraph (g)(1)(i) of this section, may solids and is not siftproof, a means of
be used provided sufficient cushioning containing any liquid or solid contents
is added to fill void space(s) and to pre- in the event of leakage must be pro-
vent significant moving of the inner vided in the form of a leakproof liner,
packagings. plastic bag, or other equally efficient
(2) Selective testing of combination means of containment. For packagings
packagings. Variation 2. Articles or containing liquids, the absorbent mate-
inner packagings of any type, for solids rial required in paragraph (g)(2)(v) of
or liquids, may be assembled and trans- this section must be placed inside the
ported without testing in an outer means of containing liquid contents;
packaging under the following condi- and
tions: (vii) Packagings must be marked in
(i) The outer packaging must have accordance with 178.503 of this part as
been successfully tested in accordance having been tested to Packing Group I
with 178.603 with fragile (e.g. glass) performance for combination pack-
inner packagings containing liquids at agings. The marked maximum gross
the Packing Group I drop height; mass may not exceed the sum of the
(ii) The total combined gross mass of mass of the outer packaging plus one
inner packagings may not exceed one- half the mass of the filled inner pack-
half the gross mass of inner packagings
agings of the tested combination pack-
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Pipeline and Hazardous Materials Safety Admin., DOT 178.601
(3) Variation 3. Packagings other than nally tested inner packagings in ac-
combination packagings which are pro- cordance with the conditions set out in
duced with reductions in external di- Variation 1 in paragraph (g)(1) of this
mensions (i.e., length, width or diame- section.
ter) of up to 25 percent of the dimen- (5) Variation 5. Single packagings
sions of a tested packaging may be (i.e., non-bulk packagings other than
used without further testing provided combination packagings), that differ
an equivalent level of performance is from a tested design type only to the
maintained. The packagings must, in extent that the closure device or
all other respects (including wall gasketing differs from that used in the
thicknesses), be identical to the tested originally tested design type, may be
design-type. The marked gross mass used without further testing, provided
(when required) must be reduced in an equivalent level of performance is
proportion to the reduction in volume. maintained, subject to the following
(4) Variation 4. Variations are per- conditions (the qualifying tests):
mitted in outer packagings of a tested (i) A packaging with the replacement
design-type combination packaging, closure devices or gasketing must suc-
without further testing, provided an cessfully pass the drop test specified in
equivalent level of performance is 178.603 in the orientation which most
maintained, as follows: severely tests the integrity of the clo-
(i) Each external dimension (length, sure or gasket;
width and height) is less than or equal (ii) When intended to contain liquids,
to the corresponding dimension of the a packaging with the replacement clo-
tested design-type; sure devices or gasketing must success-
(ii) The structural design of the test- fully pass the leakproofness test speci-
ed outer packaging (i.e. methods of fied in 178.604, the hydrostatic pres-
construction, materials of construc- sure test specified in 178.605, and the
tion, strength characteristics of mate- stacking test specified in 178.606.
rials of construction, method of closure Replacement closures and gasketings
and material thicknesses) is main- qualified under the above test require-
tained; ments are authorized without addi-
(iii) The inner packagings are iden- tional testing for packagings described
tical to the inner packagings used in in paragraph (g)(3) of this section. Re-
the tested design type except that their placement closures and gasketings
size and mass may be less; and they are qualified under the above test require-
oriented within the outer packaging in ments also are authorized without ad-
the same manner as in the tested pack- ditional testing for different tested de-
aging; sign types packagings of the same type
(iv) The same type or design of ab- as the originally tested packaging, pro-
sorbent materials, cushioning mate- vided the original design type tests are
rials and any other components nec- more severe or comparable to tests
essary to contain and protect inner which would otherwise be conducted on
packagings, as used in the tested de- the packaging with the replacement
sign type, are maintained. The thick- closures or gasketings. (For example:
ness of cushioning material between The packaging used in the qualifying
inner packagings and between inner tests has a lesser packaging wall thick-
packagings and the outside of the ness than the packaging with replace-
packaging may not be less than the ment closure devices or gasketing; the
thicknesses in the tested design type gross mass of the packaging used in the
packaging; and qualifying drop test equals or exceeds
(v) Sufficient additional cushioning the mass for which the packaging with
material is used to take up void spaces replacement closure devices or
and to prevent significant moving of gasketing was tested; the packaging
the inner packagings. used in the qualifying drop test was
An outer packaging qualifying for use dropped from the same or greater
wreier-aviles on DSK3TPTVN1PROD with CFR
in transport in accordance with all of height than the height from which the
the above conditions may also be used packaging with replacement closure
without testing to transport inner devices or gasketing was dropped in de-
packagings substituted for the origi- sign type tests; and the specific gravity
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178.601 49 CFR Ch. I (10111 Edition)
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Pipeline and Hazardous Materials Safety Admin., DOT 178.602
(2) Supply packagings, in quantities copy of the test report must be main-
sufficient to conduct tests in accord- tained by a person certifying compli-
ance with this subpart, to the Asso- ance with this part. The test report
ciate Administrator or a designated must be made available to a user of a
representative of the Associate Admin- packaging or a representative of the
istrator. Department upon request. The test re-
(j) Coatings. If an inner treatment or port, at a minimum, must contain the
coating of a packaging is required for following information:
safety reasons, the manufacturer shall (1) Name and address of test facility;
design the packaging so that the treat- (2) Name and address of applicant
ment or coating retains its protective (where appropriate);
properties even after withstanding the (3) A unique test report identifica-
tests prescribed by this subpart. tion;
(k) Number of test samples. Except as (4) Date of the test report;
provided in this section, one test sam- (5) Manufacturer of the packaging;
ple must be used for each test per- (6) Description of the packaging de-
formed under this subpart. sign type (e.g. dimensions, materials,
(1) Stainless steel drums. Provided the closures, thickness, etc.), including
validity of the test results is not af- methods of manufacture (e.g. blow
fected, a person may perform the de- molding) and which may include draw-
sign qualification testing of stainless ing(s) and/or photograph(s);
steel drums using three (3) samples (7) Maximum capacity;
rather than the specified eighteen (18) (8) Characteristics of test contents,
samples under the following provisions: e.g. viscosity and relative density for
(i) The packaging must be tested in liquids and particle size for solids;
accordance with this subpart by sub- (9) Test descriptions and results; and
jecting each of the three containers to (10) Signed with the name and title of
the following sequence of tests: signatory.
(A) The stacking test in 178.606, [Amdt. 17897, 55 FR 52723, Dec. 21, 1990, as
(B) The leakproofness test in 178.604, amended at 56 FR 66285, Dec. 20, 1991; 57 FR
(C) The hydrostatic pressure test in 45465, Oct. 1, 1992; Amdt. 178102, 59 FR 28494,
178.608, and June 2, 1994; Amdt. 178106, 59 FR 67521, 67522,
Dec. 29, 1994; Amdt. 178117, 61 FR 50628, Sept.
(D) Diagonal top chime and flat on 26, 1996; 66 FR 45386, Aug. 28, 2001; 67 FR 53143,
the side drop tests in 178.603. Both Aug. 14, 2002; 68 FR 75758, Dec. 31, 2003; 68 FR
drop tests may be conducted on the 61942, Oct. 30, 2003; 75 FR 5396, Feb 2, 2010; 75
same sample. FR 60339, Sept. 30, 2010]
(ii) For periodic retesting of stainless
steel drums, a reduced sample size of 178.602 Preparation of packagings
one container is authorized. and packages for testing.
(2) Packagings other than stainless steel (a) Except as otherwise provided in
drums. Provided the validity of the test this subchapter, each packaging and
results is not affected, several tests package must be closed in preparation
may be performed on one sample with for testing and tests must be carried
the approval of the Associate Adminis- out in the same manner as if prepared
trator. for transportation, including inner
(l) Record retention. Following each packagings in the case of combination
design qualification test and each peri- packagings.
odic retest on a packaging, a test re- (b) For the drop and stacking test,
port must be prepared. The test report inner and single-unit receptacles other
must be maintained at each location than bags must be filled to not less
where the packaging is manufactured than 95% of maximum capacity (see
and each location where the design 171.8 of this subchapter) in the case of
qualification tests are conducted, for solids and not less than 98% of max-
as long as the packaging is produced imum in the case of liquids. Bags con-
and for at least two years thereafter, taining solids shall be filled to the
wreier-aviles on DSK3TPTVN1PROD with CFR
and at each location where the periodic maximum mass at which they may be
retests are conducted until such tests used. The material to be transported in
are successfully performed again and a the packagings may be replaced by a
new test report produced. In addition, a non-hazardous material, except for
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178.603 49 CFR Ch. I (10111 Edition)
Steel drums, Aluminum drums, Metal Six(three for each First drop (using three samples): The package must strike the
drums (other than steel or alu- drop). 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.
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.
Bagssingle-ply with a side seam ..... Three(three drops First drop: Flat on a wide face (using all three samples). Sec-
per bag). ond drop: Flat on a narrow face (using all three samples).
Third drop: On an end of the bag (using all three samples).
Bagssingle-ply without a side seam, Three(two drops per First drop: Flat on a wide face (using all three samples). Sec-
or multi-ply. bag). ond drop: On an end of the bag (using all three samples).
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Pipeline and Hazardous Materials Safety Admin., DOT 178.603
design qualification testing), the drop 1.2, drop height must be determined ac-
test may be conducted with two sam- cording to packing group, as follows:
ples, one sample each for the two drop (A) Packing Group I: 1.8 m (5.9 feet).
orientations. These samples may have (B) Packing Group II: 1.2 m (3.9 feet).
been previously used for the hydro- (C) Packing Group III: 0.8 m (2.6 feet).
static pressure or stacking test. Excep-
(ii) Where the materials to be trans-
tions for the number of steel and alu-
ported have a specific gravity exceed-
minum packaging samples used for
ing 1.2, the drop height must be cal-
conducting the drop test are subject to
the approval of the Associate Adminis- culated on the basis of the specific
trator. gravity (SG) of the material to be car-
(c) Special preparation of test samples ried, rounded up to the first decimal, as
for the drop test. (1) Testing of plastic follows:
drums, plastic jerricans, plastic boxes (A) Packing Group I: SG 1.5 m (4.9
other than expanded polystyrene boxes, feet).
composite packagings (plastic mate- (B) Packing Group II: SG 1.0 m (3.3
rial), and combination packagings with feet).
plastic inner packagings other than (C) Packing Group III: SG 0.67 m
plastic bags intended to contain solids (2.2 feet).
or articles must be carried out when (f) Criteria for passing the test. A pack-
the temperature of the test sample and age is considered to successfully pass
its contents has been reduced to 18 C the drop tests if for each sample test-
(0 F) or lower. Test liquids must be ed
kept in the liquid state, if necessary,
(1) For packagings containing liquid,
by the addition of anti-freeze. Water/
each packaging does not leak when
anti-freeze solutions with a minimum
equilibrium has been reached between
specific gravity of 0.95 for testing at
18 C (0 F) or lower are considered the internal and external pressures, ex-
acceptable test liquids. Test samples cept for inner packagings of combina-
prepared in this way are not required tion packagings when it is not nec-
to be conditioned in accordance with essary that the pressures be equalized;
178.602(d). (2) For removable head drums for sol-
(d) Target. The target must be a rigid, ids, the entire contents are retained by
non-resilient, flat and horizontal sur- an inner packaging (e.g., a plastic bag)
face. even if the closure on the top head of
(e) Drop height. Drop heights, meas- the drum is no longer sift-proof;
ured as the vertical distance from the (3) For a bag, neither the outermost
target to the lowest point on the pack- ply nor an outer packaging exhibits
age, must be equal to or greater than any damage likely to adversely affect
the drop height determined as follows: safety during transport;
(1) For solids and liquids, if the test (4) The packaging or outer packaging
is performed with the solid or liquid to of a composite or combination pack-
be transported or with a non-hazardous aging must not exhibit any damage
material having essentially the same likely to affect safety during transport.
physical characteristic, the drop height Inner receptacles, inner packagings, or
must be determined according to pack- articles must remain completely with-
ing group, as follows: in the outer packaging and there must
(i) Packing Group I: 1.8 m (5.9 feet). be no leakage of the filling substance
(ii) Packing Group II: 1.2 m (3.9 feet). from the inner receptacles or inner
(iii) Packing Group III: 0.8 m (2.6 packagings;
feet). (5) Any discharge from a closure is
(2) For liquids in single packagings slight and ceases immediately after
and for inner packagings of combina- impact with no further leakage; and
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217
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178.604 49 CFR Ch. I (10111 Edition)
method of restraint must not affect the the test pressure for 5 minutes. Plastic
results of the test. The test must be packagings and composite packagings
conducted, for other than production (plastic material), including their clo-
testing, for a minimum time of five sures, must be subjected to the test
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Pipeline and Hazardous Materials Safety Admin., DOT 178.606
types other than bags must be sub- at room temperature on an empty, un-
jected to a stacking test. sealed packaging. The test sample
(b) Number of test samples. Three test must be centered on the bottom platen
samples are required for each different of the testing machine. The top platen
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178.607 49 CFR Ch. I (10111 Edition)
must be lowered until it comes in con- expected contents; in no case may the
tact with the test sample. Compression maximum deflection exceed one inch.
must be applied end to end. The speed [Amdt. 17897, 55 FR 52723, Dec. 21, 1990, as
of the compression tester must be one- amended at 56 FR 66286, Dec. 20, 1991; 57 FR
half inch plus or minus one-fourth inch 45465, Oct. 1, 1992; Amdt. 178102, 59 FR 28494,
per minute. An initial preload of 50 June 2, 1994; Amdt. 178106, 59 FR 67522, Dec.
pounds must be applied to ensure a 29, 1994; 65 FR 58632, Sept. 29, 2000; 66 FR
45386, Aug. 28, 2001; 70 FR 34076, June 13, 2005;
definite contact between the test sam-
72 FR 55696, Oct. 1, 2007]
ple and the platens. The distance be-
tween the platens at this time must be 178.607 Cooperage test for bung-type
recorded as zero deformation. The force wooden barrels.
A to then be applied must be calculated (a) Number of samples. One barrel is
using the formula: required for each different packaging.
Liquids: A = (n1) [w + (s v 8.3 (b) Method of testing. Remove all
.98)] 1.5; hoops above the bilge of an empty bar-
Solids: A = (n1) (m 2.2 1.5) rel at least two days old.
(c) Criteria for passing the test. A pack-
Where: aging passes the cooperage test only if
A = applied load in pounds the diameter of the cross-section of the
m = the certified maximum gross mass for upper part of the barrel does not in-
the container in kilograms. crease by more than 10 percent.
n = minimum number of containers that,
when stacked, reach a height of 3 meters. 178.608 Vibration standard.
s = specific gravity of lading. (a) Each packaging must be capable
w = maximum weight of one empty container of withstanding, without rupture or
in pounds. leakage, the vibration test procedure
v = actual capacity of container (rated ca- outlined in this section.
pacity + outage) in gallons.
(b) Test method. (1) Three sample
And: packagings, selected at random, must
8.3 corresponds to the weight in pounds of 1.0 be filled and closed as for shipment.
gallon of water. (2) The three samples must be placed
.98 corresponds to the minimum filling per- on a vibrating platform that has a
centage of the maximum capacity for liq- vertical or rotary double-amplitude
uids. (peak-to-peak displacement) of one
1.5 is a compensation factor that converts inch. The packages should be con-
the static load of the stacking test into a strained horizontally to prevent them
load suitable for dynamic compression
from falling off the platform, but must
testing.
be left free to move vertically, bounce
2.2 is the conversion factor for kilograms to
pounds.
and rotate.
(3) The test must be performed for
(d) Criteria for passing the test. No test
one hour at a frequency that causes the
sample may leak. In composite pack- package to be raised from the vibrating
agings or combination packagings, platform to such a degree that a piece
there must be no leakage of the filling of material of approximately 1.6 mm
substance from the inner receptacle, or (0.063 inch) thickness (such as steel
inner packaging. No test sample may strapping or paperboard) can be passed
show any deterioration which could ad- between the bottom of any package
versely affect transportation safety or and the platform.
any distortion likely to reduce its (4) Immediately following the period
strength, cause instability in stacks of of vibration, each package must be re-
packages, or cause damage to inner moved from the platform, turned on its
packagings likely to reduce safety in side and observed for any evidence of
transportation. For the dynamic com- leakage.
pression test, a container passes the (5) Other methods, at least equally
wreier-aviles on DSK3TPTVN1PROD with CFR
test if, after application of the required effective, may be used, if approved by
load, there is no buckling of the side- the Associate Administrator.
walls sufficient to cause damage to its (c) Criteria for passing the test. A pack-
aging passes the vibration test if there
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Pipeline and Hazardous Materials Safety Admin., DOT 178.609
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178.609 49 CFR Ch. I (10111 Edition)
(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 min-
rainfall of approximately 50 mm (2 imum of 200 mm (7.9 inches). One sam-
inches) 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), meas-
test 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 per-
an 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 de- the primary receptacle(s). For a suc-
scribed 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) fol-
conditioning period may be reduced to
lowing each impact.
4 hours.
(i) Variations. The following vari-
(g) Where packaging is intended to
contain dry ice, a test additional to ations in the primary receptacles
that specified in paragraph (d) or (e) or placed within the secondary packaging
(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 equiva-
the dry ice dissipates and then be sub- lent level of performance must be
jected to the test described in para- maintained.
graph (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 sub- to the tested primary receptacles may
jected to the tests described in para- be used provided they meet all of the
graph (h)(1) of this section and pack- following 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)(2) 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 pri-
inches), 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
samples 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
must be aimed to impact the primary to prevent significant movement of the
receptacle(s). For a successful test, primary receptacles.
there must be no leakage from the pri- (v) Primary receptacles are oriented
mary receptacle(s) following each im- within the intermediate packaging in
pact. the same manner as in the tested pack-
(2) Samples must be dropped onto the age.
end of a cylindrical steel rod. The rod (2) Variation 2. A lesser number of the
must be set vertically in a level, hard tested primary receptacles, or of the
surface. It must have a diameter of 38 alternative types of primary recep-
mm (1.5 inches) and a radius not ex- tacles identified in paragraph (i)(1) of
wreier-aviles on DSK3TPTVN1PROD with CFR
ceeding 6 mm (0.2 inches) at the edges this section, may be used provided suf-
of the upper end. The rod must pro- ficient cushioning is added to fill the
trude from the surface a distance at void space(s) and to prevent significant
least equal to that between the pri- movement of the primary receptacles.
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Pipeline and Hazardous Materials Safety Admin., DOT 178.702
in the event of leakage must be pro- tion; followed, when specified in an in-
vided. This can be a leakproof liner, dividual section, by a numeral indi-
plastic bag, or other equally effective cating the category of intermediate
means of containment. bulk container.
223
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178.703 49 CFR Ch. I (10111 Edition)
224
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Pipeline and Hazardous Materials Safety Admin., DOT 178.703
(iii) For a rigid plastic IBC con- stack load and with a manufacturers
taining liquids, made from plastic with symbol in place of the manufacturers
structural equipment withstanding the name and address:
(iv) For a composite IBC containing with the symbol of a DOT approved
liquids, with a rigid plastic inner re- third-party test laboratory:
ceptacle and an outer steel body and
ER26JY94.003</GPH>
(b) Additional marking. In addition to used, the metric unit indicated (e.g.,
ER26JY94.002</GPH>
225
ER26JY94.000</GPH>
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178.704 49 CFR Ch. I (10111 Edition)
(iii) Gauge test pressure in kPa; (5) Each flexible IBC may be marked
(iv) Date of last leakproofness test, if with a pictogram displaying rec-
applicable (month and year); and ommended lifting methods.
(v) Date of last inspection (month (6) For each composite IBC, the inner
and year). receptacle must be marked with at
(2) For each metal IBC, the following least the following information:
markings must be included on a metal (i) The code number designating the
corrosion-resistant plate: IBC design type, the name and address
(i) Rated capacity in L of water at 20 or symbol of the manufacturer, the
C (68 F); date of manufacture and the country
(ii) Tare mass in kilograms; authorizing the allocation of the mark
(iii) Date of last leakproofness test, if as specified in paragraph (a) of this sec-
applicable (month and year); tion;
(iv) Date of last inspection (month (ii) When a composite IBC is designed
and year); in such a manner that the outer casing
(v) Maximum loading/discharge pres- is intended to be dismantled for trans-
sure, in kPa, if applicable; port when empty (such as, for the re-
(vi) Body material and its minimum turn of the IBC for reuse to the origi-
thickness in mm; and nal consignor), each of the parts in-
(vii) Serial number assigned by the tended to be detached when so disman-
manufacturer. tled must be marked with the month
(3) Markings required by paragraph and year of manufacture and the name
(b)(1) or (b)(2) of this section may be or symbol of the manufacturer.
preceded by the narrative description (7) The symbol applicable to an IBC
of the marking, e.g. Tare Mass: * * * designed for stacking or not designed
where the * * * are replaced with the for stacking, as appropriate, must be
tare mass in kilograms of the IBC. marked on all IBCs manufactured, re-
(4) For each fiberboard and wooden paired or remanufactured after Janu-
IBC, the tare mass in kg must be ary 1, 2011 as follows:
shown. (i)
cated by the marking in paragraph (a) Each IBC must be resistant to, or
(a)(1)(vii) of this section, divided by 1.8. protected from, deterioration due to
The letters and numbers indicating the exposure to the external environment.
226
ER04JA10.097</GPH>
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Pipeline and Hazardous Materials Safety Admin., DOT 178.705
IBCs intended for solid hazardous ma- tain liquids and solids. Metal IBC types
terials must be sift-proof and water-re- are designated:
sistant. (1) 11A, 11B, 11N for solids that are
(b) All service equipment must be so loaded or discharged by gravity.
positioned or protected as to minimize (2) 21A, 21B, 21N for solids that are
potential loss of contents resulting loaded or discharged at a gauge pres-
from damage during IBC handling and sure greater than 10 kPa (1.45 psig).
transportation. (3) 31A, 31B, 31N for liquids or solids.
(c) Each IBC, including attachments, (b) Definitions for metal IBCs:
and service and structural equipment, (1) Metal IBC means an IBC with a
must be designed to withstand, without metal body, together with appropriate
loss of hazardous materials, the inter- service and structural equipment.
nal pressure of the contents and the (2) Protected means providing the IBC
stresses of normal handling and trans- body with additional external protec-
port. An IBC intended for stacking tion against impact and abrasion. For
must be designed for stacking. Any example, a multi-layer (sandwich) or
lifting or securing features of an IBC double wall construction or a frame
must be of sufficient strength to with- with a metal lattice-work casing.
stand the normal conditions of han- (c) Construction requirements for
dling and transportation without gross metal IBCs are as follows:
distortion or failure and must be posi- (1) Body. The body must be made of
tioned so as to cause no undue stress in ductile metal materials. Welds must be
any part of the IBC. made so as to maintain design type in-
tegrity of the receptacle under condi-
(d) An IBC consisting of a packaging
tions normally incident to transpor-
within a framework must be so con-
tation.
structed that:
(i) The use of dissimilar metals must
(1) The body is not damaged by the not result in deterioration that could
framework; affect the integrity of the body.
(2) The body is retained within the (ii) Aluminum IBCs intended to con-
framework at all times; and tain flammable liquids must have no
(3) The service and structural equip- movable parts, such as covers and clo-
ment are fixed in such a way that they sures, made of unprotected steel liable
cannot be damaged if the connections to rust, which might cause a dangerous
between body and frame allow relative reaction from friction or percussive
expansion or motion. contact with the aluminum.
(e) Bottom discharge valves must be (iii) Metals used in fabricating the
secured in the closed position and the body of a metal IBC must meet the fol-
discharge system suitably protected lowing requirements:
from damage. Valves having lever clo- (A) For steel, the percentage elon-
sures must be secured against acci- gation at fracture must not be less
dental opening. The open or closed po- than 10,000/Rm with a minimum of 20
sition of each valve must be readily ap- percent; where Rm = minimum tensile
parent. For each IBC containing a liq- strength of the steel to be used, in N/
uid, a secondary means of sealing the mm2; if U.S. Standard units of psi are
discharge aperture must also be pro- used for tensile strength then the ratio
vided, e.g., by a blank flange or equiva- becomes 10,000 (145/Rm).
lent device. (B) For aluminum, the percentage
(f) IBC design types must be con- elongation at fracture must not be less
structed in such a way as to be bottom- than 10,000/(6Rm) with an absolute min-
lifted or top-lifted as specified in imum of eight percent; if U.S. Standard
178.811 and 178.812. units of psi are used for tensile
[Amdt. 178103, 59 FR 38068, July 26, 1994, as
strength then the ratio becomes 10,000
amended at 66 FR 45386, Aug. 28, 2001; 68 FR 145 / (6Rm).
61942, Oct. 30, 2003] (C) Specimens used to determine the
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227
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178.705 49 CFR Ch. I (10111 Edition)
Capacity (C) in liters 1 Types 11A, 11B, 11N Types 21A, 21B, 21N, 31A, 31B, 31N
(B) For metals other than the ref- (Rm1) must be the minimum value ac-
erence steel described in paragraph cording to material standards. How-
(c)(1)(iii)(A) of this section, the min- ever, for austenitic (stainless) steels,
imum wall thickness is the greater of the specified minimum value for Rm,
1.5 mm (0.059 inches) or as determined according to the material standards,
by use of the following equivalence for- may be increased by up to 15% when a
mula: greater value is provided in the mate-
rial inspection certificate. When no
FORMULA FOR METRIC UNITS material standard exists for the mate-
rial in question, the value of Rm must
21.4 e 0 be the minimum value indicated in the
e1 = 3 material inspection certificate.
Rm1 A1 (2) Pressure relief. The following pres-
sure relief requirements apply to IBCs
FORMULA FOR U.S. STANDARD intended for liquids:
UNITS
(i) IBCs must be capable of releasing
a sufficient amount of vapor in the
21.4 e 0
e1 = event of fire engulfment to ensure that
3
( Rm1 A1 )/145 no rupture of the body will occur due
to pressure build-up. This can be
where: achieved by spring-loaded or non-re-
e1 = required equivalent wall thickness of the closing pressure relief devices or by
metal to be used (in mm or if eo is in other means of construction.
inches, use formula for U.S. Standard (ii) The start-to-discharge pressure
units). may not be higher than 65 kPa (9 psig)
eo = required minimum wall thickness for
the reference steel (in mm or if eo is in
and no lower than the vapor pressure of
inches, use formula for U.S. Standard the hazardous material plus the partial
units). pressure of the air or other inert gases,
Rm1 = guaranteed minimum tensile strength measured in the IBC at 55 C (131 F),
of the metal to be used (in N/mm2 or for determined on the basis of a maximum
U.S. Standard units, use psi). degree of filling as specified in
A1 = minimum elongation (as a percentage)
173.35(d) of this subchapter. This does
of the metal to be used on fracture under
tensile stress (see paragraph (c)(1) of this not apply to fusible devices unless such
section). devices are the only source of pressure
relief for the IBC. Pressure relief de-
wreier-aviles on DSK3TPTVN1PROD with CFR
228
EP26JN96.000</MATH>
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Pipeline and Hazardous Materials Safety Admin., DOT 178.707
(793 gallons) or less than 450 L (119 gal- content or the inhibitor content do not
lons). adversely affect the physical properties
of the material of construction.
[Amdt. 178103, 59 FR 38068, July 26, 1994, as
amended by Amdt. 178108, 60 FR 40038, Aug. (2) Additives may be included in the
4, 1995; Amdt. 178117, 61 FR 50629, Sept. 26, composition of the plastic material to
1996; 66 FR 33452, June 21, 2001; 66 FR 45386, improve the resistance to aging or to
45387, Aug. 28, 2001; 68 FR 45041, July 31, 2003; serve other purposes, provided they do
75 FR 5396, Feb. 2, 2010] not adversely affect the physical or
chemical properties of the material of
178.706 Standards for rigid plastic construction.
IBCs. (3) No used material other than pro-
(a) The provisions in this section duction residues or regrind from the
apply to rigid plastic IBCs intended to same manufacturing process may be
contain solids or liquids. Rigid plastic used in the manufacture of rigid plastic
IBC types are designated: IBCs.
(1) 11H1 fitted with structural equip- (4) Rigid plastic IBCs intended for the
ment designed to withstand the whole transportation of liquids must be capa-
load when IBCs are stacked, for solids ble of releasing a sufficient amount of
which are loaded or discharged by grav- vapor to prevent the body of the IBC
ity. from rupturing if it is subjected to an
(2) 11H2 freestanding, for solids which internal pressure in excess of that for
are loaded or discharged by gravity. which it was hydraulically tested. This
(3) 21H1 fitted with structural equip- may be achieved by spring-loaded or
ment designed to withstand the whole non-reclosing pressure relief devices or
load when IBCs are stacked, for solids by other means of construction.
which are loaded or discharged under (d) Rigid plastic IBCs may not have a
pressure. volumetric capacity greater than 3,000
(4) 21H2 freestanding, for solids which L (793 gallons) or less than 450 L (119
are loaded or discharged under pres- gallons).
sure. [Amdt. 178103, 59 FR 38068, July 26, 1994, as
(5) 31H1 fitted with structural equip- amended at 66 FR 45386, 45387, Aug. 28, 2001;
ment designed to withstand the whole 75 FR 5396, Feb. 2, 2010]
load when IBCs are stacked, for liquids.
(6) 31H2 freestanding, for liquids. 178.707 Standards for composite
(b) Rigid plastic IBCs consist of a IBCs.
rigid plastic body, which may have (a) The provisions in this section
structural equipment, together with apply to composite IBCs intended to
appropriate service equipment. contain solids and liquids. To complete
(c) Rigid plastic IBCs must be manu- the marking codes listed below, the
factured from plastic material of letter Z must be replaced by a cap-
known specifications and be of a ital letter in accordance with
strength relative to its capacity and to 178.702(a)(2) to indicate the material
the service it is required to perform. In used for the outer packaging. Com-
addition to conformance to 173.24 of posite IBC types are designated:
this subchapter, plastic materials must (1) 11HZ1 Composite IBCs with a rigid
be resistant to aging and to degrada- plastic inner receptacle for solids load-
tion caused by ultraviolet radiation. ed or discharged by gravity.
(1) If protection against ultraviolet (2) 11HZ2 Composite IBCs with a
radiation is necessary, it must be pro- flexible plastic inner receptacle for sol-
vided by the addition of a pigment or ids loaded or discharged by gravity.
inhibiter such as carbon black. These (3) 21HZ1 Composite IBCs with a rigid
additives must be compatible with the plastic inner receptacle for solids load-
contents and remain effective through- ed or discharged under pressure.
out the life of the IBC body. Where use (4) 21HZ2 Composite IBCs with a
is made of carbon black, pigments or flexible plastic inner receptacle for sol-
wreier-aviles on DSK3TPTVN1PROD with CFR
inhibitors, other than those used in the ids loaded or discharged under pres-
manufacture of the tested design type, sure.
retesting may be omitted if changes in (5) 31HZ1 Composite IBCs with a rigid
the carbon black content, the pigment plastic inner receptacle for liquids.
229
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178.707 49 CFR Ch. I (10111 Edition)
230
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Pipeline and Hazardous Materials Safety Admin., DOT 178.708
cut, sliced, or sawn veneer, commer- ance 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 pal-
glued 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.
equipment of the outer packaging. (i) The pallet or integral base must
Outer packagings must be firmly be designed to avoid protrusions that
nailed or secured to corner posts or may cause damage to the IBC in han-
ends or be assembled by equally suit- dling.
able devices.
(ii) The outer packaging must be se-
(iii) Outer packagings of reconsti-
cured to any detachable pallet to en-
tuted wood must be constructed of
sure stability in handling and transpor-
water-resistant reconstituted wood
tation. Where a detachable pallet is
such as hardboard or particle board.
used, its top surface must be free from
Materials other than reconstituted
wood may be used for the construction sharp protrusions that might damage
of structural equipment of reconsti- the IBC.
tuted wood outer packaging. (iii) Strengthening devices, such as
(iv) Fiberboard outer packagings timber supports to increase stacking
must be constructed of strong, solid, or performance, may be used but must be
double-faced corrugated fiberboard external to the inner receptacle.
(single or multiwall). (iv) The load-bearing surfaces of IBCs
(A) Water resistance of the outer sur- intended for stacking must be designed
face must be such that the increase in to distribute loads in a stable manner.
mass, as determined in a test carried An IBC intended for stacking must be
out over a period of 30 minutes by the designed so that loads are not sup-
Cobb method of determining water ab- ported by the inner receptacle.
sorption, is not greater than 155 grams (6) Intermediate IBCs of type 31HZ2
per square meter (0.0316 pounds per must be limited to a capacity of not
square foot)see ISO 535 (E) (IBR, see more than 1,250 L.
171.7 of this subchapter). Fiberboard (d) Composite IBCs may not have a
must have proper bending qualities. Fi- volumetric capacity greater than 3,000
berboard must be cut, creased without L (793 gallons) or less than 450 L (119
cutting through any thickness of fiber- gallons).
board, and slotted so as to permit as-
sembly without cracking, surface [Amdt. 178103, 59 FR 38068, July 26, 1994, as
breaks, or undue bending. The fluting amended by Amdt. 178119, 62 FR 24743, May
of corrugated fiberboard must be firm- 6, 1997; 66 FR 45387, Aug. 28, 2001; 67 FR 61016,
ly glued to the facings. Sept. 27, 2002; 68 FR 75758, Dec. 31, 2003; 69 FR
54046, Sept. 7, 2004; 75 FR 5396, Feb. 2, 2010]
(B) The ends of fiberboard outer
packagings may have a wooden frame 178.708 Standards for fiberboard
or be constructed entirely of wood. IBCs.
Wooden battens may be used for rein-
forcements. (a) The provisions of this section
(C) Manufacturers joints in the bod- apply to fiberboard IBCs intended to
ies of outer packagings must be taped, contain solids that are loaded or dis-
lapped and glued, or lapped and charged by gravity. Fiberboard IBCs
stitched with metal staples. are designated: 11G.
(D) Lapped joints must have an ap- (b) Definitions for fiberboard IBC
propriate overlap. types:
(E) Where closing is effected by glu- (1) Fiberboard IBCs consist of a fiber-
ing or taping, a water-resistant adhe- board body with or without separate
wreier-aviles on DSK3TPTVN1PROD with CFR
231
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178.709 49 CFR Ch. I (10111 Edition)
(2) Liner means a separate tube or ical handling of an IBC filled to its
bag, including the closures of its open- maximum permissible gross mass.
ings, inserted in the body but not form- (i) The pallet or integral base must
ing an integral part of it. be designed to avoid protrusions that
(c) Construction requirements for fi- may cause damage to the IBC in han-
berboard IBCs are as follows: dling.
(1) Top lifting devices are prohibited (ii) The outer packaging must be se-
in fiberboard IBCs. cured to any detachable pallet to en-
(2) Fiberboard IBCs must be con- sure stability in handling and trans-
structed of strong, solid or double- port. Where a detachable pallet is used,
faced corrugated fiberboard (single or its top surface must be free from sharp
multiwall) that is appropriate to the protrusions that might damage the
capacity of the outer packaging and its IBC.
intended use. Water resistance of the (iii) Strengthening devices, such as
timber supports to increase stacking
outer surface must be such that the in-
performance, may be used but must be
crease in mass, as determined in a test
external to the inner liner.
carried out over a period of 30 minutes
(iv) The load-bearing surfaces of IBCs
by the Cobb method of determining
intended for stacking must be designed
water absorption, is not greater than
to distribute loads in a stable manner.
155 grams per square meter (0.0316
(d) Fiberboard IBCs may not have a
pounds per square foot)see ISO 535 (E) volumetric capacity greater than 3,000
(IBR, see 171.7 of this subchapter). Fi- L (793 gallons) or less than 450 L (119
berboard must have proper bending gallons).
qualities. Fiberboard must be cut,
creased without cutting through any [Amdt. 178103, 59 FR 38068, July 26, 1994, as
thickness of fiberboard, and slotted so amended at 66 FR 45386, Aug. 28, 2001; 68 FR
75758, Dec. 31, 2003; 75 FR 5396, Feb. 2, 2010]
as to permit assembly without crack-
ing, surface breaks, or undue bending. 178.709 Standards for wooden IBCs.
The fluting of corrugated fiberboard
must be firmly glued to the facings. (a) The provisions in this section
apply to wooden IBCs intended to con-
(i) The walls, including top and bot-
tain solids that are loaded or dis-
tom, must have a minimum puncture
charged by gravity. Wooden IBC types
resistance of 15 Joules (11 foot-pounds
are designated:
of energy) measured according to ISO
(1) 11C Natural wood with inner liner.
3036 (IBR, see 171.7 of this subchapter). (2) 11D Plywood with inner liner.
(ii) Manufacturers joints in the bod- (3) 11F Reconstituted wood with
ies of IBCs must be made with an ap- inner liner.
propriate overlap and be taped, glued, (b) Definitions for wooden IBCs:
stitched with metal staples or fastened (1) Wooden IBCs consist of a rigid or
by other means at least equally effec- collapsible wooden body together with
tive. Where joints are made by gluing an inner liner (but no inner packaging)
or taping, a water-resistant adhesive and appropriate service and structural
must be used. Metal staples must pass equipment.
completely through all pieces to be fas- (2) Liner means a separate tube or
tened and be formed or protected so bag, including the closures of its open-
that any inner liner cannot be abraded ings, inserted in the body but not form-
or punctured by them. ing an integral part of it.
(3) The strength of the material used (c) Construction requirements for
and the construction of the liner must wooden IBCs are as follows:
be appropriate to the capacity of the (1) Top lifting devices are prohibited
IBC and the intended use. Joints and in wooden IBCs.
closures must be sift-proof and capable (2) The strength of the materials used
of withstanding pressures and impacts and the method of construction must
liable to occur under normal conditions be appropriate to the capacity and in-
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232
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Pipeline and Hazardous Materials Safety Admin., DOT 178.710
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 (d) Wooden IBCs may not have a vol-
other methods at least equally effec- umetric capacity greater than 3,000 L
tive are used). Materials other than (793 gallons) or less than 450 L (119 gal-
natural wood may be used for the con- lons).
struction of structural equipment of [Amdt. 178103, 59 FR 38068, July 26, 1994, as
the outer packaging. amended at 66 FR 45386, Aug. 28, 2001; 75 FR
(ii) Plywood used in construction of 5397, Feb. 2, 2010]
bodies must be at least 3-ply. Plywood
must be made of well-seasoned, rotary- 178.710 Standards for flexible IBCs.
cut, sliced or sawn veneer, commer- (a) The provisions of this section
cially dry, and free from defects that apply to flexible IBCs intended to con-
would materially lessen the strength of tain solid hazardous materials. Flexi-
the body. All adjacent plies must be ble IBC types are designated:
glued with water-resistant adhesive. (1) 13H1 woven plastic without coat-
Materials other than plywood may be ing or liner.
used for the construction of structural (2) 13H2 woven plastic, coated.
equipment of the outer packaging. (3) 13H3 woven plastic with liner.
(iii) Reconstituted wood used in con- (4) 13H4 woven plastic, coated and
struction of bodies must be water re- with liner.
sistant reconstituted wood such as (5) 13H5 plastic film.
hardboard or particle board. Materials (6) 13L1 textile without coating or
other than reconstituted wood may be liner.
used for the construction of structural (7) 13L2 textile, coated.
equipment of the outer packaging. (8) 13L3 textile with liner.
(iv) Wooden IBCs must be firmly (9) 13L4 textile, coated and with
nailed or secured to corner posts or liner.
ends or be assembled by similar de- (10) 13M1 paper, multiwall.
vices. (11) 13M2 paper, multiwall, water re-
(3) The strength of the material used sistant.
and the construction of the liner must (b) Definitions for flexible IBCs:
be appropriate to the capacity of the (1) Flexible IBCs consist of a body con-
IBC and its intended use. Joints and structed of film, woven plastic, woven
closures must be sift-proof and capable fabric, paper, or combination thereof,
of withstanding pressures and impacts together with any appropriate service
liable to occur under normal conditions equipment and handling devices, and if
of handling and transportation. necessary, an inner coating or liner.
(4) Any integral pallet base forming (2) Woven plastic means a material
part of an IBC, or any detachable pal- made from stretched tapes or
let, must be suitable for the mechan- monofilaments.
ical handling of an IBC filled to its (3) Handling device means any sling,
maximum permissible gross mass. loop, eye, or frame attached to the
(i) The pallet or integral base must body of the IBC or formed from a con-
be designed to avoid protrusions that tinuation of the IBC body material.
may cause damage to the IBC in han- (c) Construction requirements for
dling. flexible IBCs are as follows:
wreier-aviles on DSK3TPTVN1PROD with CFR
(ii) The outer packaging must be se- (1) The strength of the material and
cured to any detachable pallet to en- the construction of the flexible IBC
sure stability in handling and transpor- must be appropriate to its capacity and
tation. Where a detachable pallet is its intended use.
233
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178.800 49 CFR Ch. I (10111 Edition)
(2) All materials used in the con- (2) Must be designed and tested to a
struction of flexible IBCs of types 13M1 capacity of no less than 50 kg (110
and 13M2 must, after complete immer- pounds).
sion in water for not less than 24 hours, [Amdt. 178103, 59 FR 38068, July 26, 1994, as
retain at least 85 percent of the tensile amended by Amdt. 178108, 60 FR 40038, Aug.
strength as measured originally on the 4, 1995; 66 FR 45386, Aug. 28, 2001; 75 FR 5397,
material conditioned to equilibrium at Feb. 2, 2010]
67 percent relative humidity or less.
(3) Seams must be stitched or formed Subpart OTesting of IBCs
by heat sealing, gluing or any equiva-
lent method. All stitched seam-ends 178.800 Purpose and scope.
must be secured. This subpart prescribes certain test-
(4) In addition to conformance with ing requirements for IBCs identified in
the requirements of 173.24 of this sub- subpart N of this part.
chapter, flexible IBCs must be resistant [Amdt. 178103, 59 FR 38074, July 26, 1994, as
to aging and degradation caused by ul- amended by 66 FR 45386, Aug. 28, 2001]
traviolet radiation.
(5) For plastic flexible IBCs, if nec- 178.801 General requirements.
essary, protection against ultraviolet (a) General. The test procedures pre-
radiation must be provided by the addi- scribed in this subpart are intended to
tion of pigments or inhibitors such as ensure that IBCs containing hazardous
carbon black. These additives must be materials can withstand normal condi-
compatible with the contents and re- tions of transportation and are consid-
main effective throughout the life of ered minimum requirements. Each
the container. Where use is made of packaging must be manufactured and
carbon black, pigments, or inhibitors, assembled so as to be capable of suc-
other than those used in the manufac- cessfully passing the prescribed tests
ture of the tested design type, re- and of conforming to the requirements
testing may be omitted if the carbon of 173.24 of this subchapter at all
times while in transportation.
black content, the pigment content or
(b) Responsibility. It is the responsi-
the inhibitor content does not ad-
bility of the IBC manufacturer to as-
versely affect the physical properties
sure that each IBC is capable of passing
of the material of construction. Addi- the prescribed tests. To the extent that
tives may be included in the composi- an IBC assembly function, including
tion of the plastic material to improve final closure, is performed by the per-
resistance to aging, provided they do son who offers a hazardous material for
not adversely affect the physical or transportation, that person is respon-
chemical properties of the material. sible for performing the function in ac-
(6) No used material other than pro- cordance with 173.22 and 178.2 of this
duction residues or regrind from the subchapter.
same manufacturing process may be (c) Definitions. For the purpose of this
used in the manufacture of plastic subpart:
flexible IBCs. This does not preclude (1) IBC design type refers to an IBC
the re-use of component parts such as that does not differ in structural de-
fittings and pallet bases, provided such sign, size, material of construction,
components have not in any way been wall thickness, manner of construction
damaged in previous use. and representative service equipment.
(7) When flexible IBCs are filled, the (2) Design qualification testing is the
ratio of height to width may not be performance of the drop, leakproofness,
more than 2:1. hydrostatic pressure, stacking, bot-
tom-lift or top-lift, tear, topple, right-
(d) Flexible IBCs: (1) May not have a
ing and vibration tests, as applicable,
volumetric capacity greater than 3,000
prescribed in this subpart, for each dif-
wreier-aviles on DSK3TPTVN1PROD with CFR
L (793 gallons) or less than 56 L (15 gal- ferent IBC design type, at the start of
lons); and production of that packaging.
(3) Periodic design requalification test is
the performance of the applicable tests
234
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Pipeline and Hazardous Materials Safety Admin., DOT 178.801
specified in paragraph (c)(2) of this sec- shall achieve successful test results for
tion on an IBC design type, in order to the periodic design requalification at
requalify the design for continued pro- sufficient frequency to ensure each
duction at the frequency specified in packaging produced by the manufac-
paragraph (e) of this section. turer is capable of passing the design
(4) Production inspection is the inspec- qualification tests. Design requalifica-
tion 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 ac- requalification testing specified in
cordance with paragraph (f) of this sec- paragraph (e)(1) of this section are au-
tion 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 pro-
formance of the applicable test and in- grams that assure that proposed de-
spections 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, except that the IBC must be
thicknesses or fabric weight remain fitted with its primary bottom closure.
the same; (ii) The inner receptacle of a com-
(iv) A packaging which differs in posite IBC may be tested without the
service equipment. outer IBC body, provided the test re-
(d) Design qualification testing. The sults are not affected.
packaging manufacturer shall achieve (2) Applicable inspection require-
successful test results for the design ments in 180.352 of this subchapter
qualification testing at the start of must be performed on each IBC ini-
production of each new or different IBC tially after production.
design type. The service equipment se- (g) Test samples. The IBC manufac-
lected for this design qualification turer shall conduct the design quali-
testing shall be representative of the fication and periodic design requali-
type of service equipment that will be fication tests prescribed in this subpart
fitted to any finished IBC body under using random samples of IBCs, accord-
the design. Application of the certifi- ing to the appropriate test section.
cation mark by the manufacturer shall (h) Selective testing of IBCs. Variation
constitute certification that the IBC of a tested IBC design type is permitted
design type passed the prescribed tests without further testing, provided selec-
in this subpart. tive testing demonstrates an equiva-
(e) Periodic design requalification test- lent or greater level of safety than the
ing. (1) Periodic design requalification design type tested and which has been
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178.802 49 CFR Ch. I (10111 Edition)
subpart N of this part, or tested using tive service equipment, etc.); max-
methods other than those specified in imum IBC capacity; characteristics of
this subpart, may be used if approved test contents; test descriptions and re-
by the Associate Administrator. Such sults (including drop heights, hydro-
IBCs must be shown to be equally effec- static pressures, tear propagation
tive, and testing methods used must be length, etc.). Each test report must be
equivalent. signed with the name of the person
(j) Proof of compliance. Notwith- conducting the test, and name of the
standing the periodic design requali- person responsible for testing.
fication testing intervals specified in (2) The person who certifies each IBC
paragraph (e) of this section, the Asso- must make all records of design quali-
ciate Administrator, or a designated fication tests and periodic design re-
representative, may at any time re- qualification tests available for inspec-
quire demonstration of compliance by tion by a representative of the Depart-
a manufacturer, through testing in ac- ment upon request.
cordance with this subpart, that pack-
[Amdt. 178103, 59 FR 38074, July 26, 1994, as
agings meet the requirements of this
amended by Amdt. 178108, 60 FR 40038, Aug.
subpart. As required by the Associate 4, 1995; 66 FR 45386, Aug. 28, 2001; 66 FR 33452,
Administrator, or a designated rep- June 21, 2001; 68 FR 75758, Dec. 31, 2003; 73 FR
resentative, the manufacturer shall ei- 57008, Oct. 1, 2008; 74 FR 2269, Jan. 14, 2009; 75
ther: FR 5397, Feb. 2, 2010]
(1) Conduct performance tests or
have tests conducted by an inde- 178.802 Preparation of fiberboard
pendent testing facility, in accordance IBCs for testing.
with this subpart; or (a) Fiberboard IBCs and composite
(2) Make a sample IBC available to IBCs with fiberboard outer packagings
the Associate Administrator, or a des- must be conditioned for at least 24
ignated representative, for testing in hours in an atmosphere maintained:
accordance with this subpart. (1) At 50 percent 2 percent relative
(k) Coatings. If an inner treatment or humidity, and at a temperature of 23
coating of an IBC is required for safety 2 C (73 F 4 F); or
reasons, the manufacturer shall design (2) At 65 percent 2 percent relative
the IBC so that the treatment or coat- humidity, and at a temperature of 20
ing retains its protective properties 2 C (68 F 4 F), or 27 C 2 C (81 F
even after withstanding the tests pre- 4 F).
scribed by this subpart. (b) Average values for temperature
(l) Record retention. (1) The person and humidity must fall within the lim-
who certifies an IBC design type shall its in paragraph (a) of this section.
keep records of design qualification Short-term fluctuations and measure-
tests for each IBC design type and for ment limitations may cause individual
each periodic design requalification as measurements to vary by up to 5 per-
specified in this part. These records cent relative humidity without signifi-
must be maintained at each location cant impairment of test reproduc-
where the IBC is manufactured and at ibility.
each location where design qualifica-
(c) For purposes of periodic design re-
tion and periodic design requalification
qualification only, fiberboard IBCs or
testing is performed. These records
composite IBCs with fiberboard outer
must be maintained for as long as IBCs
packagings may be at ambient condi-
are manufactured in accordance with
tions.
each qualified design type and for at
least 2.5 years thereafter. These [Amdt. 178103, 59 FR 38074, July 26, 1994, as
records must include the following in- amended at 66 FR 45386, Aug. 28, 2001]
formation: name and address of test fa-
cility; name and address of the person 178.803 Testing and certification of
certifying the IBC; a unique test report IBCs.
wreier-aviles on DSK3TPTVN1PROD with CFR
identification; date of test report; man- Tests required for the certification of
ufacturer of the IBC; description of the each IBC design type are specified in
IBC design type (e.g., dimensions, ma- the following table. The letter X indi-
terials, closures, thickness, representa- cates that one IBC (except where
236
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Pipeline and Hazardous Materials Safety Admin., DOT 178.810
Hydrostatic .................... 3 X 3 X 3 X
Drop ............................... 4 X 4 X 4 X 4 X 4 X 5 X
Topple ........................... 5 X
Righting ......................... 2,5 X
Tear ............................... 5 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 lift tests must be performed.
3 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 be-
fore October 1, 1994 and for non-DOT specification portable tanks tested before October 1, 1994, intended for export.
7 This test must be performed only if the IBC is designed to be stacked.
[Amdt. 178108, 60 FR 40039, Aug. 4, 1995, as amended at 64 FR 51919, Sept. 27, 1999; 66 FR 45386,
45390, Aug. 28, 2001]
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178.811 49 CFR Ch. I (10111 Edition)
(3) The specific gravity and viscosity the dimension of the side of entry (un-
of a substituted non-hazardous mate- less the points of entry are fixed). The
rial used in the drop test for liquids forks must penetrate to three quarters
must be similar to the hazardous mate- of the direction of entry. The test must
rial intended for transportation. Water be repeated from each possible direc-
also may be used for the liquid drop tion of entry.
test under the following conditions: (d) Criteria for passing the test. For all
(i) Where the substances to be carried IBC design types designed to be lifted
have a specific gravity not exceeding from the base, there may be no perma-
1.2, the drop heights must be those nent deformation which renders the
specified in paragraph (d)(1) of this sec- IBC unsafe for transportation and no
tion for each IBC design type; and loss of contents.
(ii) Where the substances to be car- [Amdt. 178103, 59 FR 38074, July 26, 1994, as
ried have a specific gravity exceeding amended at 66 FR 45386, Aug. 28, 2001]
1.2, the drop heights must be as fol-
lows: 178.812 Top lift test.
(A) Packing Group I: SG 1.5 m (4.9 (a) General. The top lift test must be
feet). conducted for the qualification of all
(B) Packing Group II: SG 1.0 m (3.3 IBC design types designed to be lifted
feet). from the top or, for flexible IBCs, from
(C) Packing Group III: SG 0.67 m the side.
(2.2 feet). (b) Special preparation for the top lift
(e) Criteria for passing the test. For all test. (1) Metal, rigid plastic, and com-
IBC design types, there may be no dam- posite IBC design types must be loaded
age which renders the IBC unsafe to be to twice the maximum permissible
transported for salvage or for dispos- gross mass with the load being evenly
able, and no loss of contents. The IBC distributed.
shall be capable of being lifted by an (2) Flexible IBC design types must be
appropriate means until clear of the filled to six times the maximum net
floor for five minutes. A slight dis- mass, the load being evenly distrib-
charge from a closure upon impact is uted.
not considered to be a failure of the (c) Test method. (1) A metal or flexible
IBC provided that no further leakage IBC must be lifted in the manner for
occurs. A slight discharge (e.g., from which it is designed until clear of the
closures or stitch holes) upon impact is floor and maintained in that position
not considered a failure of the flexible for a period of five minutes.
IBC provided that no further leakage (2) Rigid plastic and composite IBC
occurs after the IBC has been raised design types must be:
clear of the ground. (i) Lifted by each pair of diagonally
[Amdt. 178103, 59 FR 38074, July 26, 1994, as opposite lifting devices, so that the
amended at 66 FR 45386, Aug. 28, 2001; 69 FR hoisting forces are applied vertically,
76186, Dec. 20, 2004; 71 FR 78635, Dec. 29, 2006; for a period of five minutes; and
74 FR 2269, Jan. 14, 2009; 75 FR 5397, Feb. 2, (ii) Lifted by each pair of diagonally
2010] opposite lifting devices, so that the
hoisting forces are applied towards the
178.811 Bottom lift test. center at 45 to the vertical, for a pe-
(a) General. The bottom lift test must riod of five minutes.
be conducted for the qualification of (3) If not tested as indicated in para-
all IBC design types designed to be lift- graph (c)(1) of this section, a flexible
ed from the base. IBC design type must be tested as fol-
(b) Special preparation for the bottom lows:
lift test. The IBC must be loaded to 1.25 (i) Fill the flexible IBC to 95% full
times its maximum permissible gross with a material representative of the
mass, the load being evenly distrib- product to be shipped.
uted. (ii) Suspend the flexible IBC by its
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Pipeline and Hazardous Materials Safety Admin., DOT 178.814
and a maximum of 80% of the cross sec- tain solids that are loaded or dis-
tional 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 leak-
the filled flexible IBC and the force ap- age of air from the IBC.
plied through the platen must be a [Amdt. 178103, 59 FR 38074, July 26, 1994, as
minimum of six times the maximum amended at 64 FR 10782, Mar. 5, 1999; 66 FR
net mass of the flexible IBC. The test 45185, 45386, Aug. 28, 2001]
must be conducted for a period of five
minutes. 178.814 Hydrostatic pressure test.
(v) Other equally effective methods (a) General. The hydrostatic pressure
of top lift testing and preparation may test must be conducted for the quali-
be used with approval of the Associate fication of all metal, rigid plastic, and
Administrator. composite IBC design types intended to
(d) Criteria for passing the test. For all contain solids that are loaded or dis-
IBC design types designed to be lifted charged under pressure or intended to
from the top, there may be no perma- contain liquids.
nent deformation which renders the (b) Special preparation for the hydro-
IBC, including the base pallets when static pressure test. For metal IBCs, the
applicable, unsafe for transportation, test must be carried out before the fit-
and no loss of contents. ting of any thermal insulation equip-
[Amdt. 178103, 59 FR 38074, July 26, 1994, as ment. For all IBCs, pressure relief de-
amended at 66 FR 33452, June 21, 2001; 66 FR vices and vented closures must be re-
45386, Aug. 28, 2001; 68 FR 45042, July 31, 2003] moved and their apertures plugged or
rendered inoperative.
178.813 Leakproofness test. (c) Test method. Hydrostatic gauge
(a) General. The leakproofness test pressure must be measured at the top
must be conducted for the qualification of the IBC. The test must be carried
of all IBC design types and on all pro- out for a period of at least 10 minutes
duction units intended to contain sol- applying a hydrostatic gauge pressure
ids that are loaded or discharged under not less than that indicated in para-
pressure or intended to contain liquids. graph (d) of this section. The IBCs may
(b) Special preparation for the not be mechanically restrained during
leakproofness test. Vented closures must the test.
either be replaced by similar non-vent- (d) Hydrostatic gauge pressure applied.
ed closures or the vent must be sealed. (1) For metal IBC design types, 31A,
For metal IBC design types, the initial 31B, 31N: 65 kPa gauge pressure (9.4
test must be carried out before the fit- psig).
ting of any thermal insulation equip- (2) For metal IBC design types 21A,
ment. The inner receptacle of a com- 21B, 21N, 31A, 31B, 31N: 200 kPa (29
posite IBC may be tested without the psig). For metal IBC design types 31A,
outer packaging provided the test re- 31B and 31N, the tests in paragraphs
sults are not affected. (d)(1) and (d)(2) of this section must be
(c) Test method and pressure applied. conducted consecutively.
The leakproofness test must be carried (3) For metal IBCs design types 21A,
out for a suitable length of time using 21B, and 21N, for Packing Group I sol-
air at a gauge pressure of not less than ids: 250 kPa (36 psig) gauge pressure.
20 kPa (2.9 psig). Leakproofness of IBC (4) For rigid plastic IBC design types
design types must be determined by 21H1 and 21H2 and composite IBC de-
coating the seams and joints with a sign types 21HZ1 and 21HZ2: 75 kPa (11
heavy oil, a soap solution and water, or psig).
other methods suitable for the purpose (5) For rigid plastic IBC design types
of detecting leaks. Other methods, if at 31H1 and 31H2 and composite IBC de-
least equally effective, may be used in sign types 31HZ1 and 31HZ2: whichever
accordance with appendix B of this is the greater of:
part, or if approved by the Associate (i) The pressure determined by any
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178.815 49 CFR Ch. I (10111 Edition)
(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 ca- not 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 pres- load being evenly distributed.
sure of the hazardous material plus at- (c) Test method. (1) Design Qualifica-
mospheric pressure) is used, 1.5 multi- tion Testing. All IBCs must be placed on
plied by the vapor pressure of the haz- their base on level, hard ground and
ardous material at 55 C (131 F) minus subjected to a uniformly distributed
100 kPa (14.5 psi). If this method is cho- superimposed test load for a period of
sen, the hydrostatic test pressure ap- at least five minutes (see paragraph
plied must be at least 100 kPa gauge (c)(5) of this section).
pressure (14.5 psig); or (2) Fiberboard, wooden and composite
(C) If absolute pressure (vapor pres- IBCs with outer packagings con-
sure of the hazardous material plus at- structed of other than plastic mate-
mospheric pressure) is used, 1.75 multi- rials must be subject to the test for 24
plied by the vapor pressure of the haz- hours.
ardous material at 50 C (122 F) minus (3) Rigid plastic IBC types and com-
100 kPa (14.5 psi). If this method is cho- posite IBC types with plastic outer
sen, the hydrostatic test pressure ap- packagings (11HH1, 11HH2, 21HH1,
plied must be at least 100 kPa gauge 21HH2, 31HH1 and 31HH2) which bear
pressure (14.5 psig); or the stacking load must be subjected to
(ii) Twice the greater of: (A) The the test for 28 days at 40 C (104 F).
static pressure of the hazardous mate- (4) For all IBCs, the load must be ap-
rial on the bottom of the IBC filled to plied by one of the following methods:
98 percent capacity; or (i) One or more IBCs of the same type
(B) The static pressure of water on loaded to their maximum permissible
the bottom of the IBC filled to 98 per- gross mass and stacked on the test
cent capacity. IBC;
(e) Criteria for passing the test(s). (1) (ii) The calculated superimposed test
For metal IBCs, subjected to the 65 load weight loaded on either a flat
kPa (9.4 psig) test pressure specified in plate or a reproduction of the base of
paragraph (d)(1) of this section, there the IBC, which is stacked on the test
may be no leakage or permanent defor- IBC.
mation that would make the IBC un- (5) Calculation of superimposed test
safe for transportation. load. For all IBCs, the load to be placed
(2) For metal IBCs intended to con- on the IBC must be 1.8 times the com-
tain liquids, when subjected to the 200 bined maximum permissible gross mass
kPa (29 psig) and the 250 kPa (36 psig) of the number of similar IBCs that may
test pressures specified in paragraphs be stacked on top of the IBC during
(d)(2) and (d)(3) of this section, respec- transportation.
tively, there may be no leakage. (d) Periodic Retest. (1) The package
(3) For rigid plastic IBC types 21H1, must be tested in accordance with
21H2, 31H1, and 31H2, and composite paragraph (c) of this section; or
IBC types 21HZ1, 21HZ2, 31HZ1, and (2) The packaging may be tested
31HZ2, there may be no leakage and no using a dynamic compression testing
permanent deformation which renders machine. The test must be conducted
the IBC unsafe for transportation. at room temperature on an empty, un-
[Amdt. 178103, 59 FR 38074, July 26, 1994, as sealed packaging. The test sample
amended at 66 FR 45185, 45386, Aug. 28, 2001] must be centered on the bottom platen
of the testing machine. The top platen
178.815 Stacking test. must be lowered until it comes in con-
(a) General. The stacking test must tact with the test sample. Compression
be conducted for the qualification of must be applied end to end. The speed
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all IBC design types intended to be of the compression tester must be one-
stacked. half inch plus or minus one-fourth inch
(b) Special preparation for the stacking per minute. An initial preload of 50
test. (1) All IBCs except flexible IBC de- pounds must be applied to ensure a
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Pipeline and Hazardous Materials Safety Admin., DOT 178.818
definite contact between the test sam- not less than 95 percent of its capacity
ple and the platens. The distance be- and to its maximum net mass, with the
tween the platens at this time must be load being evenly distributed.
recorded as zero deformation. The force (c) Test method. A flexible IBC must
A then to be applied must be cal- be toppled onto any part of its top
culated using the applicable formula: upon a rigid, non-resilient, smooth,
Liquids: A = (1.8)(n 1) [w + (s v 8.3 flat, and horizontal surface.
.98)] 1.5; (d) Topple height. For all flexible
IBCs, the topple height is specified as
or follows:
Solids: A = (1.8)(n 1) [w + (s v 8.3 (1) Packing Group I: 1.8 m (5.9 feet).
.95)] 1.5 (2) Packing Group II: 1.2 m (3.9 feet).
(3) Packing Group III: 0.8 m (2.6 feet).
Where:
(e) Criteria for passing the test. For all
A = applied load in pounds.
n = maximum number of IBCs being stacked
flexible IBCs, there may be no loss of
during transportation. contents. A slight discharge (e.g., from
w = maximum weight of one empty container closures or stitch holes) upon impact is
in pounds. not considered to be a failure, provided
s = specific gravity (liquids) or density (sol- no further leakage occurs.
ids) of the lading.
v = actual capacity of container (rated ca- [Amdt. 178103, 59 FR 38074, July 26, 1994, as
pacity + outage) in gallons. amended at 66 FR 45386, Aug. 28, 2001]
and:
8.3 corresponds to the weight in pounds of 1.0 178.817 Righting test.
gallon of water. (a) General. The righting test must be
1.5 is a compensation factor converting the conducted for the qualification of all
static load of the stacking test into a load
flexible IBCs designed to be lifted from
suitable for dynamic compression testing.
the top or side.
(e) Criteria for passing the test. (1) For (b) Special preparation for the righting
metal, rigid plastic, and composite test. The flexible IBC must be filled to
IBCs, there may be no permanent de- not less than 95 percent of its capacity
formation, which renders the IBC un- and to its maximum net mass, with the
safe for transportation, and no loss of load being evenly distributed.
contents. (c) Test method. The flexible IBC,
(2) For fiberboard and wooden IBCs, lying on its side, must be lifted at a
there may be no loss of contents and no speed of at least 0.1 m/second (0.33 ft/s)
permanent deformation, which renders to an upright position, clear of the
the whole IBC, including the base pal- floor, by one lifting device, or by two
let, unsafe for transportation. lifting devices when four are provided.
(3) For flexible IBCs, there may be no (d) Criterion for passing the test. For
deterioration, which renders the IBC all flexible IBCs, there may be no dam-
unsafe for transportation, and no loss age to the IBC or its lifting devices
of contents. which renders the IBC unsafe for trans-
(4) For the dynamic compression portation or handling.
test, a container passes the test if,
[Amdt. 178103, 59 FR 38074, July 26, 1994, as
after application of the required load,
amended at 66 FR 45386, Aug. 28, 2001]
there is no permanent deformation to
the IBC, which renders the whole IBC, 178.818 Tear test.
including the base pallet, unsafe for
(a) General. The tear test must be
transportation; in no case may the
conducted for the qualification of all
maximum deflection exceed one inch.
flexible IBC design types.
[75 FR 5397, Feb. 2, 2010] (b) Special preparation for the tear test.
The flexible IBC must be filled to not
178.816 Topple test. less than 95 percent of its capacity and
(a) General. The topple test must be to its maximum net mass, the load
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178.819 49 CFR Ch. I (10111 Edition)
wall of a wide face, is made at a 45 (c) Criteria for passing the test. An IBC
angle to the principal axis of the IBC, passes the vibration test if there is no
halfway between the bottom surface rupture or leakage.
and the top level of the contents. The [Amdt. 178103, 59 FR 38074, July 26, 1994, as
IBC must then be subjected to a uni- amended by Amdt. 178108, 60 FR 40038, Aug.
formly distributed superimposed load 4, 1995; Amdt. 178110, 60 FR 49111, Sept. 21,
equivalent to twice the maximum net 1995; 66 FR 45386, Aug. 28, 2001; 75 FR 5397,
Feb. 2, 2010]
mass. The load must be applied for at
least five minutes. An IBC which is de-
signed to be lifted from the top or the Subpart PLarge Packagings
side must, after removal of the super- Standards
imposed load, be lifted clear of the
floor and maintained in that position SOURCE: 75 FR 5397, Feb. 2, 2010, unless oth-
for a period of five minutes. erwise noted.
(d) Criterion for passing the test. The 178.900 Purpose and scope.
IBC passes the tear test if the cut does
not propagate more than 25 percent of (a) This subpart prescribes require-
its original length. ments for Large Packaging intended
for the transportation of hazardous
[Amdt. 178103, 59 FR 38074, July 26, 1994, as materials. Standards for these pack-
amended at 66 FR 45386, Aug. 28, 2001] agings are based on the UN Rec-
ommendations.
178.819 Vibration test. (b) Terms used in this subpart are de-
(a) General. The vibration test must fined in 171.8 of this subchapter.
be conducted for the qualification of
178.905 Large Packaging identifica-
all rigid IBC design types. Flexible IBC tion codes.
design types must be capable of with-
standing the vibration test. Large packaging code designations
consist of: two numerals specified in
(b) Test method. (1) A sample IBC, se-
paragraph (a) of this section; followed
lected at random, must be filled and
by the capital letter(s) specified in
closed as for shipment. IBCs intended paragraph (b) of this section.
for liquids may be tested using water (a) Large packaging code number
as the filling material for the vibration designations are as follows: 50 for rigid
test. Large Packagings; or 51 for flexible
(2) The sample IBC must be placed on Large Packagings.
a vibrating platform with a vertical or (b) Large Packagings code letter des-
rotary double-amplitude (peak-to-peak ignations are as follows:
displacement) of one inch. The IBC (1) A means steel (all types and
must be constrained horizontally to surface treatments).
prevent it from falling off the plat- (2) B means aluminum.
form, but must be left free to move (3) C means natural wood.
vertically and bounce. (4) D means plywood.
(3) The test must be performed for (5) F means reconstituted wood.
(6) G means fiberboard.
one hour at a frequency that causes the
(7) H means plastic.
package to be raised from the vibrating
(8) M means paper, multiwall.
platform to such a degree that a piece (9) N means metal (other than
of material of approximately 1.6-mm steel or aluminum).
(0.063-inch) thickness (such as steel
strapping or paperboard) can be passed 178.910 Marking of Large Pack-
between the bottom of the IBC and the agings.
platform. Other methods at least (a) The manufacturer must:
equally effective may be used (see (1) Mark every Large Packaging in a
178.801(i)). durable and clearly visible manner.
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Pipeline and Hazardous Materials Safety Admin., DOT 178.910
243
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178.915 49 CFR Ch. I (10111 Edition)
178.920 Standards for metal Large tic materials. These additives must be
Packagings. compatible with the contents and re-
(a) The provisions in this section main effective throughout the life of
apply to metal Large Packagings in- the plastic Large Packaging body.
244
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Pipeline and Hazardous Materials Safety Admin., DOT 178.935
Where use is made of carbon black, pig- The fluting or corrugated fiberboard
ments or inhibitors, other than those must be firmly glued to the facings.
used in the manufacture of the tested (i) The walls, including top and bot-
design type, retesting may be omitted tom, must have a minimum puncture
if changes in the carbon black content, resistance of 15 Joules (11 foot-pounds
the pigment content or the inhibitor of energy) measured according to ISO
content do not adversely affect the 3036 (IBR, see 171.7 of this subchapter).
physical properties of the material of (ii) Manufacturers joints in the
construction. outer packaging of Large Packagings
(2) Additives may be included in the must be made with an appropriate
composition of the plastic material to overlap and be taped, glued, stitched
improve the resistance to aging or to with metal staples or fastened by other
serve other purposes, provided they do means at least equally effective. Where
not adversely affect the physical or joints are made by gluing or taping, a
chemical properties of the material of water resistant adhesive must be used.
construction. Metal staples must pass completely
(3) No used material other than pro- through all pieces to be fastened and be
duction residues or regrind from the formed or protected so that any inner
same manufacturing process may be liner cannot be abraded or punctured
used in the manufacture of rigid plastic by them.
Large Packagings. (2) Integral and detachable pallets. (i)
(c) Rigid plastic Large Packagings: Any integral pallet base forming part
(1) May not have a volumetric capac- of a Large Packaging or any detach-
ity greater than 3,000 L (793 gallons); able pallet must be suitable for me-
and chanical handling with the Large
(2) May not have a volumetric capac- Packaging filled to its maximum per-
ity less than 450 L (119 gallons). missible gross mass.
(ii) The pallet or integral base must
178.930 Standards for fiberboard be designed to avoid protrusions caus-
Large Packagings. ing damage to the fiberboard Large
(a) The provisions in this section Packagings in handling.
apply to fiberboard Large Packagings (iii) The body must be secured to any
intended to contain solids. Rigid fiber- detached pallet to ensure stability in
board Large Packaging types are des- handling and transport. Where a de-
ignated: tachable pallet is used, its top surface
(1) 50G fiberboard must be free from protrusions that
(2) [Reserved] might damage the Large Packaging.
(b) Construction requirements for fiber- (3) Strengthening devices, such as
board Large Packagings. (1) Fiberboard timber supports to increase stacking
Large Packagings must be constructed performance may be used but must be
of strong, solid or double-faced cor- external to the liner.
rugated fiberboard (single or (4) The load-bearing surfaces of Large
multiwall) that is appropriate to the Packagings intended for stacking must
capacity of the Large Packagings and be designed to distribute the load in a
to their intended use. Water resistance stable manner.
of the outer surface must be such that (c) Fiberboard Large Packagings may
the increase in mass, as determined in not have a volumetric capacity greater
a test carried out over a period of 30 than 3,000 L (793 gallons) and not less
minutes by the Cobb method of deter- than 450 L (119 gallons).
mining water absorption, is not greater [75 FR 5397, Feb. 2, 2010, as amended at 75 FR
than 155 grams per square meter (0.0316 60339, Sept. 30, 2010]
pounds per square foot)see ISO 535 (E)
(IBR, see 171.7 of this subchapter). Fi- 178.935 Standards for wooden Large
berboard must have proper bending Packagings.
qualities. Fiberboard must be cut, (a) The provisions in this section
wreier-aviles on DSK3TPTVN1PROD with CFR
creased without cutting through any apply to wooden Large Packagings in-
thickness of fiberboard, and slotted so tended to contain solids. Wooden Large
as to permit assembly without crack- Packaging types are designated:
ing, surface breaks or undue bending. (1) 50C natural wood.
245
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178.940 49 CFR Ch. I (10111 Edition)
may cause damage to the Large Pack- by the addition of pigments or inhibi-
aging in handling. tors such as carbon black. These addi-
(iii) The body must be secured to any tives must be compatible with the con-
detachable pallet to ensure stability in tents and remain effective throughout
246
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Pipeline and Hazardous Materials Safety Admin., DOT 178.955
the life of the Large Packaging. Where performed by the person who offers a
use is made of carbon black, pigments hazardous material for transportation,
or inhibitors other than those used in that person is responsible for per-
the manufacture of the tested design forming the function in accordance
type, retesting may be omitted if the with 173.22 and 178.2 of this sub-
carbon black content, the pigment con- chapter.
tent or the inhibitor content do not ad- (c) Definitions. For the purpose of this
versely affect the physical properties subpart:
of the material of construction. (1) Large packaging design type refers
(6) Additives may be included in the to a Large Packaging which does not
composition of the material of the differ in structural design, size, mate-
Large Packaging to improve the resist- rial of construction and packing.
ance to aging, provided they do not ad-
(2) Design qualification testing is the
versely affect the physical or chemical
performance of the drop, stacking, and
properties of the material.
(7) When flexible material Large bottom-lift or top-lift tests, as applica-
Packagings are filled, the ratio of ble, prescribed in this subpart, for each
height to width must be no more than different Large Packaging design type,
2:1. at the start of production of that pack-
(c) Flexible Large Packagings: aging.
(1) May not have a volumetric capac- (3) Periodic design requalification test is
ity greater than 3,000 L (793 gallons); the performance of the applicable tests
(2) May not have a volumetric capac- specified in paragraph (c)(2) of this sec-
ity less than 56 L (15 gallons); and tion on a Large Packaging design type,
(3) Must be designed and tested to a to requalify the design for continued
capacity of not less than 50 kg (110 production at the frequency specified
pounds). in paragraph (e) of this section.
(4) Production inspection is the inspec-
Subpart QTesting of Large tion, which must initially be conducted
Packagings on each newly manufactured Large
Packaging.
(5) Different Large Packaging design
SOURCE: 75 FR 5400, Feb. 2, 2010, unless oth-
erwise noted. type is one which differs from a pre-
viously qualified Large Packaging de-
178.950 Purpose and scope. sign type in structural design, size, ma-
This subpart prescribes certain test- terial of construction, wall thickness,
ing requirements for Large Packagings or manner of construction, but does
identified in subpart P of this part. not include:
(i) A packaging which differs in sur-
178.955 General requirements. face treatment;
(a) General. The test procedures pre- (ii) A rigid plastic Large Packaging,
scribed in this subpart are intended to which differs with regard to additives
ensure that Large Packagings con- used to comply with 178.925(b) or
taining hazardous materials can with- 178.940(b);
stand normal conditions of transpor- (iii) A packaging which differs only
tation. These test procedures are con- in its lesser external dimensions (i.e.,
sidered minimum requirements. Each height, width, length) provided mate-
packaging must be manufactured and rials of construction and material
assembled so as to be capable of suc- thickness or fabric weight remain the
cessfully passing the prescribed tests same;
and to conform to the requirements of (6) Remanufactured Large Packaging is
173.24 of this subchapter while in a metal or rigid Large Packaging that
transportation. is produced as a UN type from a non-
(b) Responsibility. The Large Pack- UN type or is converted from one UN
aging manufacturer is responsible for design type to another UN design type.
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178.955 49 CFR Ch. I (10111 Edition)
(7) Reused Large Packaging is a Large ing by the person certifying compli-
Packaging intended to be refilled and ance with this paragraph and retained
has been examined and found free of de- in accordance with paragraph (l) of this
fects affecting its ability to withstand section. Permitted variations are as
the performance tests. See also follows:
173.36(c) of this subchapter. (1) Inner packagings of equivalent or
(d) Design qualification testing. The smaller size may be used provided
packaging manufacturer must achieve (i) The inner packagings are of simi-
successful test results for the design lar design to the tested inner pack-
qualification testing at the start of agings (i.e., shaperound, rectangular,
production of each new or different etc.);
Large Packaging design type. Applica- (ii) The material of construction of
tion of the certification mark by the the inner packagings (glass, plastic,
manufacturer constitutes certification metal, etc.) offers resistance to impact
that the Large Packaging design type and stacking forces equal to or greater
passed the prescribed tests in this sub- than that of the originally tested inner
part. packaging;
(e) Periodic design requalification test- (iii) The inner packagings have the
ing. (1) Periodic design requalification same or smaller openings and the clo-
must be conducted on each qualified sure is of similar design (e.g., screw
Large Packaging design type if the cap, friction lid, etc.);
manufacturer is to maintain authoriza-
(iv) Sufficient additional cushioning
tion for continued production. The
material is used to take up void spaces
Large Packaging manufacturer must
and to prevent significant movement of
achieve successful test results for the
the inner packagings;
periodic design requalification at suffi-
(v) Inner packagings are oriented
cient frequency to ensure each pack-
within the outer packaging in the same
aging produced by the manufacturer is
manner as in the tested package; and
capable of passing the design qualifica-
tion tests. Design requalification tests (vi) The gross mass of the package
must be conducted at least once every does not exceed that originally tested.
24 months. (2) A lesser number of the tested
(2) Changes in the frequency of design inner packagings, or of the alternative
requalification testing specified in types of inner packagings identified in
paragraph (e)(1) of this section are au- paragraph (g)(1) of this section, may be
thorized if approved by the Associate used provided sufficient cushioning is
Administrator. added to fill void space(s) and to pre-
(f) Test samples. The manufacturer vent significant movement of the inner
must conduct the design qualification packagings.
and periodic tests prescribed in this (h) Proof of compliance. In addition to
subpart using random samples of pack- the periodic design requalification
agings, in the numbers specified in the testing intervals specified in paragraph
appropriate test section. (e) of this section, the Associate Ad-
(g) Selective testing. The selective ministrator, or a designated represent-
testing of Large Packagings, which dif- ative, may at any time require dem-
fer only in minor respects from a test- onstration of compliance by a manu-
ed type is permitted as described in facturer, through testing in accordance
this section. For air transport, Large with this subpart, to ensure packagings
Packagings must comply with meet the requirements of this subpart.
173.27(c)(1) and (c)(2) of this sub- As required by the Associate Adminis-
chapter. Variations are permitted in trator, or a designated representative,
inner packagings of a tested Large the manufacturer must either:
Packaging, without further testing of (1) Conduct performance tests or
the package, provided an equivalent have tests conducted by an inde-
level of performance is maintained and pendent testing facility, in accordance
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Pipeline and Hazardous Materials Safety Admin., DOT 178.960
for testing in accordance with this sub- pared for transportation, including
part. inner packagings. All closures must be
(i) Record retention. Following each installed using proper techniques and
design qualification test and each peri- torques.
odic retest on a Large Packaging, a (b) For the drop and stacking test,
test report must be prepared. The test inner receptacles must be filled to not
report must be maintained at each lo- less than 95 percent of maximum ca-
cation where the Large Packaging is pacity (see 171.8 of this subchapter) in
manufactured and each location where the case of solids and not less than 98
the design qualification tests are con- percent of maximum in the case of liq-
ducted, for as long as the Large Pack- uids. Bags must be filled to the max-
aging is produced and for at least two
imum mass at which they may be used.
years thereafter, and at each location
For Large Packagings where the inner
where the periodic retests are con-
packagings are designed to carry liq-
ducted until such tests are successfully
uids and solids, separate testing is re-
performed again and a new test report
produced. In addition, a copy of the quired for both liquid and solid con-
test report must be maintained by a tents. The material to be transported
person certifying compliance with this in the packagings may be replaced by a
part. The test report must be made non-hazardous material, except for
available to a user of a Large Pack- chemical compatibility testing or
aging or a representative of the De- where this would invalidate the results
partment upon request. The test re- of the tests.
port, at a minimum, must contain the (c) If the material to be transported
following information: is replaced for test purposes by a non-
(1) Name and address of test facility; hazardous material, the material used
(2) Name and address of applicant must be of the same or higher specific
(where appropriate); gravity as the material to be carried,
(3) A unique test report identifica- and its other physical properties
tion; (grain, size, viscosity) which might in-
(4) Date of the test report; fluence the results of the required tests
(5) Manufacturer of the packaging; must correspond as closely as possible
(6) Description of the packaging de- to those of the hazardous material to
sign type (e.g., dimensions, materials, be transported. It is permissible to use
closures, thickness, etc.), including additives, such as bags of lead shot, to
methods of manufacture (e.g., blow achieve the requisite total package
molding) and which may include draw- mass, so long as they do not affect the
ing(s) and/or photograph(s);
test results.
(7) Maximum capacity;
(8) Characteristics of test contents, (d) Paper or fiberboard Large Pack-
e.g., viscosity and relative density for agings must be conditioned for at least
liquids and particle size for solids; 24 hours immediately prior to testing
(9) Mathematical calculations per- in an atmosphere maintained
formed to conduct and document test- (1) At 50 percent 2 percent relative
ing (for example, drop height, test ca- humidity, and at a temperature of 23 C
pacity, outage requirements, etc.); 2 C (73 F 4 F). Average values
(10) Test descriptions and results; and should fall within these limits. Short-
(11) Signature with the name and term fluctuations and measurement
title of signatory. limitations may cause individual meas-
[75 FR 5400, Feb. 2, 2010, as amended at 75 FR
urements to vary by up to 5 percent
60339, Sept. 30, 2010; 76 FR 3389, Jan. 19, 2011] relative humidity without significant
impairment of test reproducibility;
178.960 Preparation of Large Pack- (2) At 65 percent 2 percent relative
agings for testing. humidity, and at a temperature of 20 C
(a) Except as otherwise provided in 2 C (68 F 4 F), or 27 C 2 C (81
wreier-aviles on DSK3TPTVN1PROD with CFR
this subchapter, each Large Packaging F 4 F). Average values should fall
and package must be closed in prepara- within these limits. Short-term fluc-
tion for testing and tests must be car- tuations and measurement limitations
ried out in the same manner as if pre- may cause individual measurements to
249
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178.965 49 CFR Ch. I (10111 Edition)
vary by up to 5 percent relative hu- (3) The specific gravity and viscosity
midity without significant impairment of a substituted non-hazardous mate-
of test reproducibility; or rial used in the drop test for liquids
(3) For testing at periodic intervals must be similar to the hazardous mate-
only (i.e., other than initial design rial intended for transportation. Water
qualification testing), at ambient con- also may be used for the liquid drop
ditions. test under the following conditions:
(i) Where the substances to be carried
178.965 Drop test. have a specific gravity not exceeding
(a) General. The drop test must be 1.2, the drop heights must be those
conducted for the qualification of all specified in paragraph (e)(1) of this sec-
Large Packaging design types and per- tion for each Large Packaging design
formed periodically as specified in type; and
178.955(e) of this subpart. (ii) Where the substances to be car-
(b) Special preparation for the drop test. ried have a specific gravity exceeding
Large Packagings must be filled in ac- 1.2, the drop heights must be as fol-
cordance with 178.960. lows:
(c) Conditioning. Rigid plastic Large (A) Packing Group I: SG 1.5 m (4.9
Packagings and Large Packagings with feet).
plastic inner receptacles must be con- (B) Packing Group II: SG 1.0 m (3.3
ditioned for testing by reducing the feet).
temperature of the packaging and its (C) Packing Group III: SG 0.67 m
contents to 18 C (0 F) or lower. Test (2.2 feet).
liquids must be kept in the liquid (f) Criteria for passing the test. For all
state, if necessary, by the addition of Large Packaging design types there
anti-freeze. Water/anti-freeze solutions may be no loss of the filling substance
with a minimum specific gravity of 0.95 from inner packaging(s) or article(s).
for testing at 18 C (0 F) or lower are Ruptures are not permitted in Large
considered acceptable test liquids, and Packaging for articles of Class 1 which
may be considered equivalent to water permit the spillage of loose explosive
for test purposes. Large Packagings substances or articles from the Large
conditioned in this way are not re- Packaging. Where a Large Packaging
quired to be conditioned in accordance undergoes a drop test, the sample
with 178.960(d). passes the test if the entire contents
(d) Test method. (1) Samples of all are retained even if the closure is no
Large Packaging design types must be longer sift-proof.
dropped onto a rigid, non-resilient,
smooth, flat and horizontal surface. [75 FR 5400, Feb. 2, 2010, as amended at 75 FR
The point of impact must be the most 60339, Sept. 30, 2010]
vulnerable part of the base of the Large
178.970 Bottom lift test.
Packaging being tested. Following the
drop, the Large Packaging must be re- (a) General. The bottom lift test must
stored to the upright position for ob- be conducted for the qualification of
servation. all Large Packagings design types de-
(2) Large Packaging design types signed to be lifted from the base.
with a capacity of 0.45 cubic meters (b) Special preparation for the bottom
(15.9 cubic feet) or less must be subject lift test. The Large Packaging must be
to an additional drop test. loaded to 1.25 times its maximum per-
(e) Drop height. (1) For all Large missible gross mass, the load being
Packagings, drop heights are specified evenly distributed.
as follows: (c) Test method. All Large Packaging
(i) Packing group I: 1.8 m (5.9 feet) design types must be raised and low-
(ii) Packing group II: 1.2 m (3.9 feet) ered twice by a lift truck with the
(iii) Packing group III: 0.8 m (2.6 feet) forks centrally positioned and spaced
(2) Drop tests are to be performed at three quarters of the dimension of
wreier-aviles on DSK3TPTVN1PROD with CFR
with the solid or liquid to be trans- the side of entry (unless the points of
ported or with a non-hazardous mate- entry are fixed). The forks must pene-
rial having essentially the same phys- trate to three quarters of the direction
ical characteristics. of entry.
250
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Pipeline and Hazardous Materials Safety Admin., DOT 178.980
(d) Criteria for passing the test. For all Large Packaging. The test must be
Large Packagings design types de- conducted for a period of five minutes.
signed to be lifted from the base, there (v) Other equally effective methods
may be no permanent deformation of top lift testing and preparation may
which renders the Large Packaging un- be used with approval of the Associate
safe for transport and there must be no Administrator.
loss of contents. (d) Criterion for passing the test. For
all Large Packagings design types de-
178.975 Top lift test. signed to be lifted from the top, there
(a) General. The top lift test must be may be no permanent deformation
conducted for the qualification of all of which renders the Large Packagings
Large Packagings design types to be unsafe for transport and no loss of con-
lifted from the top or, for flexible tents.
Large Packagings, from the side.
(b) Special preparation for the top lift 178.980 Stacking test.
test. (1) Metal and rigid plastic Large (a) General. The stacking test must
Packagings design types must be load- be conducted for the qualification of
ed to twice its maximum permissible all Large Packagings design types in-
gross mass. tended to be stacked.
(2) Flexible Large Packaging design (b) Special preparation for the stacking
types must be filled to six times the test. (1) All Large Packagings except
maximum permissible gross mass, the flexible Large Packaging design types
load being evenly distributed. must be loaded to their maximum per-
(c) Test method. (1) A Large Pack- missible gross mass.
aging must be lifted in the manner for (2) Flexible Large Packagings must
which it is designed until clear of the be filled to not less than 95 percent of
floor and maintained in that position their capacity and to their maximum
for a period of five minutes. net mass, with the load being evenly
(2) Rigid plastic Large Packaging de- distributed.
sign types must be: (c) Test method. (1) All Large Pack-
(i) Lifted by each pair of diagonally agings must be placed on their base on
opposite lifting devices, so that the level, hard ground and subjected to a
hoisting forces are applied vertically uniformly distributed superimposed
for a period of five minutes; and test load for a period of at least five
(ii) Lifted by each pair of diagonally minutes (see paragraph (c)(5) of this
opposite lifting devices so that the section).
hoisting forces are applied towards the (2) Fiberboard and wooden Large
center at 45 to the vertical, for a pe- Packagings must be subjected to the
riod of five minutes. test for 24 hours.
(3) If not tested as indicated in para- (3) Rigid plastic Large Packagings
graph (c)(1) of this section, a flexible which bear the stacking load must be
Large Packaging design type must be subjected to the test for 28 days at 40
tested as follows: C (104 F).
(i) Fill the flexible Large Packaging (4) For all Large Packagings, the
to 95% full with a material representa- load must be applied by one of the fol-
tive of the product to be shipped. lowing methods:
(ii) Suspend the flexible Large Pack- (i) One or more Large Packagings of
aging by its lifting devices. the same type loaded to their max-
(iii) Apply a constant downward force imum permissible gross mass and
through a specially designed platen. stacked on the test Large Packaging;
The platen will be a minimum of 60 (ii) The calculated superimposed test
percent and a maximum of 80 percent load weight loaded on either a flat
of the cross sectional surface area of plate or a reproduction of the base of
the flexible Large Packaging. the Large Packaging, which is stacked
(iv) The combination of the mass of on the test Large Packaging; or
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the filled flexible Large Packaging and (5) Calculation of superimposed test
the force applied through the platen load. For all Large Packagings, the
must be a minimum of six times the load to be placed on the Large Pack-
maximum net mass of the flexible aging must be 1.8 times the combined
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178.985 49 CFR Ch. I (10111 Edition)
maximum permissible gross mass of renders the Large Packaging unsafe for
the number of similar Large Packaging transportation and no loss of contents.
that may be stacked on top of the (3) For the dynamic compression
Large Packaging during transpor- test, a container passes the test if,
tation. after application of the required load,
(d) Periodic Retest. (1) The package there is no permanent deformation to
must be tested in accordance with the Large Packaging which renders the
178.980(c) of this subpart; or whole Large Packaging; including the
(2) The packaging may be tested base pallet, unsafe for transportation;
using a dynamic compression testing in no case may the maximum deflec-
machine. The test must be conducted tion exceed one inch.
at room temperature on an empty, un-
sealed packaging. The test sample [75 FR 5400, Feb. 2, 2010, as amended at 75 FR
60339, Sept. 30, 2010]
must be centered on the bottom platen
of the testing machine. The top platen 178.985 Vibration test.
must be lowered until it comes in con-
tact with the test sample. Compression (a) General. All rigid Large Pack-
must be applied end to end. The speed aging and flexible Large Packaging de-
of the compression tester must be one- sign types must be capable of with-
half inch plus or minus one-fourth inch standing the vibration test.
per minute. An initial preload of 50 (b) Test method. (1) A sample Large
pounds must be applied to ensure a Packaging, selected at random, must
definite contact between the test sam- be filled and closed as for shipment.
ple and the platens. The distance be- Large Packagings intended for liquids
tween the platens at this time must be may be tested using water as the filling
recorded as zero deformation. The force material for the vibration test.
A to then be applied must be cal- (2) The sample Large Packaging must
culated using the applicable formula: be placed on a vibrating platform that
has a vertical or rotary double-ampli-
Liquids: A = (1.8)(n1) [w + (s v 8.3
tude (peak-to-peak displacement) of
.98)] 1.5;
one inch. The Large Packaging must be
or constrained horizontally to prevent it
from falling off the platform, but must
Solids: A = (1.8)(n1) [w + (s v 8.3 be left free to move vertically and
.95)] 1.5 bounce.
Where: (3) The sample Large Packaging must
A = applied load in pounds. be placed on a vibrating platform that
n = maximum number of Large Packagings has a vertical double-amplitude (peak-
that may be stacked during transpor- to-peak displacement) of one inch. The
tation. Large Packaging must be constrained
w = maximum weight of one empty container
in pounds.
horizontally to prevent it from falling
s = specific gravity (liquids) or density (sol- off the platform, but must be left free
ids) of the lading. to move vertically and bounce.
v = actual capacity of container (rated ca- (4) The test must be performed for
pacity + outage) in gallons. one hour at a frequency that causes the
and: package to be raised from the vibrating
8.3 corresponds to the weight in pounds of 1.0 platform to such a degree that a piece
gallon of water.
1.5 is a compensation factor that converts of material of approximately 1.6-mm
the static load of the stacking test into a (0.063-inch) in thickness (such as steel
load suitable for dynamic compression strapping or paperboard) can be passed
testing. between the bottom of the Large Pack-
(e) Criterion for passing the test. (1) For aging and the platform. Other methods
metal or rigid plastic Large Pack- at least equally effective may be used
agings, there may be no permanent de- (see 178.801(i)).
formation which renders the Large (c) Criterion for passing the test. A
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Pipeline and Hazardous Materials Safety Admin., DOT Pt. 178, App. B
TABLE 1
[Open-hearth, basic oxygen, or electric steel of uniform quality. The following chemical composition limits are based on ladle
analysis:]
[Amdt. 1783, 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. 17897, 55 FR 52728, Dec. 21, 1990; 68 FR 75758, Dec. 31, 2003]
In addition to the method prescribed in ber. The testing chamber must be evacuated
178.604 of this subchapter, the following down to a pressure of 5 kPa which equals an
leakproofness test methods are authorized: over-pressure inside the packaging of 95 kPa.
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Pt. 178, App. C 49 CFR Ch. I (10111 Edition)
The air in the testing chamber must be ana- resentative of the Department of Transpor-
lyzed for traces of helium gas by means of a tation on request.
mass spectrograph. The test must be con-
[Amdt. 17897, 55 FR 52728, Dec. 21, 1990, as
ducted for a period of time sufficient to evac- amended at 56 FR 66287, Dec. 20, 1991; 57 FR
uate the chamber and to determine if there 45466, Oct. 1, 1992]
is leakage into or out of the packaging. If he-
lium gas is detected, the leaking packaging APPENDIX C TO PART 178NOMINAL AND
must be automatically separated from non- MINIMUM THICKNESSES OF STEEL
leaking drums and the leaking area deter-
DRUMS AND JERRICANS
mined according to the method prescribed in
178.604(d) of this subchapter. A packaging For each listed packaging capacity, the
passes the test if there is no leakage of he- following table compares the ISO 3574 (IBR,
lium. see 171.7 of this subchapter) nominal thick-
(2) Pressure differential test. The packaging ness with the corresponding ISO 3574 min-
shall be restrained while either pressure or a imum thickness.
vacuum is applied internally. The packaging
Cor-
must be pressurized to the pressure required responding
by 178.604(e) of this subchapter for the ap- ISO nomi-
Maximum capacity (L) ISO min-
nal (mm)
propriate packing group. The method of re- imum
(mm)
straint must not affect the results of the
test. The test must be conducted for a period 20 ................................................... 0.7 0.63
of time sufficient to appropriately pressurize 30 ................................................... 0.8 0.73
or evacuate the interior of the packaging 40 ................................................... 0.8 0.73
and to determine if there is leakage into or 60 ................................................... 1.0 0.92
out of the packaging. A packaging passes the 120 ................................................. 1.0 0.92
220 ................................................. 1.0 0.92
pressure differential test if there is no 450 ................................................. 1.9 1.77
change in measured internal pressure.
(3) Solution over seams. The packaging must
be restrained while an internal air pressure [Amdt. 178106, 59 FR 67522, Dec. 29, 1994, as
is applied; the method of restraint may not amended at 68 FR 75758, Dec. 31, 2003]
affect the results of the test. The exterior
surface of all seams and welds must be coat- APPENDIX D TO PART 178THERMAL
ed with a solution of soap suds or a water RESISTANCE TEST
and oil mixture. The test must be conducted
1. Scope. This test method evaluates the
for a period of time sufficient to pressurize thermal resistance capabilities of a com-
the interior of the packaging to the specified pressed oxygen generator and the outer
air pressure and to determine if there is packaging for a cylinder of compressed oxy-
leakage of air from the packaging. A pack- gen or other oxidizing gas and an oxygen
aging passes the test if there is no leakage of generator. When exposed to a temperature of
air from the packaging. 205 C (400 F) for a period of not less than
(4) Solution over partial seams test. For other three hours, the outer surface of the cylinder
than design qualification testing, the fol- may not exceed a temperature of 93 C (199
lowing test may be used for metal drums: F) and the oxygen generator must not actu-
The packaging must be restrained while an ate.
internal air pressure of 48 kPa (7.0 psig) is 2. Apparatus.
applied; the method of restraint may not af- 2.1 Test Oven. The oven must be large
fect the results of the test. The packaging enough in size to fully house the test outer
must be coated with a soap solution over the package without clearance problems. The
entire side seam and a distance of not less test oven must be capable of maintaining a
than eight inches on each side of the side minimum steady state temperature of 205 C
seam along the chime seam(s). The test must (400 F).
be conducted for a period of time sufficient 2.2 Thermocouples. At least three
to pressurize the interior of the packaging to thermocouples must be used to monitor the
temperature inside the oven and an addi-
the specified air pressure and to determine if
tional three thermocouples must be used to
there is leakage of air from the packaging. A
monitor the temperature of the cylinder.
packaging passes the test if there is no leak-
The thermocouples must be 116 inch, ceramic
age of air from the packaging. Chime cuts packed, metal sheathed, type K (Chromel-
must be made on the initial drum at the be- Alumel), grounded junction with a nominal
ginning of each production run and on the 30 American wire gauge (AWG) size con-
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initial drum after any adjustment to the ductor. The thermocouples measuring the
chime seamer. Chime cuts must be main- temperature inside the oven must be placed
tained on file in date order for not less than at varying heights to ensure even tempera-
six months and be made available to a rep- ture and proper heat-soak conditions. For
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Pipeline and Hazardous Materials Safety Admin., DOT Pt. 178, App. E
the thermocouples measuring the tempera- delamination, resin ignition, and time of oc-
ture of the cylinder: (1) Two of them must be currence of each event.
placed on the outer cylinder side wall at ap- 6.3 Record the temperature and time his-
proximately 2 inches (5 cm) from the top and tory of the cylinder temperature during the
bottom shoulders of the cylinder; and (2) one entire test for each thermocouple location.
must be placed on the cylinder valve body Temperature measurements must be re-
near the pressure relief device. Alter- corded at intervals of not more than five (5)
natively, the thermocouples may be replaced minutes. Record the maximum temperatures
with other devices such as a remote tempera- achieved at all three thermocouple locations
ture sensor, metal fuse on the valve, or coat- and the corresponding time.
ed wax, provided the device is tested and the 7. Requirements.
test report is retained for verification. Under 7.1 For a cylinder, the outer package
this alternative, it is permissible to record must provide adequate protection such that
the highest temperature to which the cyl- the outer surface of the cylinder and valve
inder is subjected instead of temperature does not exceed a temperature of 93 C (199
measurements in intervals of not more than F) at any of the three points where the
five (5) minutes. thermocouples are located.
2.3 Instrumentation. A calibrated recording 7.2 For an oxygen generator, the gener-
device or a computerized data acquisition ator must not actuate.
system with an appropriate range should be
[72 FR 4457, Jan. 31, 2008, as amended at 72
provided to measure and record the outputs
FR 55099, Sept. 28, 2007]
of the thermocouples.
3. Test Specimen. APPENDIX E TO PART 178FLAME
3.1 Specimen Configuration. Each outer
package material type and design must be
PENETRATION RESISTANCE TEST
tested, including any features such as han- (a) Criteria for Acceptance. (1) At least three
dles, latches, fastening systems, etc., that specimens of the outer packaging materials
may compromise the ability of the outer must be tested;
package to provide thermal protection. (2) Each test must be conducted on a flat 16
3.2 Test Specimen Mounting. The tested inch x 24 inch test specimen mounted in the
outer package must be supported at the four horizontal ceiling position of the test appa-
corners using fire brick or other suitable ratus to represent the outer packaging de-
means. The bottom surface of the outer sign;
package must be exposed to allow exposure (3) Testing must be conducted on all design
to heat. features (latches, seams, hinges, etc.) affect-
4. Preparation for Testing. ing the ability of the outer packaging to
4.1 It is recommended that the cylinder be safely prevent the passage of fire in the hori-
closed at ambient temperature and config- zontal ceiling position; and
ured as when filled with a valve and pressure (4) There must be no flame penetration of
relief device. The oxygen generator must be any specimen within 5 minutes after applica-
filled with an oxidizing agent and may be tion of the flame source and the maximum
tested with or without packaging. allowable temperature at a point 4 inches
4.2 Place the package or generator onto above the test specimen, centered over the
supporting bricks or a stand inside the test burner cone, must not exceed 205 C (400 F).
oven in such a manner to ensure even tem- (b) Summary of Method. This method pro-
perature flow. vides a laboratory test procedure for meas-
5. Test Procedure. uring the capability of cargo compartment
5.1 Close oven door and check for proper lining materials to resist flame penetration
reading on thermocouples. with a 2 gallon per hour (GPH) #2 Grade ker-
5.2 Raise the temperature of the oven to a osene or equivalent burner fire source. Ceil-
minimum temperature of 205 C 2 C (400 F ing and sidewall liner panels may be tested
5 F). Maintain a minimum oven tempera- individually provided a baffle is used to sim-
ture of 205 C 2 C (400 F 5 F) for at least ulate the missing panel. Any specimen that
three hours. Exposure time begins when the passes the test as a ceiling liner panel may
oven steady state temperature reaches a be used as a sidewall liner panel.
minimum of 205 C 2 C (400 F 5 F). (c) Test Specimens. (1) The specimen to be
5.3 At the conclusion of the three-hour pe- tested must measure 16 18 inches (406 3
riod, the outer package may be removed mm) by 24+18 inches (610 3 mm).
from the oven and allowed to cool naturally. (2) The specimens must be conditioned at
6. Recordkeeping. 70 F. 5 F. (21 C. 2 C.) and 55% 5% hu-
6.1 Record a complete description of the midity for at least 24 hours before testing.
material being tested, including the manu-
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Pt. 178, App. E 49 CFR Ch. I (10111 Edition)
(1) Specimen Mounting Stand. The mounting must be adjusted as specified in paragraph
stand for the test specimens consists of steel (d)(2).
angles. (f) Calibration. To ensure the proper ther-
(2) Test Burner. The burner to be used in mal output of the burner the following test
tesing must must be made:
(i) Be a modified gun type. (1) Remove the burner extension from the
(ii) Use a suitable nozzle and maintain fuel end of the draft tube. Turn on the blower
pressure to yield a 2 GPH fuel flow. For ex- portion of the burner without turning the
ample: An 80 degree nozzle nominally rated fuel or igniters on. Measure the air velocity
at 2.25 GPH and operated at 85 pounds per using a hot wire anemometer in the center of
square inch (PSI) gauge to deliver 2.03 GPH. the draft tube across the face of the opening.
(iii) Have a 12 inch (305 mm) burner exten- Adjust the damper such that the air velocity
sion installed at the end of the draft tube is in the range of 1550 to 1800 ft./min. If tabs
with an opening 6 inches (152 mm) high and are being used at the exit of the draft tube,
11 inches (280 mm) wide. they must be removed prior to this measure-
(iv) Have a burner fuel pressure regulator ment. Reinstall the draft tube extension
that is adjusted to deliver a nominal 2.0 GPH cone.
of #2 Grade kerosene or equivalent. (2) Place the calorimeter on the test stand
Burner models which have been used suc- as shown in Figure 2 at a distance of 8 inches
cessfully in testing are the Lenox Model OB (203 mm) from the exit of the burner cone to
32, Carlin Model 200 CRD and Park Model simulate the position of the horizontal test
DPL. specimen.
(3) Calorimeter. (i) The calorimeter to be
(3) Turn on the burner, allow it to run for
used in testing must be a total heat flux Foil
2 minutes for warm-up, and adjust the damp-
Type Gardon Gage of an appropriate range
er to produce a calorimeter reading of 8.0 0.5
(approximately 0 to 15.0 British thermal unit
BTU per ft.2 sec. (9.1 0.6 Watts/cm2).
(BTU) per ft.2 sec., 017.0 watts/cm2). The cal-
(4) Replace the calorimeter with the ther-
orimeter must be mounted in a 6 inch by 12
mocouple rake.
inch (152 by 305 mm) by 34 inch (19 mm) thick
insulating block which is attached to a steel (5) Turn on the burner and ensure that
angle bracket for placement in the test stand each of the seven thermocouples reads 1700
during burner calibration as shown in Figure F. 100 F. (927 C. 38 C.) to ensure steady
2 of this part of this appendix. state conditions have been achieved. If the
(ii) The insulating block must be mon- temperature is out of this range, repeat steps
itored for deterioration and the mounting 2 through 5 until proper readings are ob-
shimmed as necessary to ensure that the cal- tained.
orimeter face is parallel to the exit plane of (6) Turn off the burner and remove the
the test burner cone. thermocouple rake.
(4) Thermocouples. The seven thermocouples (7) Repeat (1) to ensure that the burner is
to be used for testing must be 116 inch ce- in the correct range.
ramic sheathed, type K, grounded (g) Test Procedure. (1) Mount a thermo-
thermocouples with a nominal 30 American couple of the same type as that used for cali-
wire gage (AWG) size conductor. The seven bration at a distance of 4 inches (102 mm)
thermocouples must be attached to a steel above the horizontal (ceiling) test specimen.
angle bracket to form a thermocouple rake The thermocouple should be centered over
for placement in the test stand during burn- the burner cone.
er calibration. (2) Mount the test specimen on the test
(5) Apparatus Arrangement. The test burner stand shown in Figure 1 in either the hori-
must be mounted on a suitable stand to posi- zontal or vertical position. Mount the insu-
tion the exit of the burner cone a distance of lating material in the other position.
8 inches from the ceiling liner panel and 2 (3) Position the burner so that flames will
inches from the sidewall liner panel. The not impinge on the specimen, turn the burn-
burner stand should have the capability of er on, and allow it to run for 2 minutes. Ro-
allowing the burner to be swung away from tate the burner to apply the flame to the
the test specimen during warm-up periods. specimen and simultaneously start the tim-
(6) Instrumentation. A recording potentiom- ing device.
eter or other suitable instrument with an ap- (4) Expose the test specimen to the flame
propriate range must be used to measure and for 5 minutes and then turn off the burner.
record the outputs of the calorimeter and The test may be terminated earlier if flame
the thermocouples. penetration is observed.
(7) Timing Device. A stopwatch or other de- (5) When testing ceiling liner panels,
vice must be used to measure the time of record the peak temperature measured 4
inches above the sample.
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Pipeline and Hazardous Materials Safety Admin., DOT Pt. 179
(1) A complete description of the materials 179.10013 Venting, loading and unloading
tested including type, manufacturer, thick- valves, measuring and sampling devices.
ness, and other appropriate data. 179.10014 Bottom outlets.
(2) Observations of the behavior of the test 179.10016 Attachments.
specimens during flame exposure such as 179.10017 Closures for openings.
delamination, resin ignition, smoke, etc., in- 179.10018 Tests of tanks.
cluding the time of such occurrence. 179.10019 Tests of safety relief valves.
(3) The time at which flame penetration 179.10020 Stamping.
occurs, if applicable, for each of the three 179.101 Individual specification require-
specimens tested. ments applicable to pressure tank car
[72FR55099, Sept. 28, 2007] tanks.
179.1011 Individual specification require-
ments.
PART 179SPECIFICATIONS FOR 179.102 Special commodity requirements for
TANK CARS pressure tank car tanks.
179.1021 Carbon dioxide, refrigerated liquid.
Subpart AIntroduction, Approvals and 179.1022 Chlorine.
Reports 179.1023 Materials poisonous by inhalation.
179.1024 Vinyl fluoride, stabilized.
Sec. 179.10217 Hydrogen chloride, refrigerated
179.1 General. liquid.
179.2 Definitions and abbreviations. 179.103 Special requirements for class 114A
179.3 Procedure for securing approval. * * * tank car tanks.
179.4 Changes in specifications for tank 179.1031 Type.
cars. 179.1032 Manway cover.
179.5 Certificate of construction. 179.1033 Venting, loading and unloading
179.6 Repairs and alterations. valves, measuring and sampling devices.
179.7 Quality assurance program. 179.1034 Safety relief devices and pressure
179.8 Limitation on actions by states, local regulators.
governments, and Indian tribes. 179.1035 Bottom outlets.
257
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Pt. 179 49 CFR Ch. I (10111 Edition)
179.201 Individual specification require- 179.3001 Tanks built under these specifica-
ments applicable to non-pressure tank tions shall meet the requirements of
car tanks. 179.300 and 179.301.
179.2011 Individual specification require- 179.3003 Type and general requirements.
ments. 179.3004 Insulation.
179.2012 [Reserved] 179.3006 Thickness of plates.
179.2013 Lined tanks. 179.3007 Materials.
179.2014 Material. 179.3008 Tank heads.
179.2015 Postweld heat treatment and cor- 179.3009 Welding.
rosion resistance. 179.30010 Postweld heat treatment.
179.2016 Manways and manway closures. 179.30012 Protection of fittings.
179.2018 Sampling device and thermometer 179.30013 Venting, loading and unloading
well. valves.
179.2019 Gauging device. 179.30014 Attachments not otherwise speci-
fied.
179.20110 Water capacity marking.
179.30015 Pressure relief devices.
179.20111 Insulation.
179.30016 Tests of tanks.
179.202179.20222 [Reserved] 179.30017 Tests of pressure relief devices.
179.220 General specifications applicable to 179.30018 Stamping.
nonpressure tank car tanks consisting of 179.30019 Inspection.
an inner container supported within an 179.30020 Reports.
outer shell (class DOT-115). 179.301 Individual specification require-
179.2201 Tanks built under these specifica- ments for multi-unit tank car tanks.
tions must meet the requirements of 179.302 [Reserved]
179.220 and 179.221.
179.2203 Type. Subpart FSpecification for Cryogenic Liq-
179.2204 Insulation. uid Tank Car Tanks and Seamless Steel
179.2206 Thickness of plates. Tanks (Classes DOT-113 and 107A)
179.2207 Materials.
179.2208 Tank heads. 179.400 General specification applicable to
179.2209 Compartment tanks. cryogenic liquid tank car tanks.
179.22010 Welding. 179.4001 General.
179.22011 Postweld heat treatment. 179.4003 Type.
179.22013 Inner container manway nozzle 179.4004 Insulation system and perform-
and cover. ance standard.
179.22014 Openings in the tanks. 179.4005 Materials.
179.22015 Support system for inner con- 179.4006 Bursting and buckling pressure.
tainer. 179.4007 Tank heads.
179.22016 Expansion capacity. 179.4008 Thickness of plates.
179.22017 Gauging devices, top loading and 179.4009 Stiffening rings.
unloading devices, venting and air inlet 179.40010 Sump or siphon bowl.
devices. 179.40011 Welding.
179.22018 Bottom outlets. 179.40012 Postweld heat treatment.
179.40013 Support system for inner tank.
179.22020 Reinforcements, when used, and
179.40014 Cleaning of inner tank.
appurtenances not otherwise specified.
179.40015 Radioscopy.
179.22022 Closure for openings.
179.40016 Access to inner tank.
179.22023 Test of tanks. 179.40017 Inner tank piping.
179.22024 Tests of pressure relief valves. 179.40018 Test of inner tank.
179.22025 Stamping. 179.40019 Valves and gages.
179.22026 Stenciling. 179.40020 Pressure relief devices.
179.221 Individual specification require- 179.40021 Test of pressure relief valves.
ments applicable to tank car tanks con- 179.40022 Protective housings.
sisting of an inner container supported 179.40023 Operating instructions.
within an outer shell. 179.40024 Stamping.
179.2211 Individual specification require- 179.40025 Stenciling.
ments. 179.401 Individual specification require-
ments applicable to inner tanks for cryo-
Subpart ESpecifications for Multi-Unit genic liquid tank car tanks.
Tank Car Tanks (Classes DOT-106A 179.4011 Individual specification require-
and 110AW) ments.
179.500 Specification DOT-107A * * * *,
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Pipeline and Hazardous Materials Safety Admin., DOT 179.3
179.5004 Thickness of wall. quirements which have not been met at
179.5005 Material. time of transfer.
179.5006 Heat treatment.
179.5007 Physical tests. [Amdt. 17917, 41 FR 38183, Sept. 9, 1976, as
179.5008 Openings in tanks. amended by Amdt. 17950, 60 FR 49076, Sept.
179.50010 Protective housing. 21, 1995; 68 FR 48571, Aug. 14, 2003]
179.50011 Loading and unloading valves.
179.50012 Pressure relief devices. 179.2 Definitions and abbreviations.
179.50013 Fixtures.
(a) The following apply in part 179:
179.50014 Test of tanks.
179.50015 Handling of tanks failing in tests. (1) AAR means Association of Amer-
179.50016 Tests of pressure relief devices. ican Railroads.
179.50017 Marking. (2) Approved means approval by the
179.50018 Inspection and reports. AAR Tank Car Committee.
APPENDIX A TO PART 179PROCEDURES FOR (3) ASTM means American Society
TANK-HEAD PUNCTURE-RESISTANCE TEST for Testing and Materials.
APPENDIX B TO PART 179PROCEDURES FOR (4) [Reserved]
SIMULATED POOL AND TORCH-FIRE TEST-
ING
(5) Definitions in part 173 of this
chapter also apply.
AUTHORITY: 49 U.S.C. 51015128; 49 CFR part (6) F means degrees Fahrenheit.
1.53.
(7) NGT means National Gas Taper
SOURCE: 29 FR 18995, Dec. 29, 1964, unless Threads.
otherwise noted. Redesignated at 32 FR 5606, (8) NPT means an American Standard
Apr. 5, 1967. Taper Pipe Thread conforming to the
requirements of NBS Handbook H28
Subpart AIntroduction, (IBR, see 171.7 of this subchapter).
Approvals and Reports (9) [Reserved]
(10) Tank car facility means an entity
179.1 General. that manufactures, repairs, inspects,
(a) This part prescribes the specifica- tests, qualifies, or maintains a tank
tions for tanks that are to be mounted car to ensure that the tank car con-
on or form part of a tank car and which forms to this part and subpart F of part
are to be marked with a DOT specifica- 180 of this subchapter, that alters the
tion. certificate of construction of the tank
(b) Except as provided in paragraph car, that ensures the continuing quali-
(c) of this section, tanks to which this fication of a tank car by performing a
part is applicable, must be built to the function prescribed in parts 179 or 180
specifications prescribed in this part. of this subchapter, or that makes any
(c) Tanks built to specifications pre- representation indicating compliance
dating those in this part may continue with one or more of the requirements
in use as provided in 180.507 of this of parts 179 or 180 of this subchapter.
subchapter. (11) Tanks means tank car tanks.
(d) Any person who performs a func- (b) [Reserved]
tion prescribed in this part, shall per-
[29 FR 18995, Dec. 20, 1964. Redesignated at 32
form that function in accordance with
FR 5606, Apr. 5, 1967, and amended by Amdt.
this part. 17910, 36 FR 21344, Nov. 6, 1971; Amdt. 17950,
(e) When this part requires a tank to 60 FR 49076, Sept. 21, 1995; Amdt. 17950, 61
be marked with a DOT specification FR 33255, June 26, 1996; 63 FR 52850, Oct. 1,
(for example, DOT-105A100W), compli- 1998; 66 FR 45186, 45390, Aug. 28, 2001; 68 fR
ance with that requirement is the re- 75759, Dec. 31, 2003]
sponsibility of the tank builder. Mark-
ing the tank with the DOT specifica- 179.3 Procedure for securing ap-
tion shall be understood to certify proval.
compliance by the builder that the (a) Application for approval of de-
functions performed by the builder, as signs, materials and construction, con-
prescribed in this part, have been per- version or alteration of tank car tanks
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179.4 49 CFR Ch. I (10111 Edition)
[29 FR 18995, Dec. 29, 1964. Redesignated at 32 (1) Ensures the finished product con-
FR 5606, Apr. 5, 1967 and amended by Amdt. forms to the requirements of the appli-
17941, 52 FR 36672, Sept. 30, 1987; 63 FR 52850, cable specification and regulations of
Oct. 1, 1998; 70 FR 73166, Dec. 9, 2005] this subchapter;
260
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Pipeline and Hazardous Materials Safety Admin., DOT 179.8
(2) Has the means to detect any non- terpretation of inspection and test re-
conformity in the manufacturing, re- sults.
pair, inspection, testing, and qualifica- (c) Each tank car facility shall en-
tion or maintenance program of the sure that only personnel qualified for
tank car; and each non-destructive inspection and
(3) Prevents non-conformities from test perform that particular operation.
recurring. (d) Each tank car facility shall pro-
(b) At a minimum, the quality assur- vide written procedures to its employ-
ance program must have the following ees to ensure that the work on the
elements tank car conforms to the specification,
(1) Statement of authority and re- AAR approval, and owners acceptance
sponsibility for those persons in charge criteria.
of the quality assurance program. (e) Each tank car facility shall train
(2) An organizational chart showing its employees in accordance with sub-
the interrelationship between man- part H of part 172 of this subchapter on
agers, engineers, purchasing, construc- the program and procedures specified
tion, inspection, testing, and quality in paragraph (b) of this section to en-
control personnel. sure quality.
(3) Procedures to ensure that the lat- (f) No tank car facility may manufac-
est applicable drawings, design calcula- ture, repair, inspect, test, qualify or
tions, specifications, and instructions maintain tank cars subject to require-
are used in manufacture, inspection, ments of this subchapter, unless it is
testing, and repair. operating in conformance with a qual-
ity assurance program and written pro-
(4) Procedures to ensure that the fab-
cedures required by paragraphs (a) and
rication and construction materials re-
(b) of this section.
ceived are properly identified and docu-
mented. [Amdt. 17950, 60 FR 49076, Sept. 21, 1995, as
(5) A description of the manufac- amended by Amdt. 17950, 61 FR 33255, June
turing, repair, inspection, testing, and 26, 1996; 68 FR 48571, Aug. 14, 2003; 68 FR 75759,
Dec. 31, 2003]
qualification or maintenance program,
including the acceptance criteria, so 179.8 Limitation on actions by states,
that an inspector can identify the char- local governments, and Indian
acteristics of the tank car and the ele- tribes.
ments to inspect, examine, and test at
Sections 5125 and 20106 of Title 49,
each point.
United States Code, limit the author-
(6) Monitoring and control of proc- ity of states, political subdivisions of
esses and product characteristics dur- states, and Indian tribes to impose re-
ing production. quirements on the transportation of
(7) Procedures for correction of hazardous materials in commerce. A
nonconformities. state, local, or Indian tribe require-
(8) Provisions indicating that the re- ment on the transportation of haz-
quirements of the AAR Specifications ardous materials by rail may be pre-
for Tank Cars (IBR, see 171.7 of this empted under either 49 U.S.C. 5125 or
subchapter), apply. 20106, or both.
(9) Qualification requirements of per- (a) Section 171.1(f) of this subchapter
sonnel performing non-destructive in- describes the circumstances under
spections and tests. which 49 U.S.C. 5125 preempts a re-
(10) Procedures for evaluating the in- quirement of a state, political subdivi-
spection and test technique employed, sion of a state, or Indian tribe.
including the accessibility of the area (b) Under the Federal Railroad Safe-
and the sensitivity and reliability of ty Act (49 U.S.C. 20106), administered
the inspection and test technique and by the Federal Railroad Administra-
minimum detectable crack length. tion (see 49 CFR parts 200244), laws,
(11) Procedures for the periodic cali- regulations and orders related to rail-
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261
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179.10 49 CFR Ch. I (10111 Edition)
covering the same subject matter as a (FRA). Tank cars must conform to the
DOT regulation or order applicable to conditions of the approval and must be
railroad safety and security (including operated only under controlled inter-
the requirements in this subpart) only change conditions agreed to by partici-
when an additional or more stringent pating railroads.
state law, regulation, or order is nec- (b) Tank cars containing poisonous-
essary to eliminate or reduce an essen- by-inhalation material meeting the ap-
tially local safety or security hazard; is plicable authorized tank car specifica-
not incompatible with a law, regula- tions listed in 173.244(a)(2) or (3), or
tion, or order of the United States Gov- 173.314(c) or (d) may have a gross
ernment; and does not unreasonably weight on rail of up to 286,000 pounds
burden interstate commerce. (129,727 kg). Tank cars exceeding 263,000
pounds and up to 286,000 pounds gross
[74 FR 1801, Jan. 13, 2009]
weight on rail must meet the require-
ments of AAR Standard S286, Free/Un-
Subpart BGeneral Design restricted Interchange for 286,000 lb
Requirements Gross Rail Load Cars (IBR; see 171.7 of
this subchapter). Any increase in
179.10 Tank mounting. weight above 263,000 pounds may not be
(a) The manner in which tanks are used to increase the quantity of the
attached to the car structure shall be contents of the tank car.
approved. The use of rivets to secure
[74 FR 1802, Jan. 13, 2009, as amended at 75
anchors to tanks prohibited.
FR 27216, May 14, 2010]
(b) [Reserved]
179.14 Coupler vertical restraint sys-
179.11 Welding certification. tem.
(a) Welding procedures, welders and (a) Performance standard. Each tank
fabricators shall be approved. car shall be equipped with couplers ca-
(b) [Reserved] pable of sustaining, without disengage-
179.12 Interior heater systems. ment or material failure, vertical loads
of at least 200,000 pounds (90,718.5 kg)
(a) Interior heater systems shall be of applied in upward and downward direc-
approved design and materials. If a tions in combination with buff loads of
tank is divided into compartments, a 2,000 pounds (907.2 kg), when coupled to
separate system shall be provided for cars which may or may not be equipped
each compartment. with couplers having this vertical re-
(b) Each interior heater system shall straint capability.
be hydrostatically tested at not less (b) Test verification. Except as pro-
than 13.79 bar (200 psig) and shall hold vided in paragraph (d) of this section,
the pressure for 10 minutes without compliance with the requirements of
leakage or evidence of distress. paragraph (a) of this section shall be
[Amdt. 17952, 61 FR 28678, June 5, 1996, as achieved by verification testing of the
amended by 66 FR 45390, Aug. 28, 2001] coupler vertical restraint system in ac-
cordance with paragraph (c) of this sec-
179.13 Tank car capacity and gross tion.
weight limitation. (c) Coupler vertical restraint tests. A
Except as provided in this section, coupler vertical restraint system shall
tank cars, built after November 30, be tested under the following condi-
1970, or any existing tank cars that are tions:
converted, may not exceed 34,500 gal- (1) The test coupler shall be tested
lons (130,597 L) capacity or 263,000 with a mating coupler (or simulated
pounds (119,295 kg) gross weight on rail. coupler) having only frictional vertical
(a) For other than tank cars con- force resistance at the mating inter-
taining poisonous-by-inhalation mate- face; or a mating coupler (or simulated
rial, a tank car may be loaded to a coupler) having the capabilities de-
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Pipeline and Hazardous Materials Safety Admin., DOT 179.15
lading, having sufficient flow capacity 6.89 Bar (100 psig) or less and 3 percent
to prevent pressure build-up in the for valves with a start-to-discharge
tank to no more than the flow rating pressure greater than 6.89 Bar (100
pressure of the pressure relief device in psig).
263
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179.16 49 CFR Ch. I (10111 Edition)
(c) Flow capacity of pressure relief de- pressure, or 33% of the tank burst pres-
vices. The total flow capacity of each sure.
reclosing and nonreclosing pressure re- (2) The approach channel and the dis-
lief device must conform to appendix A charge channel may not reduce the re-
of the AAR Specifications for Tank quired minimum flow capacity of the
Cars. pressure relief device.
(d) Flow capacity tests. The manufac- (3) The non-reclosing pressure relief
turer of any reclosing or nonreclosing device must be designed to prevent
pressure relief device must design and interchange with other fittings in-
test the device in accordance with ap- stalled on the tank car, must have a
pendix A of the AAR Specifications for structure that encloses and clamps the
Tank Cars. rupture disc in position (preventing
(e) Combination pressure relief systems. any distortion or damage to the rup-
A non-reclosing pressure relief device ture disc when properly applied), and
may be used in series with a reclosing must have a cover, with suitable means
pressure relief valve. The pressure re- of preventing misplacement, designed
lief valve must be located outboard of to direct any discharge of the lading
the non-reclosing pressure relief de- downward.
vice. (4) The non-reclosing pressure relief
(1) When a breaking pin device is device must be closed with a rupture
used in combination with a reclosing disc that is compatible with the lading
pressure relief valve, the breaking pin and manufactured in accordance with
must be designed to fail at the start-to- Appendix A of the AAR Specifications
discharge pressure specified in para- for Tank Cars. The tolerance for a rup-
graph (b) of this section, and the re- ture disc is +0 to 15 percent of the
closing pressure relief valve must be burst pressure marked on the disc.
designed to discharge at not greater (g) Location of relief devices. Each
than 95 percent of the start-to-dis- pressure relief device must commu-
charge pressure. nicate with the vapor space above the
(2) When a rupture disc is used in lading as near as practicable on the
combination with a reclosing pressure longitudinal center line and center of
relief valve, the rupture disc must be the tank.
designed to burst at the pressure speci- (h) Marking of pressure relief devices.
fied in paragraph (b) of this section, Each pressure relief device and rupture
and the reclosing pressure relief valve disc must be permanently marked in
must be designed to discharge at not accordance with the appendix A of the
greater than 95 percent of the pressure. AAR Specifications for Tank Cars.
A device must be installed to detect [Amdt. 17952, 61 FR 28678, June 5, 1996, as
any accumulation of pressure between amended by Amdt. 17952, 61 FR 50255, Sept.
the rupture disc and the reclosing pres- 25, 1996; 62 FR 51561, Oct. 1, 1997; 64 FR 51919,
sure relief valve. The detection device Sept. 27, 1999; 66 FR 45390, Aug. 28, 2001; 68 FR
must be a needle valve, trycock, or 75759, Dec. 31, 2003]
tell-tale indicator. The detection de-
vice must be closed during transpor- 179.16 Tank-head puncture-resist-
tation. ance systems.
(3) The vapor tight pressure and the (a) Performance standard. When the
start-to-discharge tolerance is based on regulations in this subchapter require
the discharge setting of the reclosing a tank-head puncture-resistance sys-
pressure relief device. tem, the system shall be capable of sus-
(f) Nonreclosing pressure relief device. taining, without any loss of lading,
In addition to paragraphs (a), (b)(4), (c), coupler-to-tank-head impacts at rel-
and (d) of this section, a nonreclosing ative car speeds of 29 km/hour (18 mph)
pressure relief device must conform to when:
the following requirements: (1) The weight of the impact car is at
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Pipeline and Hazardous Materials Safety Admin., DOT 179.20
(480,000 pounds) and the hand brake is flux through tank discontinuities, pro-
applied on the last backup car; and tective housings, underframes, metal
(3) The impacted tank car is pressur- jackets, insulation, and thermal pro-
ized to at least 6.9 Bar (100 psig). tection. A complete record of each
(b) Verification by testing. Compliance analysis shall be made, retained, and
with the requirements of paragraph (a) upon request, made available for in-
of this section shall be verified by full- spection and copying by an authorized
scale testing according to appendix A representative of the Department. The
of this part. procedures outlined in Temperatures,
(c) Alternative compliance by other Pressures, and Liquid Levels of Tank
than testing. As an alternative to re- Cars Engulfed in Fires, DOT/FRA/
quirements prescribed in paragraph (b) OR&D84/08.11, (1984), Federal Railroad
of this section, compliance with the re- Administration, Washington, DC
quirements of paragraph (a) of this sec- (available from the National Technical
tion may be met by installing full-head Information Service, Springfield, VA)
protection (shields) or full tank-head shall be deemed acceptable for ana-
jackets on each end of the tank car lyzing the fire effects on the entire sur-
conforming to the following: face of the tank car.
(1) The full-head protection (shields) (2) When the analysis shows the ther-
or full tank-head jackets must be at mal resistance of the tank car does not
least 1.27 cm (0.5 inch) thick, shaped to conform to paragraph (a) of this sec-
the contour of the tank head and made tion, the thermal resistance of the
from steel having a tensile strength tank car must be increased by using a
greater than 379.21 N/mm2 (55,000 psi). system listed by the Department under
(2) The design and test requirements paragraph (c) of this section or by test-
of the full-head protection (shields) or ing a new or untried system and
full tank-head jackets must meet the verifying it according to appendix B of
impact test requirements in Section 5.3 this part.
of the AAR Specifications for Tank (c) Systems that no longer require test
Cars (IBR, see 171.7 of this sub- verification. The Department maintains
chapter). a list of thermal protection systems
(3) The workmanship must meet the that comply with the requirements of
requirements in Section C, Part II, appendix B of this part and that no
Chapter 5, of the AAR Specifications longer require test verification. Infor-
for Design, Fabrication, and Construc- mation necessary to equip tank cars
tion of Freight Cars (IBR, see 171.7 of with one of these systems is available
this subchapter). in the PHMSA Records Center, Pipe-
[Amdt. 17950, 60 FR 49077, Sept. 21, 1995, as line and Hazardous Materials Safety
amended by Amdt. 17950, 61 FR 33255, June Administration, East Building, 1200
26, 1996; 66 FR 45390, Aug. 28, 2001; 68 FR 75759, New Jersey Avenue, SE., Washington,
Dec. 31, 2003] DC 205900001.
179.18 Thermal protection systems. [Amdt. 17950, 60 FR 49077, Sept. 21, 1995, as
amended by Amdt. 17950, 61 FR 33256, June
(a) Performance standard. When the 26, 1996; 66 FR 45390, Aug. 28, 2001; 70 FR 56099,
regulations in this subchapter require Sept. 23, 2005; 72 FR 55696, Oct. 1, 2007]
thermal protection on a tank car, the
tank car must have sufficient thermal 179.20 Service equipment; protection
resistance so that there will be no re- systems.
lease of any lading within the tank car,
If an applicable tank car specifica-
except release through the pressure re-
tion authorizes location of filling or
lease device, when subjected to:
discharge connections in the bottom
(1) A pool fire for 100 minutes; and
shell, the connections must be de-
(2) A torch fire for 30 minutes.
signed, constructed, and protected ac-
(b) Thermal analysis. (1) Compliance
cording to paragraphs E9.00 and E10.00
with the requirements of paragraph (a)
of the AAR Specifications for Tank
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179.22 49 CFR Ch. I (10111 Edition)
266
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Pipeline and Hazardous Materials Safety Admin., DOT 179.1007
P = Minimum required bursting pressure in tensile strength and elongation in the
p.s.i.; welded condition. * * *
S = Minimum tensile strength of plate mate-
rial in p.s.i., as prescribed in 179.1007; Minimum elon-
t = Minimum thickness of plate in inches Minimum ten- gation in 2
sile strength inches (per-
after forming. Specifications (p.s.i.) 0 tem- cent) 0 tem-
per, welded per, welded
(b) If plates are clad with material condition 3,4 condition (lon-
having tensile strength properties at gitudinal)
least equal to the base plate, the clad- ASTM B 209, Alloy 5052 1 25,000 18
ding may be considered a part of the ASTM B 209, Alloy 5083 2 38,000 16
base plate when determining thickness. ASTM B 209, Alloy 5086 1 35,000 14
If cladding material does not have ten- ASTM B 209, Alloy 5154 1 30,000 18
sile strength at least equal to the base ASTM B 209, Alloy 5254 1 30,000 18
ASTM B 209, Alloy 5454 1 31,000 18
plate, the base plate alone shall meet
ASTM B 209, Alloy 5652 1 25,000 18
the thickness requirement.
1 For fabrication, the parent plate material may be 0, H112,
(c) When aluminum plate is used, the or H32 temper, but design calculations must be based on
minimum width of bottom sheet of minimum tensile strength shown.
2 0 temper only.
tank shall be 60 inches, measured on 3 Weld filler metal 5556 must not be used.
the arc, but in all cases the width shall 4 Maximum stress to be used in calculations.
267
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179.1008 49 CFR Ch. I (10111 Edition)
which is suitable for welding to the (c) Tank and welded attachments,
tank. fabricated from ASTM A 240/A 240M
(IBR, see 171.7 of this subchapter),
[Amdt. 17910, 36 FR 21344, Nov. 6, 1971, as
amended by Amdt. 17932, 48 FR 27707, June Type 304L or Type 316L materials do
16, 1983; Amdt. 17947, 58 FR 50237, Sept. 24, not require postweld heat treatment,
1993; Amdt. 17952, 61 FR 28679, June 5, 1996; but these materials do require a corro-
Amdt 17952, 61 FR 50255, Sept. 25, 1996; 66 FR sion resistance test as specified in
45186, Aug. 28, 2001; 67 FR 51660, Aug. 8, 2002; 179.1007(c)(2).
68 FR 75759, Dec. 31, 2003]
[Amdt. 17910, 36 FR 21345, Nov. 6, 1971, as
179.1008 Tank heads. amended by Amdt. 17947, 58 FR 50238, Sept.
24, 1993; Amdt. 17952, 61 FR 28679, June 5,
(a) The tank head shape shall be an 1996; 67 FR 51660, Aug. 8, 2002; 68 FR 75758 and
ellipsoid of revolution in which the 75759, Dec. 31, 2003]
major axis shall equal the diameter of
the shell adjacent to the head and the 179.10012 Manway nozzle, cover and
minor axis shall be one-half the major protective housing.
axis. (a) Manway nozzles must be of ap-
(b) Each tank head made from steel proved design of forged or rolled steel
which is required to be fine grain by for steel tanks or of fabricated alu-
the material specification, which is hot minum alloy for aluminum tanks, with
formed at a temperature exceeding 1700 an access opening of at least 18 inches
F., must be normalized after forming inside diameter, or at least 14 inches by
by heating to a temperature between 18 inches around or oval. Each nozzle
1550 and 1700 F., by holding at that must be welded to the tank and the
temperature for at least 1 hour per opening reinforced in an approved man-
inch of thickness (30-minute min- ner in compliance with the require-
imum), and then by cooling in air. If ments of AAR Specifications for Tank
the material specification requires Cars, appendix E, Figure E10 (IBR, see
quenching and tempering, the treat- 171.7 of this subchapter).
ment specified in that specification (b) Manway cover shall be machined
must be used instead of the one speci- to approved dimensions and be of
fied above. forged or rolled carbon or alloy steel,
rolled aluminum alloy or nickel when
[29 FR 18995, Dec. 29, 1964. Redesignated, 32
FR 5606, Apr. 5, 1967 and amended by Amdt.
required by the lading. Minimum
17912, 39 FR 15038, Apr. 30, 1974] thickness is listed in 179.101. Manway
cover shall be attached to manway noz-
179.1009 Welding. zle by through or stud bolts not enter-
ing tank, except as provided in
(a) All joints shall be fusion-welded
179.1032(a).
in compliance with the requirements of
(c) Except as provided in 179.103,
AAR Specifications for Tank Cars, ap-
protective housing of cast, forged or
pendix W (IBR, see 171.7 of this sub-
fabricated approved materials must be
chapter). Welding procedures, welders
bolted to manway cover with not less
and fabricators shall be approved.
than twenty 34-inch studs. The shear-
(b) [Reserved]
ing value of the bolts attaching protec-
[29 FR 18995, Dec. 29, 1964, as amended at 65 tive housing to manway cover must
FR 58632, Sept. 29, 2000; 68 FR 75759, Dec. 31, not exceed 70 percent of the shearing
2003] value of bolts attaching manway cover
to manway nozzle. Housing must have
179.10010 Postweld heat treatment. steel sidewalls not less than three-
(a) After welding is complete, steel fourths inch in thickness and must be
tanks and all attachments welded equipped with a metal cover not less
thereto must be postweld heat treated than one-fourth inch in thickness that
as a unit in compliance with the re- can be securely closed. Housing cover
quirements of AAR Specifications for must have suitable stop to prevent
wreier-aviles on DSK3TPTVN1PROD with CFR
Tank Cars, appendix W (IBR, see 171.7 cover striking loading and unloading
of this subchapter). connections and be hinged on one side
(b) For aluminum tanks, postweld only with approved riveted pin or rod
heat treatment is prohibited. with nuts and cotters. Openings in wall
268
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Pipeline and Hazardous Materials Safety Admin., DOT 179.10014
of housing must be equipped with screw (e) Bottom of tank shell may be
plugs or other closures. equipped with a sump or siphon bowl,
or both, welded or pressed into the
[29 FR 18995, Dec. 29, 1964. Redesignated at 32
FR 5606, Apr. 5, 1967, and amended by Amdt.
shell. Such sumps or siphon bowls, if
17910, 36 FR 21345, Nov. 6, 1971; 68 FR 75760, applied, are not limited in size and
Dec. 31, 2003] must be made of cast, forged or fab-
ricated metal. Each sump or siphon
179.10013 Venting, loading and un- bowl must be of good welding quality
loading valves, measuring and sam- in conjunction with the metal of the
pling devices. tank shell. When the sump or siphon
(a) Venting, loading and unloading bowl is pressed in the bottom of the
valves must be of approved design, tank shell, the wall thickness of the
made of metal not subject to rapid de- pressed section must not be less than
terioration by the lading, and must that specified for the shell. The section
withstand the tank test pressure with- of a circular cross section tank to
out leakage. The valves shall be bolted which a sump or siphon bowl is at-
to seatings on the manway cover, ex- tached need not comply with the out-
cept as provided in 179.103. Valve out- of-roundness requirement specified in
lets shall be closed with approved AAR Specifications for Tank Cars, ap-
screw plugs or other closures fastened pendix W, W14.06 (IBR, see 171.7 of this
to prevent misplacement. subchapter). Any portion of a sump or
siphon bowl not forming a part of cyl-
(b) The interior pipes of the loading
inder of revolution must have walls of
and unloading valves shall be anchored
such thickness and be so reinforced
and, except as prescribed in 173.314(j),
that the stresses in the walls caused by
179.102 or 179.103, may be equipped with a given internal pressure are no greater
excess flow valves of approved design. than the circumferential stress that
(c) Gauging device, sampling valve would exist under the same internal
and thermometer well are not speci- pressure in the wall of a tank of cir-
fication requirements. When used, they cular cross section designed in accord-
shall be of approved design, made of ance with 179.1006(a), but in no case
metal not subject to rapid deteriora- shall the wall thickness be less than
tion by the lading, and shall withstand that specified in 179.1011.
the tank test pressure without leakage.
Interior pipes of the gauging device and [29 FR 18995, Dec. 29, 1964. Redesignated at 32
FR 5606, Apr. 5, 1967, and amended by Amdt.
sampling valve, except as prescribed in
17910, 36 FR 21345, Nov. 6, 1971; Amdt. 17940,
173.314(j), 179.102 or 179.103, may be 52 FR 13046, Apr. 20, 1987; Amdt. 17942, 54 FR
equipped with excess flow valves of ap- 38798, Sept. 20, 1989; 65 FR 58632, Sept. 29,
proved design. Interior pipe of the ther- 2000; 68 FR 48571, Aug. 14, 2003; 68 FR 75760,
mometer well shall be anchored in an Dec. 31, 2003]
approved manner to prevent breakage
due to vibration. The thermometer 179.10014 Bottom outlets.
well shall be closed by an approved (a) Bottom outlets for discharge of
valve attached close to the manway lading is prohibited, except as provided
cover, or other approved location, and in 179.1033. If indicated in 179.101,
closed by a screw plug. Other approved tank may be equipped with a bottom
arrangements that permit testing ther- washout of approved construction. If
mometer well for leaks without com- applied, bottom washout shall be in ac-
plete removal of the closure may be cordance with the following require-
used. ments;
(d) An excess flow valve as referred to (1) The extreme projection of the bot-
in this specification, is a device which tom washout equipment may not be
closes automatically against the out- more than that allowed by appendix E
ward flow of the contents of the tank of the AAR Specifications for Tank
in case the external closure valve is Cars (IBR, see 171.7 of this sub-
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179.10016 49 CFR Ch. I (10111 Edition)
270
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Pipeline and Hazardous Materials Safety Admin., DOT 179.1011
[Amdt. 17952, 61 FR 28679, June 5, 1996 as amended at 66 FR 45390, Aug. 28, 2001; 68 FR 75760,
Dec. 31, 2003]
271
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179.102 49 CFR Ch. I (10111 Edition)
272
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Pipeline and Hazardous Materials Safety Admin., DOT 179.10217
(d) A thermometer well may be in- (i) ASTM A 516/A 516M and A 537/A
stalled. 537M material must meet the Charpy
(e) Only an approved gaging device V-notch test requirements, in longitu-
may be installed. dinal direction of rolling, of ASTM A
273
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179.103 49 CFR Ch. I (10111 Edition)
20/A 20M (IBR, see 171.7 of this sub- MINIMUM OPERATING TEMPERATURE l
chapter). F.
(ii) AAR Specification TC 128 mate- (l) The tank car and insulation must
rial must meet the Charpy V-notch be designed to prevent the pressure of
test requirements, in longitudinal di- the lading from increasing from the
rection of rolling of 15 ft.-lb. minimum pressure at the maximum allowable
average for 3 specimens, with a 10 ft.- filling density to the start-to-discharge
lb. minimum for any one specimen, at pressure of the pressure relief valve
minus 50 F or colder, in accordance within 30 days, at an ambient tempera-
with ASTM A 370 (IBR, see 171.7 of ture of 90 F.
this subchapter). (m) Except as provided in 173.314(d),
(iii) Production welded test plates tank cars built on or after March 16,
must 2009 used for the transportation of hy-
(A) Be prepared in accordance with drogen chloride, refrigerated liquid,
AAR Specifications for Tank Cars, ap- must meet the applicable authorized
pendix W, W4.00 (IBR, see 171.7 of this tank car specification listed in
subchapter); 173.314(c).
(B) include impact test specimens of
weld metal and heat affected zone pre- [Amdt. 17932, 48 FR 27708, June 16, 1983, as
pared and tested in accordance with amended at 48 FR 50441, Nov. 1, 1983; 49 FR
AAR Specifications for Tank Cars, ap- 24317, June 12, 1984; 49 FR 42736, Oct. 24, 1984;
Amdt. 17945, 55 FR 52728, Dec. 21, 1990; 66 FR
pendix W, W9.00; and 45390, Aug. 28, 2001; 67 FR 51660, Aug. 8, 2002;
(C) meet the same impact require- 68 FR 75758, 75760, Dec. 31, 2003; 74 FR 1802,
ments as the plate material. Jan. 13, 2009]
(c) Insulation must be of approved
material. 179.103 Special requirements for
(d) Pressure relief valves must be class 114A * * * tank car tanks.
trimmed with monel or other approved (a) In addition to the applicable re-
material and equipped with a rupture quirements of 179.100 and 179.101 the
disc of silver, polytetrafluoroethylene following requirements shall be com-
coated monel, or tantalum. Each pres- plied with:
sure relief device shall have the space (b) [Reserved]
between the rupture disc and the valve
vented with a suitable auxiliary valve. 179.1031 Type.
The discharge from each pressure relief
(a) Tanks built under this section
valve must be directed outside the pro-
may be of any approved cross section.
tective housing.
(e) Loading and unloading valves (b) Any portion of the tank shell not
must be trimmed with Hastelloy B or circular in cross section shall have
C, monel, or other approved material, walls of such thickness and be so rein-
and identified as Vapor or Liquid. forced that the stresses in the walls
Excess flow valves must be installed caused by a given internal pressure are
under all liquid and vapor valves, ex- no greater than the circumferential
cept safety relief valves. stresses which would exist under the
(f) A thermometer well may be in- same internal pressure in the wall of a
stalled. tank of circular cross section designed
(g) Only an approved gaging device in accordance with paragraphs 179.100
may be installed. 6 (a) and (b), but in no case shall the
(h) A sump must be installed in the wall thickness be less than that speci-
bottom of the tank under the liquid fied in 179.101.
pipes. (c) [Reserved]
(i) All gaskets must be made of, or (d) Valves and fittings need not be
coated with, polytetrafluoroethylene mounted on the manway cover.
or other approved material. (e) One opening may be provided in
(j) The tank car tank may be each head for use in purging the tank
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Pipeline and Hazardous Materials Safety Admin., DOT 179.1035
end.
[29 FR 18995, Dec. 29, 1964. Redesignated at 32 (b) Bottom outlet equipment must be
FR 5606, Apr. 5, 1967, and amended by Amdt.
of approved design and must meet the
17910, 36 FR 21348, Nov. 6, 1971]
following requirements:
275
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179.200 49 CFR Ch. I (10111 Edition)
(1) The extreme projection of the bot- clude an in-line auxiliary valve, either
tom outlet equipment may not be more integral with the quick-coupling device
than allowed by appendix E of the AAR or located between the primary bottom
Specifications for Tank Cars (IBR, see outlet valve and the quick-coupling de-
171.7 of this subchapter). All bottom vice. The quick-coupling device closure
outlet reducers and closures and their dust cap or outlet nozzle shall be fitted
attachments shall be secured to the car with a minimum 1-inch NPT closure
by at least 38 inch chain, or its equiva- (see Fig. E17.8 and E17.9).
lent, except that bottom outlet closure (3) The valve operating mechanism
plugs may be attached by 14 inch chain. must be provided with a suitable lock-
When the bottom outlet closure is of ing arrangement to insure positive clo-
the combination cap and valve type, sure during transit.
the pipe connection to the valve shall (4) If the outlet nozzle extends 6
be closed by a plug, cap, or approved inches or more from shell of tank, a V-
quick coupling device. The bottom out- shaped breakage groove shall be cut
let equipment should include only the (not cast) in the upper part to the out-
valve, reducers and closures that are let nozzle at a point immediately below
necessary for the attachment of un- the lowest part of value closest to the
loading fixtures. The permanent at- tank. In no case may the nozzle wall
tachment of supplementary exterior thickness at the roof of the V be
fittings must be approved by the AAR more than 14-inch. On cars without
Committee on Tank Cars. continuous center sills, the breakage
(2) To provide for the attachment of groove or its equivalent may not be
unloading connections, the discharge more than 15 inches below the tank
end of the bottom outlet nozzle or re- shell. On cars with continuous center
ducer, the valve body of the exterior sills, the breakage groove or its equiva-
valve, or some fixed attachment there- lent must be above the bottom of the
to, shall be provided with one of the center sill construction.
following arrangements or an approved (5) The valve body must be of a thick-
modification thereof. (See appendix E. ness which will insure that accidental
Fig. E17 of the AAR Specifications for breakage of the outlet nozzle will occur
Tank Cars for illustrations of some of at or below the V groove, or its
the possible arrangements.) equivalent, and will not cause distor-
(i) A bolted flange closure arrange- tion of the valve seat or valve.
ment including a minimum 1-inch NPT [Amdt. 17910, 36 FR 21348, Nov. 6, 1971, as
pipe plug (see Fig. E17.1) or including amended by Amdt. 17940, 52 FR 13046, Apr.
an auxiliary valve with a threaded clo- 20, 1987; Amdt. 17941, 52 FR 36672, Sept. 30,
sure. 1987; Amdt. 17950, 60 FR 49077, Sept. 21, 1995;
(ii) A threaded cap closure arrange- Amdt. 17952, 61 FR 28680, June 5, 1996; Amdt.
17953, 61 FR 51342, Oct. 1, 1996; 66 FR 45186,
ment including a minimum 1-inch NPT
Aug. 28, 2001; 68 FR 75761, Dec. 31, 2003]
pipe plug (see Fig. E17.2) or including
an auxiliary valve with a threaded clo-
sure. Subpart DSpecifications for Non-
(iii) A quick-coupling device using a Pressure Tank Car Tanks
threaded plug closure of at least 1-inch (Classes DOT-111AW and
NPT or having a threaded cap closure 115AW)
with a minimum 1-inch NPT pipe plug
(see Fig. E17.3 through E17.5). A min- 179.200 General specifications appli-
imum 1-inch auxiliary test valve with a cable to non-pressure tank car
tanks (Class DOT-111).
threaded closure may be substituted
for the 1-inch pipe plug (see Fig E17.6). 179.2001 Tank built under these
If the threaded cap closure does not specifications must meet the re-
have a pipe plug or integral auxiliary quirements of 179.200, and
test valve, a minimum 1-inch NPT pipe 179.201.
plug shall be installed in the outlet
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Pipeline and Hazardous Materials Safety Admin., DOT 179.2006
277
EC13NO91.032</MATH>
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179.2007 49 CFR Ch. I (10111 Edition)
278
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Pipeline and Hazardous Materials Safety Admin., DOT 179.20011
(g) All parts and items of construc- inch and not more than 112-inch solid
tion in contact with the lading must be pipe plugs having NPT threads.
made of material compatible with (b) When the tank is divided into
plate material and not subject to rapid compartments by constructing each
deterioration by the lading, or be coat- compartment as a separate tank, these
ed or lined with suitable corrosion re- tanks shall be joined together by a cyl-
sistant material. inder made of plate, having a thickness
(h) All external projections that may not less than that required for the tank
be in contact with the lading and all shell and applied to the outside surface
castings, forgings, or fabrications used of tank head flanges. The cylinder shall
for fittings or attachments to tank and fit the straight flange portion of the
expansion dome, when used, in contact compartment tank head tightly. The
with lading must be made of material cylinder shall contact the head flange
to an approved specification. See AAR for a distance of at least two times the
Specifications for Tank Cars, appendix plate thickness, or a minimum of 1
M, M4.05 (IBR, see 171.7 of this sub- inch, whichever is greater. The cyl-
chapter) for approved material speci- inder shall be joined to the head flange
fications for castings for fittings.
by a full fillet weld. Distance from
[Amdt. 17910, 36 FR 21349, Nov. 9, 1971; 36 FR head seam to cylinder shall not be less
21893, Nov. 17, 1971, as amended by Amdt.179 than 112 inches or three times the plate
28, 46 FR 49906, Oct. 8, 1981; Amdt. 17940, 52 thickness, whichever is greater. Voids
FR 13046, Apr. 20, 1987; Amdt. 17952, 61 FR
28680, June 5, 1996; 66 FR 45186, Aug. 28, 2001;
created by the space between heads of
67 FR 51660, Aug. 8, 2002; 68 FR 75761, Dec. 31, tanks joined together to form a com-
2003; 70 FR 34076, June 13, 2005] partment tank shall be provided with a
tapped drain hole at their lowest point
179.2008 Tank heads. and a tapped hole at top of tank. The
(a) All external tank heads must be top hole shall be closed and the bottom
an ellipsoid of revolution in which the hole may be closed with solid pipe
major axis must equal the diameter of plugs not less than 34 inch nor more
the shell and the minor axis must be than 112 inches having NPT threads.
one-half the major axis. [29 FR 18995, Dec. 29, 1964. Redesignated at 32
(b) Internal compartment tank heads FR 5606, Apr. 5, 1967, and amended by Amdt.
may be 2:1 ellipsoidal, 3:1 ellipsoidal, or 17910, 36 FR 21350, Nov. 6, 1971; 66 FR 45186,
flanged and dished to thicknesses as Aug. 28, 2001; 68 FR 75761, Dec. 31, 2003]
specified in 179.2006. Flanged and
dished heads must have main inside ra- 179.20010 Welding.
dius not exceeding 10 feet, and inside (a) All joints shall be fusion-welded
knuckle radius must not be less than in compliance with the requirements of
334 inches for steel, alloy steel, or nick- AAR Specifications for Tank Cars, ap-
el tanks, and not less than 5 inches for pendix W (IBR, see 171.7 of this sub-
aluminum alloy tanks. chapter). Welding procedures, welders
[Amdt. 17910, 36 FR 21350, Nov. 6, 1971] and fabricators shall be approved.
(b) Welding is not permitted on or to
179.2009 Compartment tanks. ductile iron or malleable iron fittings.
(a) When a tank is divided into com-
[29 FR 18995, Dec. 29, 1964. Redesignated at 32
partments, by inserting interior heads, FR 5606, Apr. 5, 1967, and amended by Amdt.
interior heads must be inserted in ac- 17910, 36 FR 21350, Nov. 6, 1971; 68 FR 75761,
cordance with AAR Specifications for Dec. 31, 2003]
Tank Cars, appendix E, E7.00 (IBR, see
171.7 of this subchapter), and must 179.20011 Postweld heat treatment.
comply with the requirements specified
When specified in 179.2011, after
in 179.2011. Voids between compart-
welding is complete, postweld heat
ment heads must be provided with at
treatment must be in compliance with
least one tapped drain hole at their
the requirements of AAR Specifica-
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179.20013 49 CFR Ch. I (10111 Edition)
280
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Pipeline and Hazardous Materials Safety Admin., DOT 179.20016
(b) Manway covers shall be designed and enclosed within a housing. Other
to provide a secure closure of the approved devices may be used in lieu of
manway. outage scale or telltale pipe.
(c) Manway covers must be of ap- (e) Bottom of tank shell may be
proved cast, forged, or fabricated met- equipped with a sump or siphon bowl,
als. Malleable iron, if used, must com- or both, welded or pressed into the
ply with ASTM A 47 (IBR, see 171.7 of shell. Such sumps or siphon bowls, if
this subchapter), Grade 35018. Cast iron applied are not limited in size and
manway covers must not be used. must be made of cast, forged, or fab-
(d) All joints between manway covers ricated metal. Each sump or siphon
and their seats shall be made tight bowl must be of good welding quality
against leakage of vapor and liquid by in conjunction with the metal of the
use of gaskets of suitable material. tank shell. When sump or siphon bowl
(e) For other manway cover require- is pressed in the bottom of the tank
ments see 179.2011. shell, the wall thickness of the pressed
section must not be less than that
[29 FR 18995, Dec. 29, 1964. Redesignated at 32
FR 5606, Apr. 5, 1967, and amended by Amdt.
specified for the shell. The section of a
17910, 36 FR 21350, Nov. 6, 1971; Amdt. 17937, circular cross section tank to which a
50 FR 11066, Mar. 19, 1985; 68 FR 75762, Dec. 31, sump or siphon bowl is attached need
2003] not comply with the out-of-roundness
requirement specified in appendix W,
179.20016 Gauging devices, top load- W14.06, of the AAR Specifications for
ing and unloading devices, venting Tank Cars. Any portion of a sump or si-
and air inlet devices. phon bowl not forming a part of a cyl-
(a) When installed, these devices inder of revolution must have walls of
shall be of an approved design which such thickness and be so reinforced
will prevent interchange with any that the stresses in the walls caused by
other fixture, and be tightly closed. a given internal pressure are not great-
Unloading pipes shall be securely an- er than the circumferential stress
chored within the tank. Each tank or which would exist under the same in-
compartment may be equipped with ternal pressure in the wall of a tank of
one separate air connection. circular cross section designed in ac-
(b) When the characteristics of the cordance with 179.2006 (a) and (d). In
commodity for which the car is author- no case shall the wall thickness be less
ized are such that these devices must than that specified in 179.2011.
be equipped with valves or fittings to (f) When top loading and discharge
permit the loading and unloading of devices, or venting and air inlet de-
the contents, these devices, including vices are installed with exposed piping
valves, shall be of an approved design, to a removed location, shutoff valves
and be provided with a protective hous- must be applied directly to reinforcing
ing except when plug or ball type pads or nozzles at their communication
valves with operating handles removed through the tank shell, and must be
are used. Provision shall be made for enclosed in a protective housing with
closing pipe connections of valves. provision for a seal. The piping must
(c) A tank may be equipped with a include breakage grooves, and suitable
vacuum relief valve of an approved de- bracing. Relief valves must be applied
sign. Protective housing is not re- to liquid lines for protection in case
quired. lading is trapped. Provision must be
(d) When using a visual gauging de- made to insure closure of the valves
vice on a car with a hinged manway while the car is in transit.
cover, an outage scale visible through (g) Protective housing, when re-
the manway opening shall be provided. quired, must be fabricated of approved
If loading devices are applied to permit material and have cover and sidewalls
tank loading with cover closed, a tell- not less than 0.119 inch in thickness.
tale pipe may be provided. Telltale pipe
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179.20017 49 CFR Ch. I (10111 Edition)
the valve due to stresses or shocks in- closest to the tank. In no case may the
cident to transportation. nozzle wall thickness at the root of the
(5) Bottom outlet nozzle of interior V be more than 14 inch. The outlet
valves and the valve body of exterior nozzle on interior valves or the valve
282
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Pipeline and Hazardous Materials Safety Admin., DOT 179.20019
body on exterior valves may be steam tank, a V-shaped breakage groove shall
jacketed, in which case the breakage be cut (not cast) in the upper part of
groove or its equivalent must be below the nozzle at a point immediately
the steam chamber but above the bot- below the lowest part of the inside clo-
tom of center sill construction. If the sure seat or plug. In no case may the
outlet nozzle is not a single piece, or if nozzle wall thickness at the root of the
exterior valves are applied, provisions V be more than 14 inch. Where the
shall be made for the equivalent of the nozzle is not a single piece, provisions
breakage groove. On cars without con- shall be made for the equivalent of the
tinuous center sills, the breakage breakage groove. The nozzle must be of
groove or its equivalent must be no a thickness to insure that accidental
more than 15 inches below the tank breakage will occur at or below the
shell. On cars with continuous center V groove or its equivalent. On cars
sills, the breakage groove or its equiva- without continuous center sills, the
lent must be above the bottom of the
breakage groove or its equivalent may
center sill construction.
not be more than 15 inches below the
(8) The flange on the outlet nozzle or
outer shell. On cars with continuous
the valve body of exterior valves must
be of a thickness which will prevent center sills, the breakage groove or its
distortion of the valve seat or valve by equivalent must be above the bottom
any change in contour of the shell re- of the center sill construction.
sulting from expansion of lading, or (4) The closure plug and seat must be
other causes, and which will insure readily accessible or removable for re-
that accidental breakage of the outlet pairs, including grinding.
nozzle will occur at or below the V (5) The closure of the washout nozzle
groove, or its equivalent. must be equipped with a 34-inch solid
(9) The valve must have no wings or screw plug. Plug must be attached by
stem projecting below the V groove at least a 14-inch chain.
or its equivalent. The valve and seat (6) Joints between closures and their
must be readily accessible or remov- seats may be gasketed with suitable
able for repairs, including grinding. material.
(10) The valve operating mechanism
on interior valves must have means for [29 FR 18995, Dec. 29, 1964. Redesignated at 32
FR 5606, Apr. 5, 1967, and amended by Amdt.
compensating for variation in the
17910, 36 FR 21351, Nov. 6, 1971; Amdt. 17940,
vertical diameter of the tank produced 52 FR 13047, Apr. 20, 1987; 68 FR 75762, Dec. 31,
by expansion, weight of the liquid con- 2003]
tents, or other causes, and may operate
from the interior of the tank, but in 179.20019 Reinforcements, when
the event the rod is carried through used, and appurtenances not other-
the dome, or tank shell, leakage must wise specified.
be prevented by packing in stuffing box
(a) All attachments to tank and
or other suitable seals and a cap.
dome shall be applied by approved
(b) If indicated in 179.2011, tank
means. Rivets if used shall be caulked
may be equipped with bottom washout
of approved construction. If applied, inside and outside.
bottom washout shall be in accordance (b) Reinforcing pads must be used be-
with the following requirements: tween external brackets and shells if
(1) The extreme projection of the bot- the attachment welds exceed 6 lineal
tom washout equipment may not be inches of 14-inch fillet or equivalent
more than that allowed by appendix E weld per bracket or bracket leg. When
of the AAR Specifications for Tank reinforcing pads are used, they must
Cars. not be less than one-fourth inch in
(2) Bottom washout shall be of cast, thickness, have each corner rounded to
forged or fabricated metal. If welded to a 1 inch minimum radius, and be at-
tank, they shall be of good weldable tached to the tank by continuous fillet
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179.20021 49 CFR Ch. I (10111 Edition)
111A60ALW1 ... Optional .......... 240 12 60 Optional .......... Optional .......... 6(a).
111A60ALW2 ... Optional .......... 240 12 60 No ................... Optional.
111A60W1 ....... Optional .......... 240
7 16 60 Optional .......... Optional .......... 6(a).
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Pipeline and Hazardous Materials Safety Admin., DOT 179.2013
Minimum
Bursting Test
DOT Specifica- plate Bottom Bottom References
Insulation pressure pressure
tion 1 thickness outlet washout (179.201 - ***)
(psig) (psig)
(inches)
[Amdt. 17952, 61 FR 28680, June 5, 1996, as amended by 66 FR 45390, Aug. 28, 2001; 68 FR 48571,
Aug. 14, 2003]
(3) Other approved lining materials the lading need not be covered with
may be used provided the material is rubber or other acid resistant material.
resistant to the corrosive or solvent ac- (e) Hard rubber or polyvinyl chloride
tion of the lading in the liquid or gas may be used for pressure retaining
285
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179.2014 49 CFR Ch. I (10111 Edition)
parts of safety vents provided the ma- sion resistance specified in 179.200
terial is resistant to the corrosive or 7(d), Footnote 2.
solvent action of the lading in the liq- [68 FR 75762, Dec. 31, 2003]
uid or gas phase and is suitable for the
service temperatures. 179.2016 Manways and manway clo-
(f) Polyvinyl chloride lined tanks. sures.
Tank car tanks or each compartment (a) The manway cover for spec. DOT
thereof may be lined with elastomeric 104W, 111A60ALW1, 111A60W1,
polyvinyl chloride having a minimum 111A100ALW1, 111A100W1, 111A100W3,
lining thickness of three thirty-seconds or 111A100W6 must be designed to make
inch. it impossible to remove the cover while
(g) Polyurethane lined tanks. Tank the interior of the tank is subjected to
car tanks or each compartment thereof pressure.
may be lined with elastomeric poly- (b) The manway cover for spec. DOT
urethane having a minimum lining 11A60W5, or 111A100W5 must be made of
thickness of one-sixteenth inch. a suitable metal. The top, bottom and
edge of manway cover must be acid re-
[Amdt. 17910, 36 FR 21352, Nov. 6, 1971, as sistant material covered as prescribed
amended at 66 FR 45186, Aug. 28, 2001; 68 FR in 179.2013. Through-bolt holes must
48571, Aug. 14, 2003]
be lined with acid resistant material at
179.2014 Material. least one-eighth inch in thickness.
Cover made of metal not affected by
All fittings, tubes, and castings and the lading need not be acid resistant
all projections and their closures, ex- material covered.
cept for protective housing, must also (c) The manway ring and cover for
meet the requirements specified in specifications DOT-103CW, 103DW,
ASTM A 262 (IBR, see 171.7 of this sub- 103EW, 111360W7, or 11A100W6 must be
chapter), except that when preparing made of the metal and have the same
the specimen for testing the carburized inspection procedures specified in AAR
surface may be finished by grinding or Specifications for Tank Cars, appendix
machining. M, M3.03 (IBR, see 171.7 of this sub-
chapter).
[68 FR 75762, Dec. 31, 2003]
[Amdt. 17910, 36 FR 21353, Nov. 6, 1971; 66 FR
179.2015 Postweld heat treatment 45186, Aug. 28, 2001; 68 FR 48571, Aug. 14, 2003;
and corrosion resistance. 68 FR 75762, Dec. 31, 2003]
(a) Tanks and attachments welded di- 179.2018 Sampling device and ther-
rectly thereto must be postweld heat mometer well.
treated as a unit at the proper tem- (a) Sampling valve and thermometer
perature except as indicated below. well are not specification require-
Tanks and attachments welded directly ments. When used, they must be of ap-
thereto fabricated from ASTM A 240/A proved design, made of metal not sub-
240M (IBR, see 171.7 of this sub- ject to rapid deterioration by lading,
chapter) Type 430A, Type 304 and Type and must withstand a pressure of 100
316 materials must be postweld heat psig without leakage. Interior pipes of
treated as a unit and must be tested to the sampling valve must be equipped
demonstrate that they possess the cor- with excess flow valves of an approved
rosion resistance specified in 179.200 design. Interior pipe of thermometer
7(d), Footnote 2. Tanks and attach- well must be closed by an approved
ments welded directly thereto, fab- valve attached close to fitting where it
ricated from ASTM A 240/A 240M Type passes through the tank and closed by
304L or Type 316L materials are not re- a screw plug. Other approved arrange-
quired to be postweld heat treated. ments that permit testing thermom-
(b) Tanks and attachments welded di- eter well for leaks without complete
wreier-aviles on DSK3TPTVN1PROD with CFR
rectly thereto, fabricated from ASTM removal of the closure may be used.
A 240/A 240M Type 304L and Type 316 (b) [Reserved]
materials must be tested to dem- [Amdt. 17910, 36 FR 21348, Nov. 6, 1971, as
onstrate that they possess the corro- amended at 66 FR 45390, Aug. 28, 2001]
286
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Pipeline and Hazardous Materials Safety Admin., DOT 179.2206
287
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179.2207 49 CFR Ch. I (10111 Edition)
2 This specification is incorporated by reference (IBR, see
t = Minimum thickness of plate in inches
171.7 of this subchapter).
after forming.
(b) The wall thickness after forming (c) Aluminum alloy plate: Aluminum
of the inner container heads, if flanged alloy plate must be suitable for weld-
and dished, must be not less than speci- ing and comply with one of the fol-
fied in 179.2211, or not less than that lowing specifications (IBR, see 171.7 of
calculated by the following formula: this subchapter): * * *
5 PL Minimum Minimum
elongation
t= tensile in 2 inches
strength
6 SE Specifications (p.s.i.) (percent)
weld metal
Where: welded (longitu-
condition3,4
E = 0.9 welded joint efficiency; except E=1.0 dinal)
for seamless heads;
ASTM B 209, Alloy 5052 1 ............. 25,000 18
L = Main inside radius to which head is
ASTM B 209, Alloy 5083 2 ............. 38,000 16
dished, measured on concave side in inches;
ASTM B 209, Alloy 5086 1 ............. 35,000 14
P = Minimum required bursting pressure in
ASTM B 209, Alloy 5154 1 ............. 30,000 18
psig;
ASTM B 209, Alloy 5254 1 ............. 30,000 18
S = Minimum tensile strength of plate mate-
ASTM B 209, Alloy 5454 1 ............. 31,000 18
rial in psi as prescribed in AAR Specifica-
ASTM B 209, Alloy 5652 1 ............. 25,000 18
tions for Tank Cars, appendix M, Table M1
(IBR, see 171.7 of this subchapter); 1 For fabrication, the parent plate material may be 0 H112,
t = Minimum thickness of plate in inches or H32 temper, but design calculations must be based on the
minimum tensile strength shown.
after forming. 2 0 temper only.
3 Weld filler metal 5556 must not be used.
(c) The wall thickness after forming 4 Maximum stresses to be used in calculations.
of the cylindrical section and heads of
the outer shell must be not less than (d) High alloy steel plate: High alloy
seven-sixteenths of an inch. steel plate must comply with one of
(d) See 179.2209 for plate thickness the following specifications (IBR, see
requirements for inner container when 171.7 of this subchapter):
divided into compartments.
Minimum
[Amdt. 1799, 36 FR 21340, Nov. 6, 1971, as Minimum elongation
tensile
amended at 66 FR 45390, Aug. 28, 2001; 68 FR in 2 inches
strength
Specifications (percent)
75762, Dec. 31, 2003] (p.s.i.) weld metal
welded (longitu-
condition1
179.2207 Materials. dinal)
(a) The plate material used to fab- ASTM A 240/A 240M (incor-
ricate the inner container and nozzles porated by reference; see
171.7 of this subchapter),
must meet one of the following speci- Type 304 .................................... 75,000 30
fications and with the indicated min- ASTM A 240/A 240M (incor-
imum tensile strength and elongation porated by reference; see
in the welded condition. 171.7 of this subchapter),
Type 304L .................................. 70,000 30
(b) Carbon steel plate: The maximum ASTM A 240/A 240M (incor-
allowable carbon content must be 0.31 porated by reference; see
percent when the individual specifica- 171.7 of this subchapter),
tion allows carbon content greater Type 316 .................................... 74,000 30
ASTM A 240/A 240M (incor-
than this amount. The plates may be porated by reference; see
clad with other approved materials. 171.7 of this subchapter),
Type 316L .................................. 70,000 30
Minimum
Minimum 1 Maximum
elongation stresses to be used in calculations.
tensile in 2 inches
strength
Specifications (percent) (e) Manganese-molybdenum steel
(p.s.i.) weld metal
welded plate: Manganese-molybdenum steel
(longitu-
condition 1 dinal)
plate must be suitable for fusion weld-
ing and must comply with the fol-
wreier-aviles on DSK3TPTVN1PROD with CFR
288
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Pipeline and Hazardous Materials Safety Admin., DOT 179.22011
shell and the minor axis must be one- (b) Postweld heat treatment of the
half the major axis. cylindrical portions of the outer shell
[Amdt. 1799, 36 FR 21341, Nov. 6, 1971] to which the anchorage or draft sills
are attached must comply with AAR
289
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179.22013 49 CFR Ch. I (10111 Edition)
filled with liquid lading to any level. valves, shall be provided with a protec-
The support system must be designed tive housing except when plug or ball-
to support, without yielding, impact type valves with operating handles re-
loads producing accelerations of the moved are used. Provision must be
290
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Pipeline and Hazardous Materials Safety Admin., DOT 179.22018
and must have cover and sidewalls not be cut (not cast) in the upper part of
less than 0.119 inch in thickness. the outlet nozzle at a point imme-
[Amdt. 1799, 36 FR 21341, Nov. 6, 1971, as diately below the lowest part of the
amended at 69 FR 54047, Sept. 7, 2004] valve closest to the tank. In no case
291
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179.22020 49 CFR Ch. I (10111 Edition)
may the nozzle wall thickness at the thickness to insure that accidental
root of the V be more than 14-inch. breakage will occur at or below the
The outlet nozzle or the valve body V groove or its equivalent. On cars
may be steam jacketed, in which case without a continuous center sill, the
the breakage groove or its equivalent breakage groove or its equivalent may
must be below the steam chamber but not be more than 15 inches below the
above the bottom of the center sill con- outer shell. On cars with continuous
struction. If the outlet nozzle is not a center sills, the breakage groove or its
single piece or its exterior valves are equivalent must be above the bottom
applied, provision shall be made for the of the center sill construction.
equivalent of the breakage groove. On (4) The closure plug and seat must be
cars without continuous center sills, readily accessible or removable for re-
the breakage groove or its equivalent pairs.
may not be more than 15 inches below (5) The closure of the washout nozzle
the outer shell. On cars with contin- must be equipped with a 34-inch solid
uous center sills, the breakage groove screw plug. Plug must be attached by
or its equivalent must be above the at least a 14-inch chain.
bottom of the center sill construction. (6) Joints between closures and their
(7) The valve body must be of a thick- seats may be gasketed with suitable
ness which will prevent distortion of material.
the valve seat or valve by any change
in contour of the shell resulting from [Amdt. 1799, 36 FR 21342, Nov. 6, 1971, as
amended by Amdt. 17940, 52 FR 13048, Apr.
expansion of lading, or other causes,
20, 1987; 68 FR 75763, Dec. 31, 2003]
and which will insure that accidental
breakage of the outlet nozzle will occur 179.22020 Reinforcements, when
at or below the V groove, or its used, and appurtenances not other-
equivalent. wise specified.
(8) The valve must have no wings or
All attachments to inner container
stem projection below the V groove
and outer shell must be applied by ap-
or its equivalent. The valve and seat
proved means.
must be readily accessible or remov-
able for repairs, including grinding. [Amdt. 1799, 36 FR 21342, Nov. 6, 1971]
(b) Inner container may be equipped
with bottom washout of approved de- 179.22022 Closure for openings.
sign. If applied, bottom washout must (a) All plugs must be solid, with NPT
comply with the following require- threads, and must be of a length which
ments: will screw at least six threads inside
(1) The extreme projection of the bot- the face of fitting or tank. Plugs, when
tom washout equipment may not be inserted from the outside of the outer
more than that allowed by appendix E shell tank heads, must have the letter
of the AAR Specifications for Tank S at least three-eighths inch in size
Cars. stamped with steel stamp or cast on
(2) Bottom washout must be of cast, the outside surface to indicate the plug
forged or fabricated metals. If it is is solid.
welded to the inner container, it must (b) Openings in the outer shell used
be of good weldable quality in conjunc- during construction for installation
tion with metal of tank. must be closed in an approved manner.
(3) If washout nozzle extends below
the bottom of the outer shell, a V- [Amdt. 1799, 36 FR 21343, Nov. 6, 1971]
shaped breakage groove shall be cut
(not cast) in the upper part of the noz- 179.22023 Test of tanks.
zle at a point immediately below the (a) Each inner container or compart-
lowest part of the inside closure seat or ment must be tested hydrostatically to
plug. In no case may the nozzle wall the pressure specified in 179.2211. The
thickness at the root of the V be temperature of the pressurizing me-
wreier-aviles on DSK3TPTVN1PROD with CFR
more than 14-inch. Where the nozzle is dium must not exceed 100 F. during
not a single piece, provisions shall be the test. The container must hold the
made for the equivalent of the break- prescribed pressure for at least 10 min-
age groove. The nozzle must be of a utes without leakage or evidence of
292
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Pipeline and Hazardous Materials Safety Admin., DOT 179.2211
[Amdt. 17052, 61 FR 28681, June 5, 1996, as amended at 62 FR 51561, Oct. 1, 1997; 66 FR 45390,
Aug. 28, 2001]
wreier-aviles on DSK3TPTVN1PROD with CFR
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179.300 49 CFR Ch. I (10111 Edition)
294
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Pipeline and Hazardous Materials Safety Admin., DOT 179.30013
(c) All plates must have their heat welds in tanks less than 36 inches in-
number and the name or brand of the side diameter need not be radiotaped.
manufacturer legibly stamped on them (c) Forge-welded joints shall be thor-
at the rolling mill. oughly hammered or rolled to insure
[Amdt. 17910, 36 FR 21355, Nov. 6, 1971, as sound welds. The flanges of the heads
amended by Amdt. 17942, 54 FR 38798, Sept. shall be forge lapwelded to the shell
20, 1989; Amdt. 17943, 55 FR 27642, July 5, and then crimped inwardly toward the
1990; Amdt. 17952, 61 FR 28682, June 5, 1996; center line at least one inch on the ra-
Amdt. 17952, 61 FR 50255, Sept. 25, 1996; dius. Welding and crimping must be ac-
Amdt. 17953, 61 FR 51342, Oct. 1, 1996; 68 FR complished in one heat.
75763, Dec. 31, 2003]
[29 FR 18995, Dec. 29, 1964. Redesignated at 32
179.3008 Tank heads. FR 5606, Apr. 5, 1967, and as amended by
(a) Class DOT-110A tanks shall have Amdt. 17910, 36 FR 21355, Nov. 6, 1971; 68 FR
75763, Dec. 31, 2003]
fusion-welded heads formed concave to
pressure. Heads for fusion welding shall
179.30010 Postweld heat treatment.
be an ellipsoid of revolution 2:1 ratio of
major to minor axis. They shall be one After welding is complete, steel
piece, hot formed in one heat so as to tanks and all attachments welded
provide a straight flange at least 112 thereto, must be postweld heat treated
inches long. The thickness shall not be as a unit in compliance with the re-
less than that calculated by the fol- quirements of AAR Specifications for
lowing formula: Tank Cars, appendix W (IBR, see 171.7
of this subchapter).
Pd
t= [68 FR 75763, Dec. 31, 2003]
2 SE
where symbols are as defined in 179.3006(a). 179.30012 Protection of fittings.
(b) Class DOT-106A tanks must have
(a) Tanks shall be of such design as
forged-welded heads, formed convex to
will afford maximum protection to any
pressure. Heads for forge welding must
fittings or attachment to the head in-
be torispherical with an inside radius
cluding the housing referred to in
not greater than the inside diameter of
179.30012(b). Tank ends shall slope or
the shell. They must be one piece, hot
curve inward toward the axis so that
formed in one heat so as to provide a
the diameter at each end is at least 2
straight flange at least 4 inches long.
inches less than the maximum diame-
They must have snug drive fit into the
ter.
shell for forge welding. The wall thick-
ness after forming must be sufficient to (b) Loading and unloading valves
meet the test requirements of 179.300 shall be protected by a detachable pro-
16 and to provide for adequate thread- tective housing of approved design
ing of openings. which shall not project beyond the end
of the tank and shall be securely fas-
[29 FR 18995, Dec. 29, 1964. Redesignated at 32 tened to the tank head. Pressure relief
FR 5606, Apr. 5, 1967, and amended by Amdt. devices shall not be covered by the
17910, 36 FR 21355, Nov. 6, 1971]
housing.
179.3009 Welding. [29 FR 18995, Dec. 29, 1964, as amended at 68
(a) Longitudinal joints must be fu- FR 57634, Oct. 6, 2003]
sion welded. Head-to-shell joints must
be forge welded on class DOT-106A 179.30013 Venting, loading and un-
tanks and fusion welded on class DOT- loading valves.
110A tanks. Welding procedures, weld- (a) Valves shall be of approved type,
ers and fabricators must be approved in made of metal not subject to rapid de-
accordance with AAR Specifications terioration by lading, and shall with-
for Tank Cars, appendix W (IBR, see stand tank test pressure without leak-
171.7 of this subchapter). age. The valves shall be screwed di-
wreier-aviles on DSK3TPTVN1PROD with CFR
295
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179.30014 49 CFR Ch. I (10111 Edition)
(b) Threads for openings shall be Na- have been subjected previously to in-
tional Gas Taper Threads (NGT) tapped ternal pressure within 100 pounds of
to gage, clean cut, even and without the test pressure. Each tank shall be
checks. tested to the pressure prescribed in
179.301. Pressure shall be maintained
179.30014 Attachments not other- for 30 seconds and sufficiently longer to
wise specified.
insure complete expansion of tank.
Siphon pipes and their couplings on Pressure gage shall permit reading to
the inside of the tank head and lugs on accuracy of one percent. Expansion
the outside of the tank head for attach- gage shall permit reading of total ex-
ing the valve protective housing must pansion to accuracy of one percent. Ex-
be fusion-welded in place prior to
pansion shall be recorded in cubic cm.
postweld heat treatment. All other fix-
tures and appurtenances, except as spe- (1) No leaks shall appear and perma-
cifically provided for, are prohibited. nent volumetric expansion shall not
exceed 10 percent of total volumetric
[Amdt. 17910, 36 FR 21355, Nov. 6, 1971] expansion at test pressure.
(2) [Reserved]
179.30015 Pressure relief devices.
(b) After all fittings have been in-
(a) Unless prohibited in part 173 of stalled, each tank shall be subjected to
this subchapter, tanks shall be interior air pressure test of at least 100
equipped with one or more relief de- psig under conditions favorable to de-
vices of approved type, made of metal
tection of any leakage. No leaks shall
not subject to rapid deterioration by
appear.
the lading and screwed directly into
tank heads or attached to tank heads (c) Repairs of leaks detected in man-
by other approved methods. The total ufacture or in foregoing tests shall be
discharge capacity shall be sufficient made by the same process as employed
to prevent building up pressure in tank in manufacture of tank. Caulking, sol-
in excess of 82.5 percent of the tank dering, or similar repairing is prohib-
test pressure. When relief devices of ited.
the fusible plug type are used, the re- [29 FR 18995, Dec. 29, 1964. Redesignated at 32
quired discharge capacity shall be FR 5606, Apr. 5, 1967, and amended by Amdt.
available in each head. See AAR Speci- 17910, 36 FR 21355, Nov. 6, 1971; 66 FR 45390,
fications for Tank Cars, appendix A Aug. 28, 2001]
(IBR, see 171.7 of this subchapter), for
the formula for calculating discharge 179.30017 Tests of pressure relief de-
capacity. vices.
(b) Threads for openings shall be Na- (a) Each valve shall be tested by air
tional Gas Taper Threads (NGT) tapped or gas before being put into service.
to gage, clean cut, even and without
The valve shall open and be vapor-tight
checks.
at the pressure prescribed in 179.301.
(c) Pressure relief devices shall be set
for start-to-discharge and rupture discs (b) Rupture disks of non-reclosing
shall burst at a pressure not exceeding pressure relief devices must be tested
that specified in 179.301. and qualified as prescribed in appendix
(d) Fusible plugs shall function at a A, Paragraph 5, of the AAR Manual of
temperature not exceeding 175 F. and Standards and Recommended Prac-
shall be vapor-tight at a temperature tices, Section CPart III, AAR Speci-
of not less than 130 F. fications for Tank Cars (IBR, see 171.7
of this subchapter).
[29 FR 18995, Dec. 29, 1964, as amended at 64
FR 51920, Sept. 27, 1999; 66 FR 45390, Aug. 28,
(c) For pressure relief devices of the
2001; 68 FR 75763, Dec. 31, 2003] fusible plug type, a sample of the plug
used shall function at the temperatures
179.30016 Tests of tanks. prescribed in 179.30015.
wreier-aviles on DSK3TPTVN1PROD with CFR
(a) After postweld heat treatment, (d) The start-to-discharge and vapor-
tanks shall be subjected to hydrostatic tight pressures shall not be affected by
expansion test in a water jacket, or by
other approved methods. No tank shall
296
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Pipeline and Hazardous Materials Safety Admin., DOT 179.301
297
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179.302 49 CFR Ch. I (10111 Edition)
(b) [Reserved]
[29 FR 18995, Dec. 29, 1964. Redesignated at 32 FR 5606, Apr. 5, 1967, and amended by Amdt.
17910, 36 FR 21355, Nov. 6, 1971; Amdt. 17940, 52 FR 13049, Apr. 20, 1987; 65 FR 58632, Sept. 29,
2000; 66 FR 45390, Aug. 28, 2001]
298
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Pipeline and Hazardous Materials Safety Admin., DOT 179.4006
tf = equilibrium temperature of the test fications for Tank Cars, appendix M
cryogenic liquid at the NER test pressure (IBR, see 171.7 of this subchapter), and
of approximately, one atmosphere, abso-
lute, in F.
must be
(1) In the annealed condition prior to
(b) DOT-113A60W tank cars must fabrication, forming and fusion weld-
(1) Be filled with hydrogen, cryogenic ing;
liquid to the maximum permitted fill
(2) Suitable for use at the tempera-
density specified in 173.319(d)(2) table
ture of the lading; and
of this subchapter prior to performing
the NER test; and (3) Compatible with the lading.
(2) Have a CHTR equal to or less than (b) Any steel casting, steel forging,
the SHTR specified in 179.4011 table steel structural shape or carbon steel
for a DOT-113A60W tank car. plate used to fabricate the outer jacket
(c) DOT-113C120W tank cars must or heads must be as specified in AAR
(1) Be filled with ethylene, cryogenic Specifications for Tank Cars, appendix
liquid to the maximum permitted fill M.
density specified in 173.319(d)(2) table (c) Impact tests must be
of this subchapter prior to performing (1) Conducted in accordance with
the NER test, or be filled with nitro- AAR Specifications for Tank Cars, ap-
gen, cryogenic liquid to 90 percent of pendix W, W9.01;
the volumetric capacity of the inner (2) Performed on longitudinal speci-
tank prior to performing the NER test; mens of the material;
and
(3) Conducted at the tank design
(2) Have a CHTR equal to or less than
service temperature or colder; and
75 percent of the SHTR specified in
179.4011 table for a DOT-113C120W (4) Performed on test plate welds and
tank car. materials used for inner tanks and ap-
(d) Insulating materials must be ap- purtenances and which will be sub-
proved. jected to cryogenic temperatures.
(e) If the insulation consists of a pow- (d) Impact test values must be equal
der having a tendency to settle, the en- to or greater than those specified in
tire top of the cylindrical portion of AAR Specifications for Tank Cars, ap-
the inner tank must be insulated with pendix W. The report of impact tests
a layer of glass fiber insulation at least must include the test values and lat-
one-inch nominal thickness, or equiva- eral expansion data.
lent, suitably held in position and cov-
ering an area extending 25 degrees to [Amdt. 17932, 48 FR 27708, June 16, 1983, as
amended at 67 FR 51660, Aug. 8, 2002; 68 FR
each side of the top center line of the
75763, Dec. 31, 2003]
inner tank.
(f) The outer jacket must be provided 179.4006 Bursting and buckling
with fittings to permit effective evacu- pressure.
ation of the annular space between the
outer jacket and the inner tank. (a) [Reserved]
(g) A device to measure the absolute (b) The outer jacket of the required
pressure in the annular space must be evacuated insulation system must be
provided. The device must be portable designed in accordance with 179.400
with an easily accessible connection or 8(d) and in addition must comply with
permanently positioned where it is the design loads specified in Section 6.2
readily visible to the operator. of the AAR Specifications for Tank
[Amdt. 17932, 48 FR 27708, June 16, 1983, as Cars (IBR, see 171.7 of this sub-
amended at 49 FR 24318, June 12, 1984; 66 FR chapter). The designs and calculations
45186, Aug. 28, 2001] must provide for the loadings trans-
ferred to the outer jacket through the
179.4005 Materials. support system.
(a) Stainless steel of ASTM A 240/A
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179.4007 49 CFR Ch. I (10111 Edition)
179.4007 Tank heads. head for the inner tank must be that
(a) Tank heads of the inner tank and specified in 179.4011, or that cal-
outer jacket must be flanged and culated by the following formula,
dished, or ellipsoidal. whichever is greater:
(b) Flanged and dished heads must t = [PL(3 + (L/r))] / (8SE)
have Where:
(1) A main inside dish radius not
t = minimum thickness of plate, after form-
greater than the outside diameter of
ing, in inches;
the straight flange; P = minimum required bursting pressure in
(2) An inside knuckle radius of not psig;
less than 6 percent of the outside di- L = main inside radius of dished head, in
ameter of the straight flange; and inches;
(3) An inside knuckle radius of at r = inside knuckle radius, in inches;
least three times the head thickness. S = minimum tensile strength of plate mate-
rial, as prescribed in AAR Specifications
179.4008 Thickness of plates. for Tank Cars, appendix M, table M1, in
psi;
(a) The minimum wall thickness, E = 0.9, a factor representing the efficiency
after forming, of the inner shell and of welded joints, except that for seamless
any 2:1 ellipsoidal head for the inner heads, E = 1.0.
tank must be that specified in 179.401 (d) The minimum wall thickness,
1, or that calculated by the following after forming, of the outer jacket shell
formula, whichever is greater: may not be less than 716 inch. The min-
t = Pd / 2SE imum wall thickness, after forming, of
the outer jacket heads may not be less
Where:
than 12 inch and they must be made
t = minimum thickness of plate, after form-
from steel specified in 179.16(c). The
ing, in inches;
P = minimum required bursting pressure in annular space is to be evacuated, and
psig; the cylindrical portion of the outer
d = inside diameter, in inches; jacket between heads, or between stiff-
S = minimum tensile strength of the plate ening rings if used, must be designed to
material, as prescribed in AAR Specifica- withstand an external pressure of 37.5
tions for Tank Cars, appendix M, Table M1 psig (critical collapsing pressure), as
(IBR, see 171.7 of this subchapter), in psi; determined by the following formula:
E = 0.9, a factor representing the efficiency
of welded joints, except that for seamless Pc = [2.6E(t/D)2.5] / [(L/D) 0.45(t/D)0.5]
heads, E = 1.0.
Where:
(b) The minimum wall thickness, Pc = Critical collapsing pressure (37.5 psig
after forming, of any 3:1 ellipsoidal minimum) in psig;
head for the inner tank must be that E = modulus of elasticity of jacket material,
specified in 179.4011, or that cal- in psi;
culated by the following formula, t = minimum thickness of jacket material,
whichever is greater: after forming, in inches;
D = outside diameter of jacket, in inches;
t = 1.83 Pd / 2SE L = distance between stiffening ring centers
in inches. (The heads may be considered as
Where: stiffening rings located 13 of the head
t = minimum thickness of plate, after form- depth from the head tangent line.)
ing, in inches;
P = minimum required bursting pressure in [Amdt. 17932, 48 FR 27708, June 16, 1983; 49
psig; FR 42736, Oct. 24, 1984; 64 FR 51920, Sept. 27,
d = inside diameter, in inches; 1999, as amended at 66 FR 45390, Aug. 28, 2001;
S = minimum tensile strength of the plate 68 FR 75763, Dec. 31, 2003]
material, as prescribed in AAR Specifica-
tions for Tank Cars, Appendix M, Table 179.4009 Stiffening rings.
M1, in psi; (a) If stiffening rings are used in de-
E = 0.9, a factor representing the efficiency signing the cylindrical portion of the
wreier-aviles on DSK3TPTVN1PROD with CFR
of welded joints, except that for seamless outer jacket for external pressure, they
heads, E=1.0.
must be attached to the jacket by
(c) The minimum wall thickness, means of fillet welds. Outside stiff-
after forming, of a flanged and dished ening ring attachment welds must be
300
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Pipeline and Hazardous Materials Safety Admin., DOT 179.40011
continuous on each side of the ring. In- width of jacket plate about the centroidal
side stiffening ring attachment welds axis parallel to the vessel axis, in inches to
may be intermittent welds on each side the fourth power;
D = outside diameter of the outer jacket, in
of the ring with the total length of
inches;
weld on each side not less than one- L = one-half of the distance from the center-
third of the circumference of the tank. line of the stiffening ring to the next line
The maximum space between welds of support on one side, plus one-half of the
may not exceed eight times the outer distance from the centerline to the next
jacket wall thickness. line of support on the other side of stiff-
(b) A portion of the outer jacket may ening ring. Both distances are measured
be included when calculating the mo- parallel to the axis of the vessel, in inches.
ment of inertia of the ring. The effec- (A line of support is:
tive width of jacket plate on each side (1) A stiffening ring which meets the re-
of the attachment of the stiffening ring quirements of this paragraph, or
(2) A circumferential line of a head at
is given by the following formula: one-third the depth of the head from
W = 0.78(Rt)0.5 the tangent line);
Pc = critical collapsing pressure (37.5 psig
Where:
minimum) in psig;
W = width of jacket effective on each side of E = modulus of elasticity of stiffening ring
the stiffening ring, in inches; material, in psi.
R = outside radius of the outer jacket, in
inches; (e) Where loads are applied to the
t = plate thickness of the outer jacket, after outer jacket or to stiffening rings from
forming, in inches. the system used to support the inner
(c) Where a stiffening ring is used tank within the outer jacket, addi-
that consists of a closed section having tional stiffening rings, or an increased
two webs attached to the outer jacket, moment of inertia of the stiffening
the jacket plate between the webs may rings designed for the external pres-
be included up to the limit of twice the sure, must be provided to carry the
value of W, as defined in paragraph support loads.
(b) of this section. The outer flange of [Amdt. 17932, 48 FR 27708, June 16, 1983, as
the closed section, if not a steel struc- amended at 66 FR 45391, Aug. 28, 2001]
tural shape, is subject to the same lim-
itations with W based on the R 179.40010 Sump or siphon bowl.
and t values of the flange. Where two A sump or siphon bowl may be in the
separate members such as two angles, bottom of the inner tank shell if
are located less than 2W apart they (a) It is formed directly into the
may be treated as a single stiffening inner tank shell, or is formed and weld-
ring member. (The maximum length of ed to the inner tank shell and is of
plate which may be considered effec- weldable quality metal that is compat-
tive is 4W.) The closed section between ible with the inner tank shell;
an external ring and the outer jacket (b) The stress in any orientation
must be provided with a drain opening. under any condition does not exceed
(d) The stiffening ring must have a the circumferential stress in the inner
moment of inertia large enough to sup- tank shell; and
port the critical collapsing pressure, as (c) The wall thickness is not less
determined by either of the following than that specified in 179.4011.
formulas:
I = [0.035D3 LPc] / E, 179.40011 Welding.
(a) Except for closure of openings and
or a maximum of two circumferential
I = [0.046D3 LPc] / E closing joints in the cylindrical portion
of the outer jacket, each joint of an
Where:
inner tank and the outer jacket must
I = required moment of inertia of stiffening
be a fusion double welded butt joint.
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301
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179.40012 49 CFR Ch. I (10111 Edition)
single welded butt joint using a back- ed and the car is equipped with a con-
ing strip on the inside of the joint. ventional draft gear:
(c) Each joint must be welded in ac- Longitudinal ...........................................7g
cordance with the requirements of Transverse ...............................................3g
AAR Specifications for Tank Cars, ap- Vertical ...................................................3g
pendix W (IBR, see 171.7 of this sub- The longitudinal acceleration may be
chapter). reduced to 3g where a cushioning de-
(d) Each welding procedure, welder, vice of approved design, which has been
and fabricator must be approved. tested to demonstrate its ability to
[Amdt. 17932, 48 FR 27708, June 16, 1983, as limit body forces to 400,000 pounds
amended at 68 FR 75763, Dec. 31, 2003] maximum at 10 miles per hour, is used
between the coupler and the tank
179.40012 Postweld heat treatment. structure.
(a) Postweld heat treatment of the (c) The inner tank and outer jacket
inner tank is not required. must be permanently bonded to each
(b) The cylindrical portion of the other electrically, by either the sup-
outer jacket, with the exception of the port system, piping, or a separate elec-
circumferential closing seams, must be trical connection of approved design.
postweld heat treated as prescribed in
AAR Specifications for Tank Cars, ap- 179.40014 Cleaning of inner tank.
pendix W (IBR, see 171.7 of this sub- The interior of the inner tank and all
chapter). Any item to be welded to this connecting lines must be thoroughly
portion of the outer jacket must be at- cleaned and dried prior to use. Proper
tached before postweld heat treatment. precautions must be taken to avoid
Welds securing the following need not contamination of the system after
be postweld heat treated when it is not cleaning.
practical due to final assembly proce-
dures: 179.40015 Radioscopy.
(1) the inner tank support system to Each longitudinal and circumferen-
the outer jacket, tial joint of the inner tank, and each
(2) connections at piping penetra- longitudinal and circumferential dou-
tions, ble welded butt joint of the outer jack-
(3) closures for access openings, and et, must be examined along its entire
(4) circumferential closing joints of length in accordance with the require-
head to shell joints. ments of AAR Specifications for Tank
(c) When cold formed heads are used Cars, appendix W (IBR, see 171.7 of
on the outer jacket they must be heat this subchapter).
treated before welding to the jacket
shell if postweld heat treatment is not [68 FR 75763, Dec. 31, 2003]
practical due to assembly procedures.
179.40016 Access to inner tank.
[Amdt. 17932, 48 FR 27708, June 16, 1983, as
amended at 68 FR 75763, Dec. 31, 2003] (a) The inner tank must be provided
with a means of access having a min-
179.40013 Support system for inner imum inside diameter of 16 inches. Re-
tank. inforcement of the access opening must
(a) The inner tank must be supported be made of the same material used in
within the outer jacket by a support the inner tank. The access closure
system of approved design. The system must be of an approved material and
and its areas of attachment to the design.
outer jacket must have adequate (b) If a welded closure is used, it
strength and ductility at operating must be designed to allow it to be re-
temperatures to support the inner tank opened by grinding or chipping and to
when filled with the lading to any level be closed again by rewelding, pref-
incident to transportation. erably without a need for new parts. A
(b) The support system must be de- cutting torch may not be used.
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Pipeline and Hazardous Materials Safety Admin., DOT 179.40019
venting must be made for material (b) Any pressure building system pro-
compatible with the product and hav- vided for the purpose of pressurizing
ing satisfactory properties at the lad- the vapor space of the inner tank to fa-
ing temperature. The outlets of all cilitate unloading the liquid lading
vapor phase and liquid phase lines must be approved.
must be located so that accidental dis- [Amdt. 17932, 48 FR 27708, June 16, 1983, as
charge from these lines will not im- amended at 66 FR 45391, Aug. 28, 2001]
pinge on any metal of the outer jacket,
car structures, trucks or safety appli- 179.40018 Test of inner tank.
ances. Suitable provison must be made (a) After all items to be welded to the
to allow for thermal expansion and inner tank have been welded in place,
contraction. the inner tank must be pressure tested
(1) Loading and unloading line. A liq- at the test pressure prescribed in
uid phase transfer line must be pro- 179.4011. The temperature of the pres-
vided and it must have a manually op- surizing medium may not exceed 38 C
erated shut-off valve located as close (100 F) during the test. The inner tank
as practicable to the outer jacket, plus must hold the prescribed pressure for a
a secondary closure that is liquid and period of not less than ten minutes
gas tight. This secondary closure must without leakage or distortion. In a
permit any trapped pressure to bleed pneumatic test, due regard for the pro-
off before the closure can be removed tection of all personnel should be taken
completely. A vapor trap must be in- because of the potential hazard in-
corporated in the line and located as volved. After a hydrostatic test the
close as practicable to the inner tank. container and piping must be emptied
On a DOT-113A60W tank car, any load- of all water and purged of all water
ing and unloading line must be vacuum vapor.
jacketed between the outer jacket and (b) Caulking of welded joints to stop
the shut-off valve and the shut-off leaks developed during the test is pro-
valve must also be vacuum jacketed. hibited. Repairs to welded joints must
(2) Vapor phase line. A vapor phase be made as prescribed in AAR Speci-
line must connect to the inner tank fications for Tank Cars, appendix W
and must be of sufficient size to permit (IBR, see 171.7 of this subchapter).
the pressure relief devices specified in [Amdt. 17932, 48 FR 27708, June 16, 1983, as
179.40020 and connected to this line to amended at 68 FR 75763, Dec. 31, 2003; 73 FR
operate at their design capacity with- 57008, Oct. 1, 2008]
out excessive pressure build-up in the
tank. The vapor phase line must have a 179.40019 Valves and gages.
manually operated shut-off valve lo- (a) Valves. Manually operated shut-
cated as close as practicable to the off valves and control valves must be
outer jacket, plus a secondary closure provided wherever needed for control of
that is liquid and gas tight. This sec- vapor phase pressure, vapor phase vent-
ondary closure must permit any ing, liquid transfer and liquid flow
trapped pressure to bleed off before the rates. All valves must be made from
closure can be removed completely. approved materials compatible with
(3) Vapor phase blowdown line. A blow- the lading and having satisfactory
down line must be provided. It must be properties at the lading temperature.
attached to the vapor phase line speci- (1) Liquid control valves must be of
fied in paragraph (a)(2) of this section, extended stem design.
upstream of the shut-off valve in that (2) Packing, if used, must be satisfac-
line. A by-pass line with a manually tory for use in contact with the lading
operated shut-off valve must be pro- and of approved materials that will ef-
vided to permit reduction of the inner fectively seal the valve stem without
tank pressure when the vapor phase causing difficulty of operation.
line is connected to a closed system. (3) Each control valve and shut-off
wreier-aviles on DSK3TPTVN1PROD with CFR
The discharge from this line must be valve must be readily operable. These
outside the housing and must be di- valves must be mounted so that their
rected upward and away from oper- operation will not transmit excessive
ating personnel. forces to the piping system.
303
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179.40020 49 CFR Ch. I (10111 Edition)
(b) Gages. Gages, except portable vapor phase piping and mounted so as
units, must be securely mounted with- to remain at ambient temperature
in suitable protective housings. A liq- prior to operation. The inner tank
uid level gage and a vapor phase pres- must be equipped with one or more
sure gage must be provided as follows: pressure relief valves and one or more
(1) Liquid level gage. (i) A gage of ap- safety vents (except as noted in para-
proved design to indicate the quantity graph (c)(3)(iv) of this section), and in-
of liquefied lading within the inner stalled without an intervening shut-off
tank, mounted where it will be readily valve (except as noted in paragraph
visible to an operator during transfer (c)(3)(iii) of this section). Additional re-
operations or storage, or a portable quirements are as follows:
gage with a readily accessible connec- (1) Safety vent. The safety vent shall
tion, or function at the pressure specified in
(ii) A fixed length dip tube, with a 179.4011. The safety vent must be flow
manually operated shut-off valve lo- rated in accordance with the applicable
cated as close as practicable to the provisions of AAR Specifications for
outer jacket. The dip tube must indi- Tank Cars, appendix A (IBR, see 171.7
cate the maximum liquid level for the of this subchapter), and provide suffi-
allowable filling density. The inner end cient capacity to meet the require-
of the dip tube must be located on the ments of AAR Specifications for Tank
longitudinal centerline of the inner Cars, appendix A, A8.07(a).
tank and within four feet of the trans- (2) Pressure relief valve. The pressure
verse centerline of the inner tank. relief valve must:
(2) Vapor phase pressure gage. A vapor
(i) be set to start-to-discharge at the
phase pressure gage of approved design,
with a manually operated shut-off pressure specified in 179.4011, and
valve located as close as practicable to (ii) meet the requirements of AAR
the outer jacket. The gage must indi- Specifications for Tank Cars, appendix
cate the vapor pressure within the A, A8.07(b).
inner tank and must be mounted where (3) Installation of safety vent and pres-
it will be readily visible to an operator. sure relief valve(i) Inlet piping. (A) The
An additional fitting for use of a test opening through all piping and fittings
gage must be provided. between the inner tank and its pres-
sure relief devices must have a cross-
179.40020 Pressure relief devices. sectional area at least equal to that of
(a) The tank must be provided with the pressure relief device inlet, and the
pressure relief devices for the protec- flow characteristics of this upstream
tion of the tank assembly and piping system must be such that the pressure
system. The discharge from these de- drop will not adversely affect the re-
vices must be directed away from oper- lieving capacity or the proper oper-
ating personnel, principal load bearing ation of the pressure relief device.
members of the outer jacket, car struc- (B) When the required relief capacity
ture, trucks and safety appliances. is met by the use of multiple pressure
Vent or weep holes in pressure relief relief device placed on one connection,
devices are prohibited. All main pres- the inlet internal cross-sectional area
sure relief devices must discharge to of this connection must be sufficient to
the outside of the protective housings provide the required flow capacity for
in which they are located, except that the proper operation of the pressure re-
this requirement does not apply to lief device system.
pressure relief valves installed to pro- (ii) Outlet piping. (A) The opening
tect isolated sections of lines between through the discharge lines must have
the final valve and end closure. a cross-sectional area at least equal to
(b) Materials. Materials used in pres- that of the pressure relief device outlet
sure relief devices must be suitable for and may not reduce the relieving ca-
use at the temperature of the lading pacity below that required to properly
wreier-aviles on DSK3TPTVN1PROD with CFR
and otherwise compatible with the lad- protect the inner tank.
ing in both the liquid and vapor phases. (B) When the required relieving ca-
(c) Inner tank. Pressure relief devices pacity is met by use of multiple pres-
for the inner tank must be attached to sure relief devices placed on a common
304
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Pipeline and Hazardous Materials Safety Admin., DOT 179.40022
outer shell at 130 F; and direct solar radiation, mud, sand, ad-
(iii) Prevent the discharge of a gas verse environmental exposure and me-
mixture exceeding 50% of the lower chanical damage incident to normal
flammability limit to the atmosphere operation of the tank car. It must be
305
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179.40023 49 CFR Ch. I (10111 Edition)
306
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Pipeline and Hazardous Materials Safety Admin., DOT 179.5004
307
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179.5005 49 CFR Ch. I (10111 Edition)
(b) Calculations to determine the (b) Steel (see Note 1) must conform
maximum marked test pressure per- to the following requirements as to
mitted to be marked on the tank shall chemical composition:
be made by the formula:
Class I Class II Class III
Designation (percent) (percent) (percent)
P = [10S(D2 d2)] / [7(D2+d2)]
Carbon, maximum ......... 0.50 0.50 0.53
Where: Manganese, maximum .. 1.65 1.65 1.85
P = Maximum marked test pressure per- Phosphorus, maximum .. .05 .05 .05
mitted; Sulphur, maximum ........ .06 .05 .05
Silicon, maximum .......... .35 .30 .37
S = U / 3.0 Molybdenum, maximum ................ .25 .30
Chromium, maximum .... ................ .30 .30
Sum of manganese and
Where:
carbon not over .......... 2.10 2.10 ................
U = Tensile strength of that specimen which
NOTE 1: Alternate steel containing other alloying elements
shows the lower tensile strength of the two may be used if approved.
specimens taken from the tank and tested
as prescribed in 179.5007(b). (1) For instructions as to the obtain-
3 = Factor of safety. ing and checking of chemical analysis,
see 179.50018(b)(3).
(D2 d2/(D2 + d2) = The smaller value ob-
(2) [Reserved]
tained for this factor by the operations
specified in 179.5004(c). 179.5006 Heat treatment.
(c) Measure at one end, in a plane (a) Each necked-down tank shall be
perpendicular to the longitudinal axis uniformly heat treated. Heat treat-
of the tank and at least 18 inches from ment shall consist of annealing or nor-
that end before necking-down: malizing and tempering for Class I,
Class II and Class III steel or oil
d = Maximum inside diameter (inches) for
the location under consideration; to be de- quenching and tempering for Class III
termined by direct measurement to an ac- steel. Tempering temperatures shall
curacy of 0.05 inch. not be less than 1000 F. Heat treat-
t = Minimum thickness of wall for the loca- ment of alternate steels shall be ap-
tion under consideration; to be determined proved. All scale shall be removed from
by direct measurement to an accuracy of outside of tank to an extent sufficient
0.001 inch. to allow proper inspection.
Take D = d + 2t. (b) To check uniformity of heat
Calculate the value of (D2d2)/(D2 + d2) treatment, Brinnel hardness tests shall
(1) Make similar measurements and be made at 18 inch intervals on the en-
calculation for a corresponding loca- tire longitudinal axis. The hardness
tion at the other end of the tank. shall not vary more than 35 points in
the length of the tank. No hardness
(2) Use the smaller result obtained,
tests need be taken within 12 inches
from the foregoing, in making calcula-
from point of head to shell tangency.
tions prescribed in paragraph (b) of this
(c) A magnetic particle inspection
section.
shall be performed after heat treat-
[29 FR 18995, Dec. 29, 1964. Redesignated at 32 ment on all tanks subjected to a
FR 5606, Apr. 5, 1967, and amended by Amdt. quench and temper treatment to detect
17931, 47 FR 43067, Sept. 30, 1982; 66 FR 45391, the presence of quenching cracks.
Aug. 28, 2001] Cracks shall be removed to sound
metal by grinding and the surface ex-
179.5005 Material. posed shall be blended smoothly into
(a) Tanks shall be made from open- the surrounding area. A wall thickness
hearth or electric steel of uniform check shall then be made of the af-
quality. Material shall be free from fected area by ultrasonic equipment or
seams, cracks, laminations, or other other suitable means acceptable to the
defects injurious to finished tank. If inspector and if the remaining wall
not free from such defects, the surface thickness is less than the minimum re-
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Pipeline and Hazardous Materials Safety Admin., DOT 179.50011
309
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179.50012 49 CFR Ch. I (10111 Edition)
310
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Pipeline and Hazardous Materials Safety Admin., DOT 179.50018
(4) Name, mark (other than trade- maximum inside diameter, and cal-
mark), or initials of company or person culated value of D, for each end of each
for whose use tank is being made, tank as prescribed in 179.5004(c).
which shall be recorded with the Bu- (6) Inspector shall stamp his official
reau of Explosives. mark on each accepted tank imme-
(5) Date (such as 101, for January diately below serial number, and make
2001) of tank test, so placed that dates certified report (see paragraph (c) of
of subsequent tests may easily be this section) to builder, to company or
added. person for whose use tanks are being
(6) Date (such as 101, for January made, to builder of car structure on
2001) of latest test of pressure relief de- which tanks are to be mounted, to the
vice or of the rupture disc, required Bureau of Explosives, and to the Sec-
only when tank is used for transpor- retary, Mechanical Division, Associa-
tation of flammable gases. tion of American Railroads.
(b) [Reserved] (c) Inspectors report required herein
[29 FR 18995, Dec. 29, 1964, as amended by shall be in the following form:
Amdt. 17952, 61 FR 28682, June 5, 1996; 66 FR (Place) lllllllllllllll
45391, Aug. 28, 2001] (Date) llllllllllllllll
179.50018 Inspection and reports. STEEL TANKS
(a) Before a tank car is placed in It is hereby certified that drawings were
service, the party assembling the com- submitted for these tanks under AAR Appli-
pleted car shall furnish to car owner, cation for Approval llllll and approved
Bureau of Explosives, and the Sec- by the AAR Committee on Tank Cars under
date of llllll.
retary, Mechanical Division, Associa-
Built for llllllllllll Company
tion of American Railroads, a report in Location at lllllllllllllllll
proper form certifying that tanks and Built by llllllllllll Company
their equipment comply with all the Location at lllllllllllllllll
requirements of this specification and Consigned to lllllllll Company
including information as to serial num- Location at lllllllllllllllll
bers, dates of tests, and ownership Quantity llllllllllllllllll
Length (inches) lllllllllllllll
marks on tanks mounted on car struc-
Outside diameter (inches) llllllllll
ture. Marks stamped into tank as required in
(b) Purchaser of tanks shall provide 179.50017 are:
for inspection by a competent inspec-
tor as follows: DOT-107A* * * *
(1) Inspector shall carefully inspect NOTE 1: The marked test pressure sub-
all material and reject that not com- stituted for the * * * * on each tank is shown
plying with 179.5005. on Record of General Data on Tanks at-
(2) Inspector shall stamp his official tached hereto.
mark on each forging or seamless tube Serial numbers ll to ll inclusive
accepted by him for use in making Inspectors mark llllllllllllll
tanks, and shall verify proper applica- Owners mark llllllllllllllll
tion of heat number to such material Test date llllllllllllllllll
by occasional inspections at steel man- Water capacity (see Record of Hydrostatic
Tests).
ufacturers plant.
Tare weights (yes or no) (see Record of Hy-
(3) Inspector shall obtain certified drostatic Tests).
chemical analysis of each heat of mate- These tanks were made by process of llll
rial. Steel used was identified as indicated by
(4) Inspector shall make inspection of the attached list showing the serial number
inside surface of tanks before necking- of each tank, followed by the heat number.
down, to insure that no seams, cracks, Steel used was verified as to chemical
laminations, or other defects exist. analysis and record thereof is attached here-
(5) Inspector shall fully verify com- to. Heat numbers were stamped into metal.
All material was inspected and each tank
pliance with specification, verify heat
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179.50018 49 CFR Ch. I (10111 Edition)
and heat-treatment of tanks were witnessed Size l inches outside diameter by l inches
and found to be efficient and satisfactory. long
Before necking-down ends, each tank was Built by llllllllllll Company
measured at each location prescribed in For lllllllllllllll Company
179.5004(c) and minimum wall thickness in
inches at each location was recorded; max- Tanks rep- Chemical analysis
imum inside diameter in inches at each loca- resented
Heat No. (serial
tion was recorded; value of D in inches at Nos.) C Mn P S Si Ni Cr Mo
each location was calculated and recorded;
maximum fiber stress in wall at location
showing larger value for
(D2+d2)/(D2d2)
was calculated for 710 the marked test pres- These analyses were made by
sure and recorded. Calculations were made (Signed) lllllllllllll
by the formula: (Place) lllllllllllll
S=[0.7P(D2d2)/(D2+d2)] (Date) llllllllllllll
Hydrostatic tests, tensile test of material, RECORD OF CHEMICAL ANALYSIS OF STEEL IN
and other tests as prescribed in this speci- TANKS
fication, were made in the presence of the in-
spector, and all material and tanks accepted Numbered llll to llll inclusive
were found to be in compliance with the re- Size ll inches outside by ll inches long
quirements of this specification. Records Built by llllllllllll Company
thereof are attached hereto. For lllllllllllllll Company
I hereby certify that all of these tanks
proved satisfactory in every way and comply Tanks
with the requirements of Department of rep- Elon- Reduc-
resent- Elastic Tensile gation tion of
Transportation Specification No. Heat ed by limit strength (percent area
No.
107A* * * *. test (se- (psi) (psi) in 2 (per-
rial inches) cent)
(Signed) lllllllllllllll Nos.)
(Inspector)
(Place) lllllllllllllll
(Date) llllllllllllllll
RECORD OF CHEMICAL ANALYSIS OF STEEL FOR (Signed) lllllllllllll
TANKS (Place) lllllllllllll
Numbered llll to llll inclusive (Date) llllllllllllll
Percent ratio of
Permanent ex- Capacity in
Serial Nos. of Actual test pres- Total expansion permanent ex- Tare weight
pansion (cubic (pounds) 2 pounds of water
tanks sure (psig) (cubic cm) pansion to total at 60 F
cm) expansion 1
1 If tests are made by method involving measurement of amount of liquid forced into tank by test pressure, then the basic data
on which calculations are made, such as pump factors, temperature of liquid, coefficient of compressibility of liquid, etc., must
also be given.
2 Do not include protective housing, but state whether with or without valves.
(Place) llllllllllllllllll
312
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Pipeline and Hazardous Materials Safety Admin., DOT Pt. 179, App. B
(Signed) llllllllllllllllll
[Amdt. 17932, 48 FR 27708, June 16, 1983, as amended by 66 FR 45391, Aug. 28, 2001]
313
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Pt. 179, App. B 49 CFR Ch. I (10111 Edition)
The bare plate must be instrumented with (2) A square bare plate with thermal prop-
not less than nine thermocouples to record erties equivalent to the material of construc-
the thermal response of the bare plate. The tion of the tank car must be used. The plate
thermocouples must be attached to the sur- dimensions must be at least four feet by four
face not exposed to the simulated pool fire feet by nominal 1.6 cm (0.625 inch) thick. The
and must be divided into nine equal squares bare plate must be instrumented with not
with a thermocouple placed in the center of less than nine thermocouples to record the
each square.
thermal response of the plate. The
(3) The pool-fire simulator must be con-
thermocouples must be attached to the sur-
structed in a manner that results in total
flame engulfment of the front surface of the face not exposed to the simulated torch and
bare plate. The apex of the flame must be di- must be divided into nine equal squares with
rected at the center of the plate. a thermocouple placed in the center of each
(4) The bare plate holder must be con- square.
structed in such a manner that the only heat (3) The bare plate holder must be con-
transfer to the back side of the bare plate is structed in such a manner that the only heat
by heat conduction through the plate and transfer to the back side of the plate is by
not by other heat paths. heat conduction through the plate and not
(5) Before the bare plate is exposed to the by other heat paths. The apex of the flame
simulated pool fire, none of the temperature must be directed at the center of the plate.
recording devices may indicate a plate tem- (4) Before exposure to the simulated torch,
perature in excess of 37.8 C (100 F) nor less none of the temperature recording devices
than 0 C (32 F).
may indicate a plate temperature in excess
(6) A minimum of two thermocouple de-
of 37.8 C (100 F) or less than 0 C (32 F).
vices must indicate 427 C (800 F) after 13
minutes, plus-or-minus one minute, of simu- (5) A minimum of two thermocouples must
lated pool-fire exposure. indicate 427 C (800 F) in four minutes, plus-
b. A thermal protection system must be or-minus 30 seconds, of torch simulation ex-
tested in the simulated pool-fire environ- posure.
ment described in paragraph 2a of this ap- b. A thermal protection system must be
pendix in the following manner: tested in the simulated torch-fire environ-
(1) The thermal protection system must ment described in paragraph 3a of this ap-
cover one side of a bare plate as described in pendix in the following manner:
paragraph 2a(2) of this appendix. (1) The thermal protection system must
(2) The non-protected side of the bare plate cover one side of the bare plate identical to
must be instrumented with not less than that used to simulate a torch fire under
nine thermocouples placed as described in paragraph 3a(2) of this appendix.
paragraph 2a(2) of this appendix to record
(2) The back of the bare plate must be in-
the thermal response of the plate.
(3) Before exposure to the pool-fire simula- strumented with not less than nine
tion, none of the thermocouples on the ther- thermocouples placed as described in para-
mal protection system configuration may in- graph 3a(2) of this appendix to record the
dicate a plate temperature in excess of 37.8 thermal response of the material.
C (100 F) nor less than 0 C (32 F). (3) Before exposure to the simulated torch,
(4) The entire surface of the thermal pro- none of the thermocouples on the back side
tection system must be exposed to the simu- of the thermal protection system configura-
lated pool fire. tion may indicate a plate temperature in ex-
(5) A pool-fire simulation test must run for cess of 37.8 C (100 F) nor less than 0 C (32
a minimum of 100 minutes. The thermal pro- F).
tection system must retard the heat flow to (4) The entire outside surface of the ther-
the plate so that none of the thermocouples mal protection system must be exposed to
on the non-protected side of the plate indi- the simulated torch-fire environment.
cate a plate temperature in excess of 427 C (5) A torch-simulation test must be run for
(800 F).
a minimum of 30 minutes. The thermal pro-
(6) A minimum of three consecutive suc-
tection system must retard the heat flow to
cessful simulation fire tests must be per-
formed for each thermal protection system. the plate so that none of the thermocouples
3. Simulated torch fire test. on the backside of the bare plate indicate a
a. A torch-fire environment must be simu- plate temperature in excess of 427 C (800 F).
lated in the following manner: (6) A minimum of two consecutive success-
(1) The source of the simulated torch must ful torch-simulation tests must be performed
be a hydrocarbon fuel with a flame tempera- for each thermal protection system.
ture of 1,204 C (2,200 F), plus-or-minus 37.8
wreier-aviles on DSK3TPTVN1PROD with CFR
C (100 F), throughout the duration of the [Amdt. 17950, 60 FR 49078, Sept. 21, 1995, as
test. Furthermore, torch velocities must be amended at 75 FR 53597, Sept. 1, 2010]
64.4 km/h 16 km/h (40 mph 10 mph) through-
out the duration of the test.
314
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Pipeline and Hazardous Materials Safety Admin., DOT 180.2
maintenance program for cargo tanks (a) Any person who performs a func-
transporting liquefied compressed gases. tion prescribed in this part shall per-
180.417 Reporting and record retention re- form that function in accordance with
quirements. this part.
315
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180.3 49 CFR Ch. I (10111 Edition)
316
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Pipeline and Hazardous Materials Safety Admin., DOT 180.205
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180.205 49 CFR Ch. I (10111 Edition)
be requalified at any time during or be- (4) The Associate Administrator de-
fore the month and year that the re- termines that the cylinder may be in
qualification is due. However, a cyl- an unsafe condition.
inder filled before the requalification (e) Cylinders containing Class 8 (corro-
becomes due may remain in service sive) liquids. A cylinder previously con-
until it is emptied. A cylinder with a taining a Class 8 (corrosive) liquid may
specified service life may not be re- not be used to transport a Class 2 ma-
filled and offered for transportation terial in commerce unless the cylinder
after its authorized service life has ex- is
pired. (1) Visually inspected, internally and
(1) Each cylinder that is requalified externally, in accordance with para-
in accordance with the requirements graph (f) of this section and the inspec-
specified 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 sig-
paragraph (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 other-
changed 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 ap- must 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 cyl- formed in accordance with the fol-
inder filled with gases in other than Di- lowing CGA Pamphlets: C6 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); C6.1 for seamless
burst pressure of a CG1, CG4, or CG aluminum cylinders (IBR, see 171.7 of
5 pressure relief device must be at test this subchapter); C6.2 for fiber rein-
pressure with a tolerance of plus zero forced composite special permit cyl-
to minus 10%. An additional 5% toler- inders (IBR, see 171.7 of this sub-
ance is allowed when a combined rup- chapter); C6.3 for low pressure alu-
ture disc is placed inside a holder. This minum cylinders (IBR, see 171.7 of
requirement does not apply if a CG2, this subchapter); C8 for DOT 3HT cyl-
CG3 or CG9 thermally activated relief inders (IBR, see 171.7 of this sub-
device or a CG7 reclosing pressure chapter); and C13 for DOT 8 series cyl-
valve is used on the cylinder. inders (IBR, see 171.7 of this sub-
(d) Conditions requiring test and inspec- chapter).
tion of cylinders. Without regard to any (2) For each cylinder with a coating
other periodic requalification require- or attachments that would inhibit in-
ments, a cylinder must be tested and spection of the cylinder, the coating or
inspected in accordance with this sec- attachments must be removed before
tion prior to further use if performing the visual inspection.
(1) The cylinder shows evidence of (3) Each cylinder subject to visual in-
dents, 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 acci- prescribed in this paragraph (f), each
dent and has been damaged to an ex- specification cylinder manufactured of
wreier-aviles on DSK3TPTVN1PROD with CFR
tent that may adversely affect its lad- aluminum alloy 6351T6 and used in
ing retention capability; self-contained underwater breathing
(3) The cylinder shows evidence of or apparatus (SCUBA), self-contained
is known to have been over-heated; or breathing apparatus (SCBA), or oxygen
318
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Pipeline and Hazardous Materials Safety Admin., DOT 180.205
service must be inspected for sustained vice itself must have an accuracy of
load cracking in accordance with Ap- 0.5%, or better, of its full scale.
pendix C of this part at the first sched- (4) The test equipment must be
uled 5-year requalification period after verified to be accurate within 1.0% of
January 1, 2007, and every five years the calibrated cylinders pressure and
thereafter. corresponding expansion values. This
(g) Pressure test. (1) Unless otherwise may be accomplished by bringing the
provided, each cylinder required to be pressure to a value shown on the cali-
retested under this subpart must be re- bration certificate for the calibrated
tested by means suitable for measuring cylinder used and verifying that the re-
the expansion of the cylinder under sulting total expansion is within 1.0%
pressure. Bands and other removable of the total expansion shown on the
attachments must be loosened or re- calibration certificate. Alternatively,
moved before testing so that the cyl- calibration may be demonstrated by
inder is free to expand in all directions. bringing the total expansion to a
(2) The pressure indicating device of known value on the calibration certifi-
the testing apparatus must permit cate for the calibrated cylinder used
reading of pressures to within 1% of and verifying that the resulting pres-
the minimum prescribed test pressure sure is within 1.0% of the pressure
of each cylinder tested, except that for shown on the calibration certificate.
an analog device, interpolation to 12 of The calibrated cylinder must show no
the marked gauge divisions is accept- permanent expansion. The retester
able. The expansion-indicating device must demonstrate calibration in con-
of the testing apparatus must also per- formance with this paragraph (g) to an
mit incremental reading of the cyl- authorized inspector on any day that it
inder expansion to 1% of the total ex- retests cylinders. A retester must
pansion of each cylinder tested or 0.1 maintain calibrated cylinder certifi-
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 re-
maintained for at least 30 seconds, and
tester shall confirm, by using a cali- as long as necessary for complete ex-
brated cylinder or other method au- pansion 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 accu- equipment, 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 (6) Training materials may be used
pressure from 90%-110% of the min- for training persons who requalify cyl-
imum prescribed test pressure of the inders using the volumetric expansion
cylinder to be tested. The accuracy of test method.
the pressure indicating device within (h) Cylinder rejection. A cylinder must
the test system can be demonstrated at be rejected when, after a visual inspec-
any point within 500 psig of the actual tion, it meets a condition for rejection
test pressure for test pressures at or under the visual inspection require-
above 3000 psig, or 10% of the actual ments of paragraph (f) of this section.
test pressure for test pressures below (1) Except as provided in paragraphs
3000 psig. (h)(3) and (h)(4) of this section, a cyl-
(ii) The expansion-indicating device, inder that is rejected may not be
as part of the retest apparatus, gives a marked as meeting the requirements of
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319
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180.207 49 CFR Ch. I (10111 Edition)
(3) Unless the cylinder is requalified mit, or the cylinder meets another cri-
in conformance with requirements in terion for condemnation in the applica-
180.211, it may not be filled with a ble special permit.
hazardous material and offered for (viii) For an aluminum or an alu-
transportation in commerce where use minum-lined composite special permit
of a specification packaging is re- cylinder, the cylinder is known to have
quired. been or shows evidence of having been
(4) A rejected cylinder with a service over-heated.
pressure of less than 900 psig may be (2) When a cylinder must be con-
requalified and marked if the cylinder demned, the requalifier must
is repaired or rebuilt and subsequently (i) Stamp a series of Xs over the
inspected and tested in conformance DOT specification number and the
with marked pressure or stamp CON-
(i) The visual inspection require- DEMNED on the shoulder, top head,
ments of paragraph (f) of this section; or neck using a steel stamp;
(ii) Part 178 of this subchapter and (ii) For composite cylinders, securely
this part; affix to the cylinder a label with the
(iii) Any special permit covering the word CONDEMNED overcoated with
manufacture, requalification, and/or epoxy near, but not obscuring, the
use of that cylinder; and original cylinder manufacturers label;
(iv) Any approval required under or
180.211. (iii) As an alternative to the stamp-
(i) Cylinder condemnation. (1) A cyl- ing or labeling as described in this
inder must be condemned when paragraph (i)(2), at the direction of the
(i) The cylinder meets a condition for owner, the requalifier may render the
condemnation under the visual inspec- cylinder incapable of holding pressure.
tion requirements of paragraph (f) of (3) No person may remove or oblit-
this section. erate the CONDEMNED marking. In
(ii) The cylinder leaks through its addition, the requalifier must notify
wall. the cylinder owner, in writing, that the
(iii) Evidence of cracking exists to cylinder is condemned and may not be
the extent that the cylinder is likely to filled with hazardous material and of-
be weakened appreciably. fered for transportation in commerce
(iv) For a DOT specification cylinder, where use of a specification packaging
other than a DOT 4E aluminum cyl- is required.
inder or a special permit cylinder, per- [67 FR 51660, Aug. 8, 2002, as amended at 68
manent expansion exceeds 10 percent of FR 24662, May 8, 2003; 68 FR 75764, Dec. 31,
total expansion. 2003; 70 FR 34077, June 13, 2005; 70 FR 73166,
(v) For a DOT 3HT cylinder Dec. 9, 2005; 71 FR 51128, Aug. 29, 2006; 73 FR
(A) The pressure test yields an elas- 4720, Jan. 28, 2008; 75 FR 53597, Sept. 1, 2010]
tic expansion exceeding the marked re-
jection elastic expansion (REE) value. 180.207 Requirements for requalifica-
(B) The cylinder shows evidence of tion of UN pressure receptacles.
denting or bulging. (a) General. (1) Each UN pressure re-
(C) The cylinder bears a manufacture ceptacle used for the transportation of
or an original test date older than hazardous materials must conform to
twenty-four years or after 4380 pressur- the requirements prescribed in para-
izations, whichever occurs first. If a graphs (a), (b) and (d) in 180.205.
cylinder is refilled, on average, more (2) No pressure receptacle due for re-
than once every other day, an accurate qualification may be filled with a haz-
record of the number of rechargings ardous material and offered for trans-
must be maintained by the cylinder portation in commerce unless that
owner or the owners agent. pressure receptacle has been success-
(vi) For a DOT 4E aluminum cyl- fully requalified and marked in accord-
inder, permanent expansion exceeds 12 ance with this subpart. A pressure re-
wreier-aviles on DSK3TPTVN1PROD with CFR
320
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Pipeline and Hazardous Materials Safety Admin., DOT 180.207
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 ..................... Metal hydride storage systems
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, Iodine pentafluoride.
UN2983, Ethylene Oxide and Propylene oxide mixture, not more than 30% ethylene oxide.
321
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180.209 49 CFR Ch. I (10111 Edition)
and tested in accordance with ISO 11623 comes due for periodic requalification,
(IBR, see 171.7 of this subchapter). as specified in the following table,
[71 FR 33894, June 12, 2006, as amended at 71 must be requalified and marked in con-
FR 54397, Sept. 14, 2006; 76 FR 3389, Jan.19, formance with the requirements of this
2011] subpart. Requalification records must
be maintained in accordance with
180.209 Requirements for requalifica- 180.215. Table 1 follows:
tion of specification cylinders.
(a) Periodic qualification of cylinders.
Each specification cylinder that be-
TABLE 1REQUALIFICATION OF CYLINDERS 1
Specification under which cylinder was Minimum test pressure Requalification period
made (psig) 2 (years)
(b) DOT 3A or 3AA cylinders. (1) A cyl- mixtures of these gases (see 173.301(d)
inder conforming to specification DOT of this subchapter); and permitted mix-
3A or 3AA with a water capacity of 56.7 tures of these gases with up to 30 per-
kg (125 lb) or less that is removed from cent by volume of carbon dioxide, pro-
any cluster, bank, group, rack, or vehi- vided the gas has a dew point at or
cle each time it is filled, may be re- below minus (52 F) at 1 atmosphere.
qualified every ten years instead of (iii) Before each refill, the cylinder is
every five years, provided the cylinder removed from any cluster, bank, group,
conforms to all of the following condi- rack or vehicle and passes the hammer
tions: test specified in CGA Pamphlet C6
(i) The cylinder was manufactured (IBR, see 171.7 of this subchapter).
after December 31, 1945. (iv) The cylinder is dried imme-
(ii) The cylinder is used exclusively diately after hydrostatic testing to re-
for air; argon; cyclopropane; ethylene; move all traces of water.
helium; hydrogen; krypton; neon; ni-
(v) The cylinder is not used for un-
trogen; nitrous oxide; oxygen; sulfur
derwater breathing.
hexafluoride; xenon; chlorinated hydro-
wreier-aviles on DSK3TPTVN1PROD with CFR
322
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Pipeline and Hazardous Materials Safety Admin., DOT 180.209
(2) If, since the last required requali- DOT 4B, 4BA, 4BW, or 4E used exclu-
fication, 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 sub-
of this section, it may be requalified chapter) or an equivalent standard con-
every 10 years instead of every five taining the same limits; anhydrous di-
years, 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 sub- chloride; 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 com-
date must be obliterated. The cylinder mercially free from corroding compo-
must 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-se- five years. As an alternative, the cyl-
ries cylinder, except a 4L cylinder, that inder may be subjected to a proof pres-
at any time shows evidence of a leak or sure test at least two times the marked
of internal or external corrosion, dent- service pressure, but this latter type of
ing, bulging or rough usage to the ex- test 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 per- year 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 re- carefully examined under test pressure
filled and offered for transportation. and removed from service if a leak or
(Refer to CGA Pamphlet C6 or C6.3, 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 cyl- mixtures of methyl bromide and ethyl-
inder of 5.44 (12 lb) or less water capac- ene dibromide, liquid; mixtures of
ity authorized for service pressure of methyl bromide and chlorpicrin, liquid;
300 psig or less must be given a com- mixtures of methyl bromide and petro-
plete external visual inspection at the leum solvents, liquid; or methyl bro-
time periodic requalification becomes mide and nonflammable, nonliquefied
due. External visual inspection must be compressed gas mixtures, liquid; com-
in accordance with CGA Pamphlet C6 mercially free of corroding compo-
or C6.1 (IBR, see 171.7 of this sub- nents, 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 re-
test 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 in-
wreier-aviles on DSK3TPTVN1PROD with CFR
and inspection, the cylinder must be ternal and external examination of the
marked in accordance with 180.213. cylinder is conducted every five years
(e) Proof pressure test A cylinder made in accordance with CGA Pamphlet C6.
in conformance with specifications The cylinder must be examined at each
323
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180.209 49 CFR Ch. I (10111 Edition)
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 Liq-
uefied Petroleum (LP) Gases (incorporated by reference;
see 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, Methylacetylene-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,trimethylamines that are commercially free
from corroding components.
DOT 4B240, DOT 4BW240 ......................................................... Ethyleneimine, stabilized.
(h) Cylinders containing anhydrous am- (i) Requalification of DOT-8 series cyl-
monia. A cylinder conforming to speci- inders. (1) Each owner of a DOT-8 series
fication DOT 3A, 3A480X, or 4AA480 cylinder used to transport acetylene
used exclusively for anhydrous ammo- must have the cylinder shell and the
nia, commercially free from corroding porous filler requalified in accordance
components, and protected externally with CGA Pamphlet C13 (IBR, see
by a suitable corrosion-resistant coat- 171.7 of this subchapter). Requalifica-
ing (such as paint) may be requalified tion must be performed in accordance
every 10 years instead of every five with the following schedule:
years.
Shell (visual inspection) requalification Porous filler requalification
Date of cylinder manu-
facture Initial Subsequent Intial Subsequent
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Before January 1, 1991 Before January 1, 2001 10 years ....................... Before January 1, 2011 Not required.
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Pipeline and Hazardous Materials Safety Admin., DOT 180.209
On or after January 1, 10 years 1 ..................... 10 years ....................... 5 to 20 years 2 ............. Not required.
1991.
1 Years from the date of cylinder manufacture.
2 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 C13 other requirements of this section, a
before October 1, 1994, an acetylene cyl- cylinder marked DOT-3HT must be re-
inder must be requalified by a person qualified in accordance with CGA C8
who holds a current RIN. (IBR, see 171.7 of this subchapter).
(3) If a cylinder valve is replaced, a (l) Requalification of foreign cylinders
cylinder valve of the same weight must filled for export. A cylinder manufac-
be used or the tare weight of the cyl- tured outside the United States, other
inder must be adjusted to compensate than as provided in 171.12(a) and
for valve weight differential. 171.23(a) of this subchapter, that has
(4) The person performing a visual in- not been manufactured, inspected, test-
spection or requalification must record ed and marked in accordance with part
the results as specified in 180.215. 178 of this subchapter may be filled
(5) The person performing a visual in- with compressed gas in the United
spection or requalification must mark States, and shipped solely for export if
the cylinder as specified in 180.213. it meets the following requirements, in
(j) Cylinder used as a fire extinguisher. addition to other requirements of this
Only a DOT specification cylinder used 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 ac- of test) in conformance with the proce-
cordance with this paragraph (j). dures and requirements of this subpart
(1) A DOT 4B, 4BA, 4B240ET or 4BW or the Associate Administrator has au-
cylinder may be tested as follows: thorized the filling company to fill for-
(i) For a cylinder with a water capac- eign cylinders under an alternative
ity of 5.44 kg (12 lb) or less, by volu- method 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- 171.12(a)(4) or 171.23(a)(4) of this sub-
formed by the end of 12 years after the chapter.
original test date and at 12-year inter- (m) DOT3AL cylinders manufactured
vals thereafter. of 6351T6 aluminum alloy. In addition
(ii) For a cylinder having a water ca- to the periodic requalification and
pacity over 5.44 kg (12 lb) marking described in 180.205, each cyl-
(A) By proof pressure test. A requali- inder manufactured of aluminum alloy
fication must be performed by the end 6351T6 used in self-contained under-
of 12 years after the original test date water breathing apparatus (SCUBA),
and at 7-year intervals; or self-contained breathing apparatus
(B) By volumetric expansion test using (SCBA), or oxygen service must be re-
the water jacket method. A requalifica- qualified and inspected for sustained
tion must be performed 12 years after load cracking in accordance with the
the original test date and at 12-year in- non-destructive examination method
tervals thereafter. described in the following table. Each
(2) A DOT 3A, 3AA, or 3AL cylinder cylinder with sustained load cracking
must be requalified by volumetric ex- that has expanded into the neck
pansion test using the water jacket threads must be condemned in accord-
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180.209, Nt. 49 CFR Ch. I (10111 Edition)
Eddy current examination combined Eddy currentIn 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 inspectionIn accordance
with CGA Pamphlet C6.1 (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.
2 The eddy current must be applied from the inside of the cylinders neck to detect any sustained load cracking that has ex-
panded into the neck threads.
[67 FR 51660, Aug. 8, 2002, as amended at 68 amendatory instruction and text is set forth
FR 24662, May 8, 2003; 68 FR 55544, Sept. 26, as follows:
2003; 68 FR 48572, Aug. 14, 2003; 68 FR 75764, At 71 FR 54397, Sept. 14, 2006, 180.209 was
Dec. 31, 2003; 70 FR 73166, Dec. 9, 2005; 71 FR amended in paragraph (a)(1), the first and
51128, Aug. 29, 2005; 72 FR 55696, Oct. 1, 2007; third entries in Table 1 were revised to read
74 FR53189, Oct. 16, 2009] as follows:
EDITORIAL NOTE: The following amendment 180.209 Requirements for requalification
could not be incorporated into 180.209 be- of specification cylinders.
cause of the inaccurate amendatory instruc- (a) * * *
tion. For the convenience of the user the (1) * * *
TABLE 1REQUALIFICATION 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)).
180.211 Repair, rebuilding and re- (1) The repair and the inspection of
heat treatment of DOT-4 series the work performed must be made in
specification cylinders. accordance with the requirements of
(a) General requirements for repair and the cylinder specification.
rebuilding. Any repair or rebuilding of a (2) The person performing the repair
DOT 4-series cylinder must be per- must use the procedure, equipment,
formed by a person holding an approval and filler metal or brazing material as
as specified in 107.805 of this chapter. authorized by the approval issued
A person performing a rebuild function under 107.805 of this chapter.
is considered a manufacturer subject to (3) Welding and brazing must be per-
the requirements of 178.2(a)(2) and formed on an area free from contami-
subpart C of part 178 of this subchapter. nants.
The person performing a repair, re- (4) A weld defect, such as porosity in
build, or reheat treatment must record a pressure retaining seam, must be
the test results as specified in 180.215. completely removed before re-welding.
Each cylinder that is successfully re- Puddling may be used to remove a weld
paired or rebuilt must be marked in ac- defect only by the tungsten inert gas
cordance with 180.213. shielded arc process.
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Pipeline and Hazardous Materials Safety Admin., DOT 180.211
(6) Reheat treatment of DOT 4B, 4BA (ii) Leak tested before and after as-
or 4BW specification cylinders after re- sembly of the insulation jacket using a
placement of non-pressure attachments mass spectrometer detection system;
is not required when the total weld ma- and
terial does not exceed 20.3 cm (8 (iii) Tested for heat conductivity re-
inches). Individual welds must be at quirements.
least 7.6 cm (3 inches) apart. (d) General rebuilding requirements. (1)
(7) After repair of a DOT 4B, 4BA or The rebuilding of a DOT 4-series cyl-
4BW cylinder, the weld area must be inder must be made in accordance with
leak tested at the service pressure of the following requirements:
the cylinder. (i) The person rebuilding the cylinder
(8) Repair of weld defects must be must use the procedures and equipment
free of cracks. as authorized by the approval issued
(9) When a non-pressure attachment under 107.805 of this chapter.
with the original cylinder specification (ii) After removal of a non-pressure
markings is replaced, all markings component and before replacement of
must be transferred to the attachment any non-pressure component, the cyl-
on the repaired cylinder. inder must be visually inspected in ac-
(10) Walls, heads or bottoms of cyl- cordance with CGA Pamphlet C6 (IBR,
inders with defects or leaks in base see 171.7 of this subchapter).
metal may not be repaired, but may be (iii) The rebuilder may rebuild a DOT
replaced as provided for in paragraph 4B, 4BA or 4BW cylinder having a
(d) of this section. water capacity of 9.07 kg (20 lb) or
(c) Additional repair requirements for greater by replacing a head of the cyl-
4L cylinders. (1) Repairs to a DOT 4L inder using a circumferential joint.
cylinder must be performed in accord- When this weld joint is located at other
ance with paragraphs (a) and (b) of this than an original welded joint, a nota-
section and are limited to the fol- tion of this modification must be
lowing: shown on the Manufacturers Report of
(i) The removal of either end of the Rebuilding in 180.215(c)(2). The weld
insulation jacket to permit access to joint must be on the cylindrical section
the cylinder, piping system, or neck of the cylinder.
tube.
(iv) Any welding and the inspection
(ii) The replacement of the neck
of the rebuilt cylinder must be in ac-
tube. At least a 13 mm (0.51 inch) piece
cordance with the requirements of the
of the original neck tube must be pro-
applicable cylinder specification and
truding above the cylinders top end.
the following requirements:
The original weld attaching the neck
(A) Rebuilding of any cylinder in-
tube to the cylinder must be sound and
volving a joint subject to internal pres-
the replacement neck tube must be
sure may only be performed by fusion
welded to this remaining piece of the
welding;
original neck tube.
(iii) The replacement of material (B) Welding must be performed on an
such as, but not limited to, the insu- area free from contaminants; and
lating material and the piping system (C) A weld defect, such as porosity in
within the insulation space is author- a pressure retaining seam, must be
ized. The replacement material must completely removed before re-welding.
be equivalent to that used at the time Puddling may be used to remove a weld
of original manufacture. defect only by using the tungsten inert
(iv) Other welding procedures that gas shielded arc process.
are permitted by CGA Pamphlet C3 (2) Any rebuilt cylinder must be
(IBR, see 171.7 of this subchapter), and (i) Heat treated in accordance with
not excluded by the definition of re- paragraph (f) of this section;
build, are authorized. (ii) Subjected to a volumetric expan-
(2) After repair, the cylinder must sion test on each cylinder. The results
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180.212 49 CFR Ch. I (10111 Edition)
the applicable cylinder specification; (3) After reheat treatment, each cyl-
and inder in the lot must be subjected to a
(iv) Made of material conforming to volumetric expansion test and meet
the specification. Determination of the acceptance criteria in the applica-
conformance shall include chemical ble specification or be scrapped.
analysis, verification, inspection and (4) After all welding and heat treat-
tensile testing of the replaced part. ment, a test of the new weld must be
Tensile tests must be performed on the performed as required by the original
replaced part after heat treatment by specification. The test results must be
lots defined in the applicable specifica- recorded in accordance with 180.215.
tion. [67 FR 51660, Aug. 8, 2002, as amended at 68
(3) For each rebuilt cylinder, an in- FR 24664, May 8, 2003; 68 FR 75764, Dec. 31,
spectors report must be prepared to in- 2003; 71 FR 54398, Sept. 14, 2006]
clude the information listed in
180.215(c). 180.212 Repair of seamless DOT 3-se-
(4) Rebuilding a cylinder with brazed ries specification cylinders and
seamless UN pressure receptacles.
seams is prohibited.
(5) When an end with the original cyl- (a) General requirements for repair of
inder specification markings is re- DOT 3-series cylinders and UN pressure
placed, all markings must be trans- receptacles. (1) No person may repair a
ferred to the rebuilt cylinder. DOT 3-series cylinder or a seamless UN
(e) Additional rebuilding requirements pressure receptacle unless
for DOT 4L cylinders. (1) The rebuilding (i) The repair facility holds an ap-
of a DOT 4L cylinder must be per- proval issued under the provisions in
formed in accordance with paragraph 107.805 of this chapter; and
(d) of this section. Rebuilding of a DOT (ii) Except as provided in paragraph
4L cylinder is: (b) of this section, the repair and the
inspection is performed under the pro-
(i) Substituting or adding material in
visions of an approval issued under sub-
the insulation space not identical to
part H of Part 107 of this chapter and
that used in the original manufacture
conform to the applicable cylinder
of that cylinder;
specification or ISO standard con-
(ii) Making a weld repair not to ex- tained in part 178 of this chapter.
ceed 150 mm (5.9 inches) in length on (2) The person performing the repair
the longitudinal seam of the cylinder must prepare a report containing, at a
or 300 mm (11.8 inches) in length on a minimum, the results prescribed in
circumferential weld joint of the cyl- 180.215.
inder; or (b) Repairs not requiring prior ap-
(iii) Replacing the outer jacket. proval. Approval is not required for the
(2) Reheat treatment of cylinders is following specific repairs:
prohibited. (1) The removal and replacement of a
(3) After rebuilding, each inner con- neck ring or foot ring on a DOT 3A,
tainment vessel must be proof pressure 3AA or 3B cylinder or a UN pressure re-
tested at 2 times its service pressure. ceptacle that does not affect a pressure
Each completed assembly must be part of the cylinder when the repair is
leak-tested using a mass spectrometer performed by a repair facility or a cyl-
detection system. inder manufacturer of these types of
(f) Reheat treatment. (1) Prior to re- cylinders. The repair may be made by
heat treatment, each cylinder must be welding or brazing in conformance with
given a visual inspection, internally the original specification. After re-
and externally, in accordance with moval and before replacement, the cyl-
180.205(f). inder must be visually inspected and
(2) Cylinders must be segregated in any defective cylinder must be re-
lots for reheat treatment. The reheat jected. The heat treatment, testing and
treatment and visual inspection must inspection of the repair must be per-
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Pipeline and Hazardous Materials Safety Admin., DOT 180.213
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180.215 49 CFR Ch. I (10111 Edition)
permanently secured to the cylinder in (4) For designation of the proof pres-
accordance with paragraph (b) of this sure test, the marking is as illustrated
section. An example of the markings in paragraph (d) of this section, except
prescribed in this paragraph (d) is as that the X is replaced with the letter
follows: S.
A1 (5) For designation of the 5-year ex-
ternal visual inspection for cylinders
9 06 X conforming to 180.209(g), the marking
is as illustrated in paragraph (d) of this
32 section, except that the X is re-
Where:
placed with the letter E.
(6) For designation of DOT 8 series
9 is the month of requalification
cylinder shell requalification only, the
A123 is the RIN
marking is as illustrated in paragraph
06 is the year of requalification, and
X represents the symbols described in
(d) of this section, except that the X
paragraphs (f)(2) through (f)(8) of this sec- is replaced with the letter S.
tion. (7) For designation of DOT 8 series
and UN cylinder shell and porous filler
(1) Upon written request, variation requalification, the marking is as illus-
from the marking requirement may be trated in paragraph (d) of this section,
approved by the Associate Adminis- except that the X is replaced with
trator. the letters FS.
(2) Exception. A cylinder subject to (8) For designation of a non-
the requirements of 171.23(a)(4) of this destructive examination combined
subchapter may not be marked with a with a visual inspection, the marking
RIN. is as illustrated in paragraph (d) of this
(e) Size of markings. The size of the section, except that the X is re-
markings must be at least 6.35 mm (14 placed with the type of test performed,
in.) high, except RIN characters must for example the letters AE for acous-
be at least 3.18 mm (18 in.) high. tic emission or UE for ultrasonic ex-
(f) Marking illustrations. Examples of amination.
required requalification markings for (9) For designation of the eddy cur-
DOT specification and special permit rent examination combined with a vis-
cylinders are illustrated as follows: ual inspection, the marking is as illus-
(1) For designation of the 5-year volu- trated in paragraph (d) of this section,
metric expansion test, 10-year volu- except the X is replaced with the let-
metric expansion test for UN cylinders ters VE.
and cylinders conforming to 180.209(f)
[67 FR 51660, Aug. 8, 2002, as amended at 70
and (h), or 12-year volumetric expan- FR 73166, Dec. 9, 2005; 71 FR 33896, June 12,
sion test for fire extinguishers con- 2006; 71 FR 51128, Aug. 29, 2006; 71 FR 78635,
forming to 173.309(b) of this sub- Dec. 29, 2006; 75 FR 53597, Sept. 1, 2010]
chapter and cylinders conforming to
180.209(e) and 180.209(g), the marking 180.215 Reporting and record reten-
is as illustrated in paragraph (d) of this tion requirements.
section. (a) Facility records. A person who re-
(2) For designation of the 10-year vol- qualifies, repairs or rebuilds cylinders
umetric expansion test for cylinders must maintain the following records
conforming to 180.209(b), the marking where the requalification is performed:
is as illustrated in paragraph (d) of this (1) Current RIN issuance letter;
section, except that the X is re- (2) If the RIN has expired and renewal
placed with a five-point star. is pending, a copy of the renewal re-
(3) For designation of special filling quest;
limits up to 10% in excess of the (3) Copies of notifications to Asso-
marked service pressure for cylinders ciate Administrator required under
conforming to 173.302a(b) of this sub- 107.805 of this chapter;
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Pipeline and Hazardous Materials Safety Admin., DOT 180.215
(5) Current copies of all special per- reason for any repeated test, rejection
mits governing exemption cylinders re- or condemnation; and legible identi-
qualified or marked by the requalifier fication of test operator. For each cyl-
at that location; and inder marked pursuant to
(6) The information contained in each 173.302a(b)(5) of this subchapter, the
applicable CGA or ASTM standard in- test sheet must indicate the method by
corporated by reference in 171.7 of this which any average or maximum wall
subchapter applicable to the requali- stress was computed. Records must be
fiers activities. This information must kept for all completed, as well as un-
be the same as contained in the edition successful tests. The entry for a second
incorporated by reference in 171.7 of test after a failure to hold test pressure
this subchapter. must indicate the date of the earlier
(b) Requalification records. Daily test.
records of visual inspection, pressure (3) Wall stress. Calculations of aver-
test, and ultrasonic examination if per- age and maximum wall stress pursuant
mitted under a special permit, as appli- to 173.302a(b)(3) of this subchapter, if
cable, must be maintained by the per- performed.
son who performs the requalification (4) Calibration certificates. The most
until either the expiration of the re- recent certificate of calibration must
qualification period or until the cyl- be maintained for each calibrated cyl-
inder is again requalified, whichever inder.
occurs first. A single date may be used (c) Repair, rebuilding or reheat treat-
for each test sheet, provided each test ment records. (1) Records covering weld-
on the sheet was conducted on that ing or brazing repairs, rebuilding or re-
date. Ditto marks or a solid vertical heat treating shall be retained for a
line may be used to indicate repetition minimum of fifteen years by the ap-
of the preceding entry for the following proved facility.
entries only: date; actual dimensions; (2) A record of rebuilding, in accord-
manufacturers name or symbol, if ance with 180.211(d), must be com-
present; owners name or symbol, if pleted for each cylinder rebuilt. The
present; and test operator. Blank record must be clear, legible, and con-
spaces may not be used to indicate rep- tain the following information:
etition of a prior entry. The records (i) Name and address of test facility,
must include the following informa- date of test report, and name of origi-
tion: nal manufacturer;
(1) Calibration test records. For each (ii) Marks stamped on cylinder to in-
test to demonstrate calibration, the clude specification number, service
date; serial number of the calibrated pressure, serial number, symbol of
cylinder; calibration test pressure; manufacturer, inspectors mark, and
total, elastic and permanent expan- other marks, if any;
sions; and legible identification of test (iii) Cylinder outside diameter and
operator. The test operator must be length in inches;
able to demonstrate that the results of (iv) Rebuild process (welded, brazed,
the daily calibration verification cor- type seams, etc.);
respond to the hydrostatic tests per- (v) Description of assembly and any
formed on that day. The daily attachments replaced (e.g., neckrings,
verification of calibration(s) may be re- footrings);
corded on the same sheets as, and with, (vi) Chemical analysis of material for
test records for that date. the cylinder, including seat and Code
(2) Pressure test and visual inspection No., type of analysis (ladle, check),
records. The date of requalification; se- chemical components (Carbon (C),
rial number; DOT specification or spe- Phosphorous (P), Sulfur (S), Silicon
cial permit number; marked pressure; (Si), Manganese (Mn), Nickel (Ni),
actual dimensions; manufacturers Chromium (Cr), Molybdenum (Mo),
name or symbol; owners name or sym- Copper (Cu), Aluminum (Al), Zinc
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Pipeline and Hazardous Materials Safety Admin., DOT 180.351
made in accordance with the require- (b) Repaired IBCs are metal, rigid
ments prescribed for its approved de- plastic or composite IBCs that, as a re-
sign and construction. Any repair to sult of impact or for any other cause
the pressure receptacles of a MEGC (such as corrosion, embrittlement or
must meet the requirements of other evidence of reduced strength as
180.212. compared to the design type), are re-
(e) Requalification markings. Each stored so as to conform to the design
MEGC must be durably and legibly type and to be able to withstand the
marked in English, with the year and design type tests. For the purposes of
month, and the type of the most recent this subchapter, the replacement of the
periodic requalification performed (e.g., rigid inner receptacle of a composite
200405 AE/UE, where AE represents IBC with one from the original manu-
acoustic emission and UE represents facturer is considered a repair. Routine
ultrasonic examination) followed by maintenance of IBCs (see definition in
the stamp of the approval agency who paragraph (c) of this section) is not
performed or witnessed the most recent considered repair. The bodies of rigid
test. plastic IBCs and the inner receptacles
(f) Records. The owner of each MEGC of composite IBCs are not repairable.
or the owners authorized agent must (c) Routine maintenance of IBCs is
retain a written record of the date and the routine performance on:
results of all repairs and required in- (1) Metal, rigid plastic or composite
spections and tests. The report must IBCs of operations such as:
contain the name and address of the (i) Cleaning;
person performing the inspection or (ii) Removal and reinstallation or re-
test. The periodic test and inspection placement of body closures (including
records must be retained until the next associated gaskets), or of service equip-
inspection or test is completed. Repair ment conforming to the original manu-
records and the initial exceptional in- facturers specifications provided that
spection and test records must be re- the leaktightness of the IBC is verified;
tained during the period the MEGC is or
in service and for one year thereafter. (iii) Restoration of structural equip-
These records must be made available ment not directly performing a haz-
for inspection by a representative of ardous material containment or dis-
the Department on request. charge pressure retention function so
[71 FR 33896, June 12, 2006] as to conform to the design type (for
example, the straightening of legs or
Subpart DQualification and lifting attachments), provided the con-
tainment function of the IBC is not af-
Maintenance of IBCs fected.
180.350 Applicability and definitions. (2) Plastics or textile flexible IBCs of
operations, such as:
This subpart prescribes require-
(i) Cleaning; or
ments, in addition to those contained
(ii) Replacement of non-integral com-
in parts 107, 171, 172, 173 and 178 of this
ponents, such as non-integral liners
subchapter, applicable to any person
and closure ties, with components con-
responsible for the continuing quali-
forming to the original manufacturers
fication, maintenance, or periodic re-
specification; provided that these oper-
testing of an IBC. The following defini-
ations do not adversely affect the con-
tions apply:
tainment function of the flexible IBC
(a) Remanufactured IBCs are metal,
or alter the design type.
rigid plastic or composite IBCs pro-
duced as a UN type from a non-UN [68 FR 45042, July 31, 2003, as amended at 69
type, or are converted from one UN de- FR 76186, Dec. 20, 2004; 76 FR 3389, Jan. 19,
sign type to another UN design type. 2011]
Remanufactured IBCs are subject to
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180.352 49 CFR Ch. I (10111 Edition)
tional and free from damage which with requirements in 178.703 of this
may cause failure. Missing, broken, or subchapter. Additional marking al-
damaged parts must be repaired or re- lowed for each design type may be
placed. present. Required markings that are
334
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180.401 49 CFR Ch. I (10111 Edition)
336
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Pipeline and Hazardous Materials Safety Admin., DOT 180.405
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180.405 49 CFR Ch. I (10111 Edition)
paragraph (c)(1) may be used when au- (d) MC 338 cargo tank. The owner of a
thorized in this part, provided cargo tank that conforms to and was
(i) The cargo tank initial construc- used under the terms of an exemption
tion began on or before the date listed issued before October 1, 1984, that au-
in table 1, column 2, as follows: thorizes the transportation of a cryo-
genic liquid shall remove the exemp-
TABLE 1 tion number stenciled on the cargo
Column 1 Column 2 tank and stamp the specification plate
(or a plate placed adjacent to the speci-
MC 300 .......................................................... Sept. 2, 1967 fication plate) DOT MC 338 followed
MC 301 .......................................................... June 12, 1961
MC 302, MC 303, MC 304, MC 305, MC Sept. 2, 1967 by the exemption number, for example,
310, MC 311. DOT MC 338E * * * *. (Asterisks to
MC 330 .......................................................... May 15, 1967 be replaced by the exemption number).
The cargo tank must be remarked prior
(ii) The cargo tank was marked or to the expiration date of the exemp-
certified before the date listed in table tion. During the period the cargo tank
2, column 2, as follows: is in service, the owner of a cargo tank
TABLE 2 that is remarked in this manner must
retain at its principal place of business
Column 1 Column 2 a copy of the last exemption in effect.
MC 306, MC 307, MC 312 ............................ Sept. 1, 1995
No new construction of cargo tanks
pursuant to such exemption is author-
(2) A cargo tank of a specification ized.
listed in paragraph (c)(1) of this section (1) The holding time must be deter-
may have its pressure relief devices mined, as required in 178.3389 of this
and outlets modified as follows: subchapter, on each cargo tank or on
(i) A Specification MC 300, MC 301, at least one cargo tank of each design.
MC 302, MC 303, or MC 305 cargo tank, Any subsequent cargo tank manufac-
to conform with a Specification MC 306 tured to the same design type (see
or DOT 406 cargo tank (See 178.3463 178.320), if not individually tested,
and 178.3464 of this subchapter). must have the optional test regimen
(ii) A Specification MC 306 cargo performed during the first shipment
tank to conform to a Specification (see 178.3389 (b) and (c) of this sub-
DOT 406 cargo tank (See 178.3463 and chapter).
178.3464 of this subchapter). (2) The holding time determined by
(iii) A Specification MC 304 cargo test for one authorized cryogenic liquid
tank, to conform with a Specification may be used as the basis for estab-
MC 307 or DOT 407 cargo tank (See lishing the holding time for other au-
178.3474 and 178.34511 of this sub- thorized cryogenic liquids.
chapter). (e) MC 331 cargo tanks. The owner of
(iv) A Specification MC 307 cargo a MC 331 ( 178.337 of this subchapter)
tank, to conform with a Specification cargo tank that conforms to and was
DOT 407 cargo tank (See 178.3474 and used under an exemption issued before
178.34511 of this subchapter). October 1, 1984, that authorizes the
(v) A Specification MC 310 or MC 311 transportation of ethane, refrigerated
cargo tank, to conform with a Speci- liquid; ethane-propane mixture, refrig-
fication MC 312 or DOT 412 cargo tank erated liquid; or hydrogen chloride, re-
(See 178.3484 and 178.34511 of this frigerated liquid shall remove the ex-
subchapter). emption number stenciled on the cargo
(vi) A Specification MC 312 cargo tank and stamp the exemption number
tank, to conform with a Specification on the specification plate (or a plate
DOT 412 cargo tank (See 178.3484 and placed adjacent to the specification
178.34511 of this subchapter). plate), immediately after the DOT
(vii) A Specification MC 330 cargo Specification, for example, DOT MC
tank, to conform with a Specification 331E * * * *. (Asterisks to be replaced
wreier-aviles on DSK3TPTVN1PROD with CFR
MC 331 cargo tank, except as specifi- by the exemption number.) The cargo
cally required by 173.315 of this sub- tank must be remarked prior to the ex-
chapter (see 178.3378 and 178.3379 of piration date of the exemption. During
this subchapter). the period the cargo tank is in service,
338
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Pipeline and Hazardous Materials Safety Admin., DOT 180.405
the owner of a cargo tank that is re- that the thickness and tensile strength
marked in this manner must retain at of shell material in combination with
the owners principal place of business the frame and circumferential rein-
a copy of the last exemption in effect. forcement produces a structural integ-
(f) MC 306, MC 307, MC 312 cargo tanks. rity at least equal to that prescribed in
Either a Registered Inspector or a De- 178.3453 of this subchapter or the
sign Certifying Engineer and the owner specification in effect at time of manu-
of a MC 306, MC 307 or MC 312 cargo facture.
tank motor vehicle constructed in ac- (iv) A cargo tank having a projection
cordance with and used under an ex- from the tank shell or head that may
emption issued before December 31, contain lading in any tank position is
1990, that authorizes a condition speci- authorized, provided such projection is
fied in this paragraph shall examine as strong as the tank shell or head and
the cargo tank motor vehicle and its is located within the motor vehicles
design to determine if it meets the re- rear-end tank protection or other ap-
quirements of the applicable MC 306, propriate accident damage protection
MC 307 or MC 312 specification in effect device.
at the time of manufacture, except as (v) A cargo tank may be constructed
specified herein. of nickel, titanium, or other ASME
(1) A cargo tank motor vehicle con- sheet or plate materials in accordance
structed after August 1, 1981, or the with an exemption.
date specified in the applicable exemp-
(2) A vacuum-loaded cargo tank con-
tion, in conformance with the fol-
structed after August 1, 1981, or the
lowing conditions that apply, may be
date specified in the applicable exemp-
remarked and certified in accordance
tion, in conformance with paragraph
with paragraphs (f) (5) and (6) of this
(f)(1) of this section, except that an
section:
outlet equipped with an external valve
(i) A vacuum-loaded cargo tank must
which is not part of a self-closing sys-
have an ASME Code stamped specifica-
tem:
tion plate marked with a minimum in-
(i) Must be equipped with a self-clos-
ternal design pressure of 25 psig, and be
ing system prior to September 1, 1993.
designed for a minimum external de-
sign pressure of 15 psig. (ii) May be remarked and certified in
(ii) An outlet equipped with a self- accordance with paragraphs (f)(5) and
closing system which includes an ex- (6) of this section after the cargo tank
ternal stop-valve must have the stop motor vehicle has been equipped with
valve and associated piping protected the self-closing system.
within the vehicles rear-end tank pro- (3) A vacuum-loaded cargo tank con-
tection device, vehicle frame or an structed prior to August 1, 1981, in con-
equally adequate accident damage pro- formance with paragraph (f)(1) of this
tection device (See 178.3458 of this section, except for paragraph (f)(1)(i),
subchapter.) The self-closing system may be remarked and certified in ac-
(See 178.34511 of this subchapter) cordance with paragraphs (f) (5) and (6)
must be equipped with a remotely ac- of this section.
tuated means of closure as follows: (4) A vacuum-loaded cargo tank con-
(A) For a cargo tank used in other structed prior to August 1, 1981, in con-
than corrosive service, the remote formance with paragraph (f)(1) of this
means of closure must be activated for section, except for paragraph (f)(1)(i) of
closure by manual or mechanical this section, and except that an outlet
means and, in case of fire, by an auto- is equipped with an external valve
matic heat activated means. which is not part of a self-closing sys-
(B) For a cargo tank used in corro- tem:
sive service, the remote means of clo- (i) Must be equipped with a self-clos-
sure may be actuated by manual or me- ing system prior to September 1, 1993.
chanical means only. (ii) May be remarked and certified in
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180.405 49 CFR Ch. I (10111 Edition)
(5) The owner of a cargo tank for blies conforming with 178.3455, except
which a determination has been made for the dimensional requirements in
that the cargo tank is in conformance 178.3455(a), the hydrostatic testing
with paragraph (f) (1), (2), (3), or (4) of requirements in 178.3455(b), and the
this section shall complete a written marking requirements in 178.3455(e)
certification, in English, signed by the of this subchapter. A manhole assem-
owner and containing at least the fol- bly meeting one of the following provi-
lowing information: sions is considered to be in compliance
(i) A statement certifying that each with this paragraph:
cargo tank conforms to 180.405 (f) (1), (i) Manhole assemblies on MC 300, MC
(2), (3), or (4); 301, MC 302, MC 303, MC 305, MC 306, MC
(ii) The applicable DOT exemption 310, MC 311, and MC 312 cargo tanks
number, the applicable specification that are marked or certified in writing
number and the owners and manufac- as conforming to 178.3455 of this sub-
turers serial number for the cargo chapter or TTMA RP No. 6198 (incor-
tank; porated by reference; see 171.7 of this
(iii) A statement setting forth any subchapter), or are tested and certified
modifications made to bring the cargo in accordance with TTMA TB No. 107
tank into conformance with 180.405(f) (incorporated by reference; see 171.7 of
(1), (2), (3), or (4), or the applicable this subchapter).
specification; (ii) Manhole assemblies on MC 304
(iv) A statement identifying the per- and MC 307 cargo tanks.
son certifying the cargo tank and the (iii) Manhole assemblies on MC 310,
date of certification. MC 311, and MC 312 cargo tanks with a
(6) The owner of a certified cargo test pressure of 36 psig or greater.
tank shall remove the exemption num- (3) [Reserved]
ber stenciled on the cargo tank and (h) Pressure relief system. Properly
shall durably mark the specification functioning reclosing pressure relief
plate (or a plate placed adjacent to the valves and frangible or fusible vents
specification plate) MC +++E need not be replaced. However, replace-
****#### (where +++ is to be re- ment of reclosing pressure relief valves
placed by the applicable specification on MC-specification cargo tanks is au-
number, * * * * by the exemption thorized subject to the following re-
number and # # # # by the alloy.) quirements:
(7) A cargo tank remarked and cer- (1) Until August 31, 1998, the owner of
tified in conformance with this para- a cargo tank may replace a reclosing
graph (f) is excepted from the provi- pressure 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 there- in 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 as-
place of business a copy of the certifi- sembly, the manhole cover must com-
cate 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 con- and the volume of lading released may
forming with 178.3455 of this sub- not exceed 1 L. Specific performance
chapter. requirements for these pressure relief
(2) On or before August 31, 1995, each valves are set forth in 178.34510(b)(3)
owner of a cargo tank marked or cer- of this subchapter.
wreier-aviles on DSK3TPTVN1PROD with CFR
tified before December 31, 1990, author- (3) As provided in paragraph (c)(2) of
ized for the transportation of a haz- this section, the owner of a cargo tank
ardous material, must have the cargo may elect to modify reclosing pressure
tank equipped with manhole assem- relief devices to more recent cargo
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Pipeline and Hazardous Materials Safety Admin., DOT 180.405
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180.407 49 CFR Ch. I (10111 Edition)
13,247.5 L (3,500 gallons) water capacity dioxide only or intended for use in
transporting in metered delivery serv- chlorine service only.
ice a Division 2.1 material, a Division (2) Each owner of an MC 338 cargo
2.2 material with a subsidiary hazard, tank motor vehicle marked or certified
or anhydrous ammonia equipped with before January 1, 1995, must equip each
an off-truck remote shut-off device remotely controlled shutoff valve with
that was installed prior to July 1, 2000. an on-vehicle remote means of auto-
The device must be capable of stopping matic closure in conformance with
the transfer of lading by operation of a 178.33811(c) of this subchapter. This
transmitter carried by a qualified per- requirement does not apply to cargo
son attending unloading of the cargo tanks used for the transportation of
tank. The device is subject to the re- argon, carbon dioxide, helium, kryp-
quirement in 177.840(o) of this sub- ton, neon, nitrogen, or xenon, or mix-
chapter for a daily test at 45.72 meters tures thereof.
(150 feet).
[Amdt. 1802, 54 FR 25032, June 12, 1989]
(3) Each specification MC 330 and MC
331 cargo tank in metered delivery EDITORIAL NOTE: For FEDERAL REGISTER ci-
service of greater than 13,247.5 L (3,500 tations affecting 180.405, see the List of CFR
gallons) water capacity transporting a Sections Affected which appears in the Find-
Division 2.1 material, a Division 2.2 ing Aids section of the printed volume and at
www.fdsys.gov.
material with a subsidiary hazard, or
anhydrous ammonia, marked and cer- 180.407 Requirements for test and in-
tified before July 1, 1999, must have an spection of specification cargo
emergency discharge control capability tanks.
as specified in 173.315(n) and 177.840 of
(a) General. (1) A cargo tank con-
this subchapter no later than the date
structed in accordance with a DOT
of its first scheduled pressure test after
specification for which a test or inspec-
July 1, 2001, or July 1, 2003, whichever
tion specified in this section has be-
is earlier.
come due, may not be filled and offered
(n) Thermal activation. No later than
for transportation or transported until
the date of its first scheduled leakage
the test or inspection has been success-
test after July 1, 1999, each specifica-
fully completed. This paragraph does
tion MC 330 or MC 331 cargo tank
not apply to any cargo tank filled prior
motor vehicle and each nonspecifica-
to the test or inspection due date.
tion cargo tank motor vehicle con-
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 pres-
liquefied 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 quali-
means of thermal activation for the in- fications prescribed in 180.409.
ternal self-closing stop valve as speci- (4) Each cargo tank must be evalu-
fied in 178.3378(a)(4) of this sub- ated in accordance with the acceptable
chapter. results of tests and inspections pre-
(o) On-truck remote control of self-clos- scribed in 180.411.
ing stop valvesMC 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 pre-
equip the cargo tank with an on-vehi- scribed test or inspection must:
cle remote means of closure of the in- (i) Be repaired and retested in accord-
ternal self-closing stop valve in con- ance with 180.413; or
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342
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Pipeline and Hazardous Materials Safety Admin., DOT 180.407
(b) Conditions requiring test and inspec- versely affect its lading retention capa-
tion of cargo tanks. Without regard to bility. A damaged cargo tank must be
any other test or inspection require- pressure tested in accordance with the
ments, a specification cargo tank must procedures set forth in paragraph (g) of
be tested and inspected in accordance this section.
with this section prior to further use if: (3) The cargo tank has been out of
(1) The cargo tank shows evidence of hazardous materials transportation
dents, cuts, gouges, corroded or ab- service for a period of one year or
raded areas, leakage, or any other con- more. Each cargo tank that has been
dition that might render it unsafe for out of hazardous materials transpor-
hazardous materials service. At a min- tation service for a period of one year
imum, any area of a cargo tank show- or more must be pressure tested in ac-
ing evidence of dents, cuts, digs, goug- cordance with 180.407(g) prior to fur-
es, or corroded or abraded areas must ther use.
be thickness tested in accordance with (4) [Reserved]
the procedures set forth in paragraphs (5) The Department so requires based
(i)(2), (i)(3), (i)(5), and (i)(6) of this sec- on the existence of probable cause that
tion and evaluated in accordance with the cargo tank is in an unsafe oper-
the criteria prescribed in 180.411. Any ating condition.
signs of leakage must be repaired in ac- (c) Periodic test and inspection. Each
cordance with 180.413. The suitability specification cargo tank must be tested
of any repair affecting the structural and inspected as specified in the fol-
integrity of the cargo tank must be de- lowing table by an inspector meeting
termined either by the testing required the qualifications in 180.409. The
in the applicable manufacturing speci- retest date shall be determined from
fication or in paragraph (g)(1)(iv) of the specified interval identified in the
this section. following table from the most recent
(2) The cargo tank has sustained inspection or the CTMV certification
damage to an extent that may ad- date.
COMPLIANCE DATESINSPECTIONS AND TEST UNDER 180.407(C)
Interval pe-
Date by which first test must be
Test or inspection (cargo tank specification, configuration, and service) riod after first
completed (see note 1) test
tion or test occurs before the compliance date listed in table I, the earlier date applies.
NOTE 2: Pressure testing is 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.
343
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180.407 49 CFR Ch. I (10111 Edition)
(d) External visual inspection and test- (vi) All markings on the cargo tank
ing. The following applies to the exter- required by parts 172, 178 and 180 of this
nal visual inspection and testing of subchapter must be legible;
cargo tanks: (vii) [Reserved]
(1) Where insulation precludes a com- (viii) All major appurtenances and
plete external visual inspection as re- structural attachments on the cargo
quired by paragraphs (d)(2) through tank including, but not limited to, sus-
(d)(6) of this section, the cargo tank pension system attachments, con-
also must be given an internal visual necting structures, and those elements
inspection in accordance with para- of the upper coupler (fifth wheel) as-
graph (e) of this section. If external sembly that can be inspected without
visual inspection is precluded because dismantling the upper coupler (fifth
any part of the cargo tank wall is ex- wheel) assembly must be inspected for
ternally lined, coated, or designed to any corrosion or damage which might
prevent an external visual inspection, prevent safe operation;
those areas of the cargo tank must be (ix) For cargo tanks transporting lad-
internally inspected. If internal visual ing corrosive to the tank, areas cov-
inspection is precluded because the ered by the upper coupler (fifth wheel)
cargo tank is lined, coated, or designed assembly must be inspected at least
so as to prevent access for internal in- once in each two year period for cor-
spection, the tank must be roded and abraded areas, dents, distor-
hydrostatically or pneumatically test- tions, defects in welds, and any other
ed in accordance with paragraph condition that might render the tank
(g)(1)(iv) of this section. Those items unsafe for transportation service. The
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 pres-
inspected for corroded or abraded sure relief valves on cargo tanks car-
areas, dents, distortions, defects in rying lading corrosive to the valve
welds and any other conditions, includ- must be removed from the cargo tank
ing leakage, that might render the for inspection and testing. Each re-
tank unsafe for transportation service; closing pressure relief valve required to
(ii) The piping, valves, and gaskets be removed and tested must open at no
must be carefully inspected for cor- less than the required set pressure and
roded areas, defects in welds, and other no more than 110 percent of the re-
conditions, including leakage, that quired set pressure, and must reseat to
might render the tank unsafe for trans- a leak-tight condition at no less than
portation service; 90 percent of the start-to-discharge
(iii) All devices for tightening man- pressure or the pressure prescribed for
hole covers must be operative and the applicable cargo tank specification.
there must be no evidence of leakage at (4) Ring stiffeners or other appur-
manhole covers or gaskets; tenances, installed on cargo tanks con-
(iv) All emergency devices and valves structed of mild steel or high-strength,
including self-closing stop valves, ex- low-alloy steel, that create air cavities
cess flow valves and remote closure de- adjacent to the tank shell that do not
vices must be free from corrosion, dis- allow for external visual inspection
tortion, erosion and any external dam- must be thickness tested in accordance
age that will prevent safe operation. with paragraphs (i)(2) and (i)(3) of this
Remote closure devices and self-closing section, at least once every 2 years. At
stop valves must be functioned to dem- least four symmetrically distributed
onstrate proper operation; readings must be taken to establish an
wreier-aviles on DSK3TPTVN1PROD with CFR
(v) Missing bolts, nuts and fusible average thickness for the ring stiffener
links or elements must be replaced, or appurtenance. If any thickness read-
and loose bolts and nuts must be tight- ing is less than the average thickness
ened; by more than 10%, thickness testing in
344
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Pipeline and Hazardous Materials Safety Admin., DOT 180.407
accordance with paragraphs (i)(2) and to a 30.5 cm (12-inch) bottom leg (end
(i)(3) of this section must be conducted bent to a 12.7 mm (0.5 inch) radius), or
from the inside of the cargo tank on equally sensitive probe; and
the area of the tank wall covered by (C) A steel calibration coupon 30.5 cm
the appurtenance or ring stiffener. 30.5 cm (12 inches 12 inches) covered
(5) Corroded or abraded areas of the with the same material and thickness
cargo tank wall must be thickness as that to be tested. The material on
tested in accordance with the proce- the coupon shall have a test hole to the
dures set forth in paragraphs (i)(2), metal substrate made by puncturing
(i)(3), (i)(5) and (i)(6) of this section. the material with a 22 gauge hypo-
(6) The gaskets on any full opening dermic needle or comparable piercing
rear head must be: tool.
(i) Visually inspected for cracks or (ii) The probe must be passed over
splits caused by weather or wear; and the surface of the calibration coupon in
(ii) Replaced if cuts or cracks which a constant uninterrupted manner until
are likely to cause leakage, or are of a the hole is found. The hole is detected
depth one-half inch or more, are found. by the white or light blue spark
(7) The inspector must record the re- formed. (A sound lining causes a dark
sults of the external visual examina- blue or purple spark.) The voltage must
tion as specified in 180.417(b). be adjusted to the lowest setting that
(e) Internal visual inspection. (1) When will produce a minimum 12.7 mm (0.5
the cargo tank is not equipped with a inch) spark measured from the top of
manhole or inspection opening, or the the lining to the probe. To assure that
cargo tank design precludes an internal the setting on the probe has not
inspection, the tank shall be changed, the spark tester must be cali-
hydrostatically or pneumatically test- brated periodically using the test cali-
ed 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 re-
areas, 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 trans- or 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 (3) Degraded or defective areas of the
(i)(2), (i)(3), (i)(5) and (i)(6) of this sec- cargo tank liner must be removed and
tion. the cargo tank wall below the defect
(4) The inspector must record the re- must be inspected. Corroded areas of
sults of the internal visual inspection the tank wall must be thickness tested
as specified in 180.417(b). in accordance with paragraphs (i)(2),
(f) Lining inspection. The integrity of (i)(3), (i)(5) and (i)(6) of this section.
the lining on all lined cargo tanks, (4) The inspector must record the re-
when lining is required by this sub- sults of the lining inspection as speci-
chapter, must be verified at least once fied in 180.417(b).
each year as follows: (g) Pressure test. All components of
(1) Rubber (elastomeric) lining must the cargo tank wall, as defined in
be tested for holes as follows: 178.320(a) of this subchapter, must be
(i) Equipment must consist of: pressure tested as prescribed by this
(A) A high frequency spark tester ca- paragraph.
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180.407 49 CFR Ch. I (10111 Edition)
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Pipeline and Hazardous Materials Safety Admin., DOT 180.407
the inspection, a suitable method must medium such as, but not limited to,
be used for detecting the existence of steam or hot water for heating the lad-
leaks. This method must consist either ing must be hydrostatically pressure
of coating the entire surface of all tested at least once every 5 years. The
joints under pressure with a solution of test pressure must be at least the max-
soap and water, or using other equally imum system design operating pressure
sensitive methods. and must be maintained for five min-
(2) When testing an insulated cargo utes. A heating system employing flues
tank, the insulation and jacketing need for heating the lading must be tested
not be removed unless it is otherwise to ensure against lading leakage into
impossible to reach test pressure and the flues or into the atmosphere.
maintain a condition of pressure equi- (5) Exceptions. (i) Pressure testing is
librium after test pressure is reached, not required for MC 330 and MC 331
or the vacuum integrity cannot be cargo tanks in dedicated sodium metal
maintained in the insulation space. If service.
an MC 338 cargo tank used for the (ii) Pressure testing is not required
transportation of a flammable gas or for uninsulated lined cargo tanks, with
oxygen, refrigerated liquid is opened a design pressure or MAWP of 15 psig
for any reason, the cleanliness must be or less, which receive an external vis-
verified prior to closure using the pro- ual inspection and a lining inspection
cedures contained in 178.33815 of this at least once each year.
subchapter. (6) Acceptance criteria. A cargo tank
(3) Each MC 330 and MC 331 cargo that leaks, fails to retain test pressure
tank constructed of quenched and tem- or pneumatic inspection pressure,
pered steel in accordance with Part shows distortion, excessive permanent
UHT in Section VIII of the ASME Code expansion, or other evidence of weak-
(IBR, see 171.7 of this subchapter), or ness that might render the cargo tank
constructed of other than quenched unsafe for transportation service, may
and tempered steel but without not be returned to service, except as
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 sys-
conjunction with the performance of tem, and
the pressure test prescribed in this sec- (ii) The specification plate heating
tion. Each MC 330 and MC 331 cargo system information is changed to indi-
tank constructed of quenched and tem- cate that the cargo tank has no work-
pered steel in accordance with Part ing heating system.
UHT in Section VIII of the ASME Code (7) The inspector must record the re-
and used for the transportation of liq- sults 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 re-
magnetic particle method immediately quirements apply to cargo tanks re-
prior 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 fluores- for 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 Bul- with all valves and accessories in place
letin TB2 (IBR, see 171.7 of this sub- and 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 re-
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180.407 49 CFR Ch. I (10111 Edition)
multi-cargo tank motor vehicle must oline Delivery Tank Using Pressure-
be tested with adjacent cargo tanks Vacuum Test, may not be used to sat-
empty and at atmospheric pressure. isfy the leak testing requirements of
Test pressure must be maintained for this paragraph. The test must be con-
at least 5 minutes. Cargo tanks in liq- ducted using air.
uefied compressed gas service must be (3) A cargo tank that fails to retain
externally inspected for leaks during leakage test pressure may not be re-
the leakage test. Suitable safeguards turned to service as a specification
must be provided to protect personnel cargo tank, except under conditions
should a failure occur. Cargo tanks specified in 180.411(d).
may be leakage tested with hazardous (4) After July 1, 2000, Registered In-
materials contained in the cargo tank spectors of specification MC 330 and MC
during the test. Leakage test pressure 331 cargo tanks, and nonspecification
must be no less than 80% of MAWP cargo tanks authorized under
marked on the specification plate ex- 173.315(k) of this subchapter must vis-
cept as follows: ually inspect the delivery hose assem-
(i) A cargo tank with an MAWP of 690 bly and piping system while the assem-
kPa (100 psig) or more may be leakage bly is under leakage test pressure uti-
tested at its maximum normal oper- lizing the rejection criteria listed in
ating pressure provided it is in dedi- 180.416(g). Delivery hose assemblies
cated service or services; or not permanently attached to the cargo
(ii) An MC 330 or MC 331 cargo tank tank motor vehicle may be inspected
in dedicated liquified petroleum gas separately from the cargo tank motor
service may be leakage tested at not vehicle. In addition to a written record
less than 414 kPa (60 psig). of the inspection prepared in accord-
(iii) An operator of a specification ance with 180.417(b), the Registered
MC 330 or MC 331 cargo tank, and a Inspector conducting the test must
nonspecification cargo tank authorized note the hose identification number,
under 173.315(k) of this subchapter, the date of the test, and the condition
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 re-
test. (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 re- materials 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 meas-
tested at not less than 16.6 kPa (2.4 uring less than the sum of the min-
psig), or as specified in paragraph (h)(2) imum prescribed thickness, plus one-
of this section. fifth of the original corrosion allow-
(2) Cargo tanks used to transport pe- ance, must be tested annually.
troleum distillate fuels that are (2) Measurements must be made
equipped with vapor collection equip- using 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.
Agencys Method 27Determination (3) Any person performing thickness
of Vapor Tightness of Gasoline Deliv- testing 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 manufacturers
CFR part 60. Test methods and proce- instruction.
dures and maximum allowable pressure (4) Thickness testing must be per-
and vacuum changes are in 40 CFR formed in the following areas of the
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Pipeline and Hazardous Materials Safety Admin., DOT 180.407
(ii) Areas of high shell stress such as TABLE IIN-SERVICE MINIMUM THICKNESS FOR
the bottom center of the tank; MC 300, MC 303, MC 304, MC 306, MC
(iii) Areas near openings; 307, MC 310, MC 311, AND MC 312 SPECI-
(iv) Areas around weld joints; FICATION CARGO TANKS CONSTRUCTED OF
(v) Areas around shell reinforce- STEEL AND STEEL ALLOYSContinued
ments;
(vi) Areas around appurtenance at- Nominal In-service
decimal minimum
tachments; Minimum manufactured thickness equiva- thickness
(US gauge or inches)
(vii) Areas near upper coupler (fifth lent for reference
(inches) (inches)
wheel) assembly attachments;
(viii) Areas near suspension system 13 ....................................................... 0.0897 0.081
attachments and connecting struc- 12 ....................................................... 0.1046 0.094
11 ....................................................... 0.1196 0.108
tures; 10 ....................................................... 0.1345 0.121
(ix) Known thin areas in the tank 9 ......................................................... 0.1495 0.135
shell and nominal liquid level lines; 8 ......................................................... 0.1644 0.148
and 7 ......................................................... 0.1793 0.161
(x) Connecting structures joining 3/16 .................................................... 0.1875 0.169
1/4 ...................................................... 0.2500 0.225
multiple cargo tanks of carbon steel in
5/16 .................................................... 0.3125 0.281
a self-supporting cargo tank motor ve- 3/8 ...................................................... 0.3750 0.338
hicle.
(5) Minimum thicknesses for MC 300,
MC 301, MC 302, MC 303, MC 304, MC 305, TABLE IIIN-SERVICE MINIMUM THICKNESS FOR
MC 306, MC 307, MC 310, MC 311, and MC MC 301, MC 302, MC 304, MC 305, MC
312 cargo tanks are determined based 306, MC 307, MC 311, AND MC 312 SPECI-
on the definition of minimum thick- FICATION CARGO TANKS CONSTRUCTED OF
ness found in 178.320(a) of this sub- ALUMINUM AND ALUMINUM ALLOYS
chapter. The following Tables I and II In-service
identify the In-Service Minimum Minimum manufactured thickness minimum
thickness
Thickness values to be used to deter- (inches)
mine the minimum thickness for the
referenced cargo tanks. The column 0.078 ...................................................................... 0.070
0.087 ...................................................................... 0.078
headed Minimum Manufactured
0.096 ...................................................................... 0.086
Thickness indicates the minimum 0.109 ...................................................................... 0.098
values required for new construction of 0.130 ...................................................................... 0.117
DOT 400 series cargo tanks, found in 0.141 ...................................................................... 0.127
Tables I and II of 178.3462, 178.3472, 0.151 ...................................................................... 0.136
0.172 ...................................................................... 0.155
and 178.3482 of this subchapter. In- 0.173 ...................................................................... 0.156
Service Minimum Thicknesses for MC 0.194 ...................................................................... 0.175
300, MC 301, MC 302, MC 303, MC 304, MC 0.216 ...................................................................... 0.194
305, MC 306, MC 307, MC 310, MC 311, and 0.237 ...................................................................... 0.213
MC 312 cargo tanks are based on 90 per- 0.270 ...................................................................... 0.243
0.360 ...................................................................... 0.324
cent of the manufactured thickness 0.450 ...................................................................... 0.405
specified in the DOT specification, 0.540 ...................................................................... 0.486
rounded to three places.
(6) An owner of a cargo tank that no
TABLE IIN-SERVICE MINIMUM THICKNESS FOR longer conforms to the minimum
MC 300, MC 303, MC 304, MC 306, MC thickness prescribed for the design as
307, MC 310, MC 311, AND MC 312 SPECI- manufactured may use the cargo tank
FICATION CARGO TANKS CONSTRUCTED OF
to transport authorized materials at
STEEL AND STEEL ALLOYS reduced maximum weight of lading or
Nominal In-service reduced maximum working pressure, or
Minimum manufactured thickness decimal minimum combinations thereof, provided the fol-
equiva- thickness
(US gauge or inches) lent for reference lowing conditions are met:
(inches) (inches) (i) A Design Certifying Engineer
19 ....................................................... 0.0418 0.038 must certify that the cargo tank de-
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180.409 49 CFR Ch. I (10111 Edition)
(ii) The cargo tank motor vehicles Registered Inspector in 171.8 of this
nameplate must reflect the revised chapter.
service limits. (b) A person who only performs an-
(7) An owner of a cargo tank that no nual external visual inspections and
longer conforms with the minimum leakage tests on a cargo tank motor
thickness prescribed for the specifica- vehicle, owned or operated by that per-
tion may not return the cargo tank to son, with a capacity of less than 13,250
hazardous materials service. The L (3,500 gallons) used exclusively for
tanks specification plate must be re- flammable liquid petroleum fuels, is
moved, obliterated or covered in a se- not required to meet the educational
cure manner. and years of experience requirements
(8) The inspector must record the re- set forth in the definition of Reg-
sults of the thickness test as specified
istered Inspector in 171.8 of this sub-
in 180.417(b).
chapter. Although not required to meet
(9) For MC 331 cargo tanks con-
the educational and years of experience
structed before October 1, 2003, min-
requirements, a person who performs
imum thickness shall be determined by
visual inspections or leakage tests or
the thickness indicated on the U1A
signs the inspection reports must have
form minus any corrosion allowance.
For MC 331 cargo tanks constructed the knowledge and ability to perform
after October 1, 2003, the minimum such inspections and tests and must
thickness will be the value indicated perform them as required by this sub-
on the specification plate. If no corro- chapter, and must register with the De-
sion allowance is indicated on the U1A partment as required by subpart F of
form then the thickness of the tank part 107 of this chapter.
shall be the thickness of the material (c) A person who performs only an-
of construction indicated on the UIA nual external visual inspections and
form with no corrosion allowance. leakage tests on a permanently mount-
(10) For 400-series cargo tanks, min- ed non-bulk tank, owned or operated
imum thickness is calculated accord- by that person, for petroleum products
ing to tables in each applicable section as authorized by 173.8(c) of this sub-
of this subchapter for that specifica- chapter, is not required to be reg-
tion: 178.3462 for DOT 406 cargo istered in accordance with subpart F of
tanks, 178.3472 for DOT 407 cargo part 107 of this chapter. In addition the
tanks, and 178.3482 for DOT 412 cargo person who signs the inspection report
tanks. required by 180.417(b) of this subpart
for such non-bulk tanks is not required
[Amdt. 1802, 54 FR 25032, June 12, 1989]
to be registered. Although not required
EDITORIAL NOTE: For FEDERAL REGISTER ci- to register, a person who performs vis-
tations affecting 180.407, see the List of CFR ual inspections or leakage tests or
Sections Affected which appears in the Find- signs the inspection reports must have
ing Aids section of the printed volume and at
www.fdsys.gov. the knowledge and ability to perform
such inspections and tests and must
180.409 Minimum qualifications for perform them as required by this sub-
inspectors and testers. chapter.
(a) Except as otherwise provided in (d) A motor carrier or cargo tank
this section, any person performing or owner who meets the requirements of
witnessing the inspections and tests paragraph (a) of this section may use
specified in 180.407(c) must an employee who is not a Registered
(1) Be registered with the Federal Inspector to perform a portion of the
Motor Carrier Safety Administration pressure retest required by 180.407(g).
in accordance with part 107, subpart F External and internal visual inspec-
of this chapter, tions must be accomplished by a Reg-
(2) Be familiar with DOT-specifica- istered Inspector, but the hydrostatic
tion cargo tanks and trained and expe- or pneumatic pressure test, as set forth
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Pipeline and Hazardous Materials Safety Admin., DOT 180.413
(1) The employee is familiar with the (g) Pressure test. Any tank that fails
cargo tank and is trained and experi- to meet the acceptance criteria found
enced in the use of the inspection and in the individual specification that ap-
testing equipment used; plies must be properly repaired.
(2) The employer submits certifi- [Amdt. 1802, 54 FR 25032, June 12, 1989, as
cation that such employee meets the amended at 68 FR 75764, Dec. 31, 2003]
qualification requirements to the Asso-
ciate Administrator, Attn: (PHH32), 180.413 Repair, modification, stretch-
Pipeline and Hazardous Materials Safe- ing, rebarrelling, or mounting of
ty Administration, Department of specification cargo tanks.
Transportation, East Building, 1200 (a) General. Any repair, modification,
New Jersey Avenue, SE., Washington, stretching, rebarrelling, or mounting
DC 20590; and of a cargo tank must be performed in
(3) The employer retains a copy of conformance with the requirements of
the testers qualifications with the doc- this section.
uments required by 180.417(b). (1) Except as otherwise provided in
[Amdt. 1802, 55 FR 37069, Sept. 7, 1990, as this section, each repair, modification,
amended by Amdt. 1803, 56 FR 66287, Dec. 20, stretching, or rebarrelling of a speci-
1991; 57 FR 45466, Oct. 1, 1992; Amdt. 18011, 62 fication cargo tank must be performed
FR 1217, Jan. 8, 1997; 66 FR 45391, Aug. 28, by a repair facility holding a valid Na-
2001; 68 FR 19288, Apr. 18, 2003; 70 FR 56100, tional Board Certificate of Authoriza-
Sept. 23, 2005; 72 FR 55697, Oct. 1, 2007] tion for use of the National Board R
stamp and must be made in accordance
180.411 Acceptable results of tests with the edition of the National Board
and inspections.
Inspection Code in effect at the time
(a) Corroded or abraded areas. The the work is performed.
minimum thickness may not be less (i) Repairs, modifications,
than that prescribed in the applicable stretchings, and rebarrellings per-
specification. formed on non-ASME stamped speci-
(b) Dents, cuts, digs and gouges. For fication cargo tanks may be performed
evaluation procedures, see CGA C6 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 12 inch. For dents away from welds, U stamp using the quality control
the maximum allowable depth is 110 of procedures used to obtain the Certifi-
the greatest dimension of the dent, but cate of Authorization; or
in no case may the depth exceed one (B) A repair facility holding a valid
inch. National Board Certificate of Author-
(2) The minimum thickness remain- ization for use of the National Board
ing beneath a cut, dig, or gouge may R stamp using the quality control
not be less than that prescribed in the procedures used to obtain the Certifi-
applicable specification. cate of Authorization.
(c) Weld or structural defects. Any (ii) A repair, modification, stretch-
cargo tank with a weld defect such as ing, or rebarrelling of a non-ASME
a crack, pinhole, or incomplete fusion, stamped cargo tank may be done with-
or a structural defect must be taken out certification by an Authorized In-
out of hazardous materials service spector, completion of the R1 form, or
until repaired. being stamped with the R stamp.
(d) Leakage. All sources of leakage (2) Prior to each repair, modification,
must be properly repaired prior to re- stretching, rebarrelling, or mounting,
turning a tank to hazardous materials the cargo tank motor vehicle must be
service. emptied of any hazardous material lad-
(e) Relief valves. Any pressure relief ing. In addition, cargo tank motor ve-
valve that fails to open and reclose at hicles used to transport flammable or
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180.413 49 CFR Ch. I (10111 Edition)
bulkheads, piping and vapor recovery ment after minor weld repairs is not
systems. required. When a repair is made of de-
(3) Each person performing a repair, fects revealed by the wet fluorescent
modification, stretching, rebarrelling magnetic particle inspection, including
or mounting of a DOT specification those repaired by grinding, the affected
cargo tank must be registered in ac- area of the cargo tank must again be
cordance with subpart F of part 107 of examined by the wet fluorescent mag-
this chapter. netic particle method after hydrostatic
(b) Repair. The suitability of each re- testing to assure that all defects have
pair affecting the structural integrity been removed.
or lading retention capability of the (c) Maintenance or replacement of pip-
cargo tank must be determined by the ing, valves, hoses, or fittings. After each
testing required either in the applica-
repair, maintenance or replacement of
ble manufacturing specification or in
a pipe, valve, hose, or fitting on a cargo
180.407(g)(1)(iv). Each repair of a cargo
tank, that component must be in-
tank involving welding on the shell or
stalled in accordance with the provi-
head must be certified by a Registered
Inspector. The following provisions sions of the applicable specification be-
apply to specific cargo tank repairs: fore the cargo tank is returned to serv-
(1) DOT 406, DOT 407, and DOT 412 ice.
cargo tanks must be repaired in ac- (1) After maintenance or replacement
cordance with the specification re- that does not involve welding on the
quirements in effect at the time of re- cargo tank wall, the repaired or re-
pair; placed piping, valve, hose, or fitting
(2) MC 300, MC 301, MC 302, MC 303, must be tested for leaks. This require-
MC 305, and MC 306 cargo tanks must ment is met when the piping, valve,
be repaired in accordance with either hose, or fitting is tested after installa-
the most recent revision of the original tion in accordance with 180.407(h)(1).
specification or with the DOT 406 speci- A hose may be tested before or after in-
fication 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 pip-
must be repaired in accordance with ei- ing, 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 manu-
repair; facturing specification or
(4) MC 310, MC 311, and MC 312 cargo 180.407(g)(1)(iv). In addition, the af-
tanks 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 re-
bon dioxide, service are excepted from
paired in accordance with the speci-
fication requirements in effect at the these testing requirements, but must
time of repair; and be tested in accordance with 180.416(f).
(6) MC 330 and MC 331 cargo tanks (d) Modification, stretching, or rebarrel-
must be repaired in accordance with ling. Modification, stretching or re-
the repair procedures described in CGA barrelling of a cargo tank motor vehi-
Technical Bulletin TB2 (IBR, see cle must conform to the following pro-
171.7 of this subchapter) and the Na- visions:
tional Board Inspection Code (IBR, see (1) The design of the modified,
171.7 of this subchapter). Each cargo stretched, or rebarrelled cargo tank
tank having cracks or other defects re- motor vehicle must be certified in
quiring welded repairs must meet all writing by a Design Certifying Engi-
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inspection, test, and heat treatment re- neer as meeting the structural integ-
quirements in 178.33716 of this sub- rity and accident damage protection
chapter in effect at the time of the re- requirements of the applicable speci-
pair, except that postweld heat treat- fication.
352
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Pipeline and Hazardous Materials Safety Admin., DOT 180.413
(2) Except as provided in paragraph ling that affects the lading retention
(d)(2)(v) of this section, all new mate- capability of the cargo tank by per-
rial and equipment affected by modi- forming the tests required in the appli-
fication, stretching, or rebarrelling cable specification or 180.407(g)(1)(iv).
must meet the requirements of the (v) Any modification that changes in-
specification in effect at the time such formation displayed on the specifica-
work is performed, and all applicable tion plate requires the installation of a
structural integrity requirements supplemental specification plate,
( 178.3373, 178.3383, or 178.3453 of nameplate, or both containing the in-
this subchapter). The work must con- formation that reflects the cargo tank
form to the requirements of the appli- as modified, stretched or rebarrelled.
cable specification as follows: The plate must include the name of the
(i) For specification MC 300, MC 301, person or facility doing the work, DOT
MC 302, MC 303, MC 305 and MC 306 registration number, date work is com-
cargo tanks, the provisions of either pleted, retest information, and any
specification MC 306 or DOT 406 until other information that differs from the
August 31, 1995 and, thereafter to speci- original plate. The supplemental plates
fication DOT 406 only; must be installed immediately adja-
(ii) For specification MC 304 and MC cent to the existing plate or plates.
307 cargo tanks, the provisions of ei- (vi) On a variable specification cargo
ther specification MC 307 or DOT 407 tank, install a supplemental or new
until August 31, 1995 and, thereafter to variable specification plate, and re-
specification DOT 407 only; place the specification listed on the
(iii) For specification MC 310, MC 311, original specification plate with the
and MC 312 cargo tanks, the provisions words see variable specification
of either specification MC 312 or DOT plate.
412 until August 31, 1995 and, thereafter (4) A Registered Inspector must cer-
to specification DOT 412 only; tify that the modified, stretched, or
(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 modifica- istered 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 ve-
stead of specification MC 338, provided hicle must be:
the structural integrity of the modified (1) Performed as required by para-
cargo 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 modi- mounting 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 de- or modification of the methods of at-
sign 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 attach-
cargo tanks structural integrity, vent- ment to the chassis in effect at the
ing, and accident damage protection time of the mounting, and performed
with the applicable specification re- under the supervision of a Registered
quirements. Inspector if the mounting of a cargo
(iii) Assure compliance with all ap- tank on a motor vehicle chassis does
plicable Federal Motor Carrier Safety not involve welding on the cargo tank
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180.415 49 CFR Ch. I (10111 Edition)
owners principal place of business all cargo tank passed the leakage test under
records of repair, modification, both 180.407(h)(1) and under EPA Method 27
stretching, or rebarrelling, including in 180.407(h)(2).
notation of any tests conducted to (c) For a cargo tank motor vehicle
verify the suitability of the repair, composed of multiple cargo tanks con-
modification, stretching, or rebarrel- structed to the same specification,
ling made to each cargo tank during which are tested and inspected at the
the time the cargo tank motor vehicle same time, one set of test and inspec-
is in service and for one year there- tion markings may be used to satisfy
after. Copies of these records must be the requirements of this section. For a
retained by a motor carrier, if not the cargo tank motor vehicle composed of
owner of the cargo tank motor vehicle, multiple cargo tanks constructed to
at its principal place of business during different specifications, which are test-
the period the cargo tank motor vehi- ed and inspected at different intervals,
cle is in the carriers service. the test and inspection markings must
[68 FR 19288, Apr. 18, 2003; 68 FR 52372, Sept. appear in the order of the cargo tanks
3, 2003, as amended at 68 FR 75764, Dec. 31, corresponding location, from front to
2003] rear.
180.415 Test and inspection mark- [Amdt. 1802, 56 FR 27879, June 17, 1991, as
ings. amended by Amdt. 1803, 56 FR 66287, Dec. 20,
1991; 57 FR 45466, Oct. 1, 1992; Amdt. 1806, 59
(a) Each cargo tank successfully FR 49135, Sept. 26, 1994; Amdt. 18010, 61 FR
completing the test and inspection re- 51343, Oct. 1, 1996; 68 FR 19290, Apr. 18, 2003; 68
quirements contained in 180.407 must FR 52372, Sept. 3, 2003]
be marked as specified in this section.
(b) Each cargo tank must be durably 180.416 Discharge system inspection
and legibly marked, in English, with and maintenance program for cargo
the date (month and year) and the type tanks transporting liquefied com-
of test or inspection performed, subject pressed gases.
to the following provisions: (a) Applicability. This section is appli-
(1) The date must be readily identifi- cable to an operator using specification
able with the applicable test or inspec- MC 330, MC 331, and nonspecification
tion. cargo tanks authorized under
(2) The markings must be in letters 173.315(k) of this subchapter for trans-
and numbers at least 32 mm (1.25 portation of liquefied compressed gases
inches) high, near the specification other than carbon dioxide. Paragraphs
plate or anywhere on the front head. (b), (c), (d)(1), (d)(5), (e), (f), and (g)(1) of
(3) The type of test or inspection may this section, applicable to delivery
be abbreviated as follows: hose assemblies, apply only to hose as-
(i) V for external visual inspection semblies installed or carried on the
and test; cargo tank.
(ii) I for internal visual inspection; (b) Hose identification. By July 1, 2000,
(iii) P for pressure test; the operator must assure that each de-
(iv) L for lining inspection; livery hose assembly is permanently
(v) T for thickness test; and marked with a unique identification
(vi) K for leakage test for a cargo number and maximum working pres-
tank tested under 180.407, except sure.
180.407(h)(2); and (c) Post-delivery hose check. After each
(vii) K-EPA27 for a cargo tank tested unloading, the operator must visually
under 180.407(h)(2) after October 1, check that portion of the delivery hose
2004. assembly deployed during the unload-
Examples to paragraph (b). The markings ing.
1099 P, V, L represent that in October 1999 (d) Monthly inspections and tests. (1)
a cargo tank passed the prescribed pressure The operator must visually inspect
test, external visual inspection and test, and
each delivery hose assembly at least
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Pipeline and Hazardous Materials Safety Admin., DOT 180.416
each calendar month the cargo tank is (1) The operator must visually exam-
in service. The inspection must include ine the delivery hose assembly while it
fusible elements and all components of is under pressure.
the piping system, including bolts, con- (2) Upon successful completion of the
nections, and seals. pressure test and inspection, the oper-
(3) At least once each calendar month ator must assure that the delivery hose
a cargo tank is in service, the operator assembly is permanently marked with
must actuate all emergency discharge the month and year of the test.
control devices designed to close the (3) After July 1, 2000, the operator
internal self-closing stop valve to as- must complete a record documenting
sure that all linkages operate as de- the test and inspection, including the
signed. appendix A to this part outlines date, the signature of the inspector,
acceptable procedures that may be the hose owner, the hose identification
used for this test. number, the date of original delivery
(4) The operator of a cargo tank must hose assembly and test, notes of any
check the internal self-closing stop defects observed and repairs made, and
valve in the liquid discharge opening an indication that the delivery hose as-
for leakage through the valve at least sembly passed or failed the tests and
once each calendar month the cargo inspections. A copy of each test and in-
tank is in service. On cargo tanks spection record must be retained by
equipped with a meter, the meter creep the operator at its principal place of
test as outlined in appendix B to this business or where the vehicle is housed
part or a test providing equivalent ac- or maintained until the next test of the
curacy is acceptable. For cargo tanks same type is successfully completed.
that are not equipped with a meter, ap- (g) Rejection criteria. (1) No operator
pendix B to this part outlines one ac- may use a delivery hose assembly de-
ceptable method that may be used to termined to have any condition identi-
check internal self-closing stop valves fied below for unloading liquefied com-
for closure. pressed gases. An operator may remove
(5) After July 1, 2000, the operator and replace damaged sections or cor-
must note each inspection in a record. rect defects discovered. Repaired hose
That record must include the inspec- assemblies may be placed back in serv-
tion date, the name of the person per- ice if retested successfully in accord-
forming the inspection, the hose as- ance with paragraph (f) of this section.
sembly identification number, the (i) Damage to the hose cover that ex-
company name, the date the hose was poses the reinforcement.
assembled and tested, and an indica- (ii) 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 pres-
test and inspection record must be re- sure, bulging under pressure, or loose
tained by the operator at its principal outer covering.
place of business or where the vehicle (iv) Damaged, slipping, or excessively
is housed or maintained until the next worn hose couplings.
test of the same type is successfully (v) Loose or missing bolts or fas-
completed. tenings on bolted hose coupling assem-
(e) Annual hose leakage test. The blies.
owner of a delivery hose assembly that (2) No operator may use a cargo tank
is not permanently attached to a cargo with a piping system found to have any
tank motor vehicle must ensure that condition identified in this paragraph
the hose assembly is annually tested in (g)(2) for unloading liquefied com-
accordance with 180.407(h)(4). pressed gases.
(f) New or repaired delivery hose assem- (i) Any external leak identifiable
blies. Each operator of a cargo tank without the use of instruments.
wreier-aviles on DSK3TPTVN1PROD with CFR
must ensure each new and repaired de- (ii) Bolts that are loose, missing, or
livery hose assembly is tested at a min- severely corroded.
imum of 120 percent of the hose max- (iii) Manual stop valves that will not
imum working pressure. actuate.
355
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180.417 49 CFR Ch. I (10111 Edition)
(iv) Rubber hose flexible connectors an owner does not have a manufactur-
with any condition outlined in para- ers certificate for a cargo tank and he
graph (g)(1) of this section. wishes to certify it as a specification
(v) Stainless steel flexible connectors cargo tank, the owner must perform
with damaged reinforcement braid. appropriate tests and inspections,
(vi) Internal self-closing stop valves under the direct supervision of a Reg-
that fail to close or that permit leak- istered Inspector, to determine if the
age through the valve detectable with- cargo tank conforms with the applica-
out the use of instruments. ble specification. Both the owner and
(vii) Pipes or joints that are severely the Registered Inspector must certify
corroded. that the cargo tank fully conforms to
[64 FR 28051, May 24, 1999] the applicable specification. The owner
must retain the certificate, as specified
180.417 Reporting and record reten- in this section.
tion requirements. (ii) ASME Code Stamped cargo tanks. If
(a) Vehicle certification. (1) Each the owner does not have the manufac-
owner of a specification cargo tank turers certificate required by the spec-
must retain the manufacturers certifi- ification and the manufacturers data
cate, the manufacturers ASME U1A report required by the ASME, the
data report, where applicable, and re- owner may contact the National Board
lated papers certifying that the speci- for a copy of the manufacturers data
fication cargo tank identified in the report, if the cargo tank was registered
documents was manufactured and test- with the National Board, or copy the
ed in accordance with the applicable information contained on the cargo
specification. This would include any tanks identification and ASME Code
certification of emergency discharge plates. Additionally, both the owner
control systems required by 173.315(n) and the Registered Inspector must cer-
of 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 speci- retain 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 docu- as 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 manufactur- must include the following informa-
ers certificate and related papers or tion:
the alternative report authorized by
(i) Owners and manufacturers
paragraph (a)(3)(i) or (ii) of this section
unique serial number for the cargo
and retain the documents as specified
tank;
in this paragraph (a)(2). A motor car-
(ii) Name of cargo tank manufac-
rier who is not the owner of a cargo
turer;
tank motor vehicle must also retain a
copy of the vehicle certification report (iii) Cargo tank DOT or MC specifica-
for as long as the cargo tank motor ve- tion 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 main- tank shell and heads when the cargo
tained at the companys principal place tank is thickness tested in accordance
of business or at the location where the with 180.407(d)(5), 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
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356
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Pipeline and Hazardous Materials Safety Admin., DOT 180.417
(c) Additional requirements for Speci- tained by the carrier at its principal
fication MC 330 and MC 331 cargo tanks. place of business during the period the
(1) After completion of the pressure cargo tank is in the carriers service
test specified in 180.407(g)(3), each and for one year thereafter. Upon a
357
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180.501 49 CFR Ch. I (10111 Edition)
358
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Pipeline and Hazardous Materials Safety Admin., DOT 180.509
under this paragraph unless the modi- car or a class or design of tank cars
fication is in compliance with an appli- may be in an unsafe operating condi-
cable requirement or provision of this tion.
subchapter. (c) Frequency of inspection and tests.
(3) Specification DOT-113A175W, Each tank car shall have an inspection
DOT-113C60W, DOT-113D60W, and DOT- and test according to the requirements
113D120W tank cars may continue in of this paragraph.
use, but new construction is not au- (1) For Class 107 tank cars and tank
thorized. cars of riveted construction, the tank
(4) Class DOT 105A and 105S tank cars car must have a hydrostatic pressure
used to transport hydrogen chloride, test and visual inspection conforming
refrigerated liquid under the terms of to the requirements in effect prior to
DOT-E 3992 may continue in service, July 1, 1996, for the tank specification.
but new construction is not authorized. (2) For Class DOT 113 tank cars, see
(5) Specification DOT-103A-ALW, 173.319(e) of this subchapter.
103AW, 103ALW, 103ANW, 103BW, (3) For fusion welded tank cars, each
103CW, 103DW, 103EW, and 104W tank tank car must have an inspection and
cars may continue in use, but new con- test in accordance with paragraphs (d)
struction is not authorized. through (k) of this section.
(i) For cars transporting materials
[Amdt. 1808, 60 FR 49079, Sept. 21, 1995, as
not corrosive to the tank, every 10
amended at 68 FR 48572, Aug. 14, 2003]
years for the tank and service equip-
180.509 Requirements for inspection ment (i.e., filling and discharge, vent-
and 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 t1 t 2
180.517(b) must be prepared for each i=
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.
r is the corrosion rate per year.
appropriate inspection and test accord-
ing to the type of defect and the type (iii) For lined or coated tank cars
of maintenance or repair performed if: transporting a material corrosive to
(1) The tank car shows evidence of the tank, every 10 years for the tank, 5
abrasion, corrosion, cracks, dents, dis- years for the service equipment.
tortions, defects in welds, or any other (A) When a lining or coating is ap-
condition that makes the tank car un- plied to protect the tank shell from the
safe for transportation. An example is lading, the owner of the lining or coat-
if maintenance is performed to replace ing shall determine the periodic inspec-
a fitting, then only a leakage pressure tion interval, test technique, and ac-
test needs to be performed. ceptance criteria for the lining or coat-
(2) The tank car was in an accident ing. The owner must maintain at its
and damaged to an extent that may ad- principal place of business all sup-
versely affect its capability to retain porting documentation used to make
its contents. such a determination, such as the lin-
(3) The tank bears evidence of dam- ing or coating manufacturers rec-
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359
EC13NO91.039</MATH>
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180.509 49 CFR Ch. I (10111 Edition)
(B) The owner of the lining or coat- of the bottom longitudinal center line;
ing shall provide the periodic inspec- the termination of longitudinal fillet
tion interval, test technique, and ac- welds greater than 0.64 cm (0.25 inch)
ceptance criteria for the lining or coat- within 121.92 cm (4 feet) of the bottom
ing to the person responsible for quali- longitudinal center line; and all tank
fying the lining and coating. shell butt welds within 60.96 cm (2 feet)
(d) Visual inspection. At a minimum, of the bottom longitudinal center line
each tank car facility must visually in- by one or more of the following inspec-
spect the tank externally and inter- tion and test methods to determine
nally as follows: that the welds are in proper condition:
(1) An internal inspection of the tank (1) Dye penetrant test;
shell and heads for abrasion, corrosion, (2) Radiography test;
cracks, dents, distortions, defects in (3) Magnetic particle test;
welds, or any other condition that (4) Ultrasonic test; or
makes the tank car unsafe for trans-
(5) Optically-aided visual inspection
portation, and except in the areas
(e.g., magnifiers, fiberscopes,
where insulation or a thermal protec-
borescopes, and machine vision tech-
tion system precludes it, an external
nology).
inspection of the tank shell and heads
for abrasion, corrosion, cracks, dents, (f) Thickness tests. (1) Each tank car
distortions, defects in welds, or any facility shall measure the thickness of
other condition that makes the tank the tank car shell, heads, sumps,
car unsafe for transportation; domes, and nozzles on each tank car by
(2) An inspection of the piping, using a device capable of accurately
valves, fittings, and gaskets for indica- measuring the thickness to within 0.05
tions of corrosion and other conditions mm (0.002 inch).
that make the tank car unsafe for (2) After repairs, alterations, conver-
transportation; sions or modifications of a tank car
(3) An inspection for missing or loose that result in a reduction to the tank
bolts, nuts, or elements that make the car shell thickness, the tank car facil-
tank car unsafe for transportation; ity shall measure the thickness of the
(4) An inspection of all closures on tank car shell in the area of reduced
the tank car for proper securement in a shell thickness to ensure that the shell
tool tight condition and an inspection thickness conforms to paragraph (g) of
of the protective housings for proper this section.
securement; (g) Service life shell thickness allow-
(5) An inspection of excess flow ance. (1) A tank car found with a shell
valves having threaded seats for tight- thickness below the required minimum
ness; and thickness after forming for its speci-
(6) An inspection of the required fication, as stated in part 179 of this
markings on the tank car for legibility. subchapter, may continue in service if:
(e) Structural integrity inspections and (i) Construction of the tank car shell
tests. At a minimum, each tank car fa- and heads is from carbon steel, stain-
cility shall inspect the tank car for less steel, aluminum, nickel, or man-
structural integrity as specified in this ganese-molybdenum steel; and
section. The structural integrity in- (ii) Any reduction in the required
spection and test shall include all minimum thickness of the tank shell
transverse fillet welds greater than 0.64 or head is not more than that provided
cm (0.25 inch) within 121.92 cm (4 feet) 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 Top shell and tank
Bottom shell 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).
wreier-aviles on DSK3TPTVN1PROD with CFR
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).
360
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Pipeline and Hazardous Materials Safety Admin., DOT 180.509
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).
ical, 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 re-
ductions 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 sure for the sensitivity and reliability
minimum, each tank car facility must of the test method and for the service-
inspect: ability of components to prevent pre-
(1) Tank car thermal protection sys- mature failure.
tems, tank head puncture resistance (2) Interior heater systems must be
systems, coupler vertical restraint sys- tested hydrostatically at 13.87 Bar (200
tems, and systems used to protect dis- psig) and must show no signs of leak-
continuities (i.e., skid protection and age.
protective housings) to ensure their in- (k) Alternative inspection and test pro-
tegrity. cedures. In lieu of the other require-
(2) Reclosing pressure relief devices ments of this section, a person may use
by: an alternative inspection and test pro-
(i) Removing the reclosing pressure cedure or interval based on a damage-
relief device from the tank car for in- tolerance fatigue evaluation (that in-
spection; and cludes a determination of the probable
(ii) Testing the reclosing pressure re- locations and modes of damage due to
lief device with air or another gas to fatigue, corrosion, or accidental dam-
ensure that it conforms to the start-to- age), when the evaluation is examined
discharge pressure for the specification by the Association of American Rail-
or hazardous material in this sub- roads Tank Car Committee and ap-
chapter. proved by the Associate Administrator
(i) Lining and coating inspection and for Safety, FRA.
test. When this subchapter requires a (l) Inspection and test compliance date
lining or coating, at a minimum, each for tank cars. (1) After July 1, 2000, each
tank car facility must inspect the lin- tank car with a metal jacket or with a
ing or coating installed on the tank car thermal protection system shall have
according to the inspection interval an inspection and test conforming to
test technique, and acceptance criteria this section no later than the date the
established by the owner of the lining tank car requires a periodic hydro-
or coating in accordance with para- static pressure test (i.e., the marked
graph (c)(3)(iii) of this section. due date on the tank car for the hydro-
(j) Leakage pressure test. (1) After re- static test).
assembly of a tank car or service (2) After July 1, 1998, each tank car
equipment, a tank car facility must without a metal jacket shall have an
perform a leak test on the tank or inspection and test conforming to this
service equipment to detect leakage, if section no later than the date the tank
any, between manway covers, cover car requires a periodic hydrostatic
plates, and service equipment. The test pressure test (i.e., the marked due date
may be conducted with the hazardous on the tank car for the hydrostatic
material in the tank. When the test test).
pressure exceeds the start-to-discharge (3) For tank cars on a 20-year peri-
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180.511 49 CFR Ch. I (10111 Edition)
midpoint between the compliance date (g) Hydrostatic test. A Class 107 tank
in paragraph (l)(1) or (2) of this section car or a riveted tank car successfully
and the remaining years until the tank passes the hydrostatic test when it
would have had a hydrostatic pressure shows no leakage, distortion, excessive
test. permanent expansion, or other evi-
dence of weakness that might render
[Amdt. 1808, 60 FR 49079, Sept. 21, 1995, as
amended by Amdt. 17950, 61 FR 33256, June
the tank car unsafe for transportation
26, 1996; 62 FR 51561, Oct. 1, 1997; 63 FR 52851, service.
Oct. 1, 1998; 66 FR 45391, Aug. 28, 2001; 68 FR [Amdt. 1808, 60 FR 49079, Sept. 21, 1995, as
75765, Dec. 31, 2003; 71 FR 54398, Sept. 14, 2006] amended by Amdt. 17950, 61 FR 33256, June
26, 1996; 66 FR 45187, Aug. 28, 2001]
180.511 Acceptable results of inspec-
tions and tests. 180.513 Repairs, alterations, conver-
Provided it conforms with other ap- sions, and modifications.
plicable requirements of this sub- (a) In order to repair tank cars, the
chapter, a tank car is qualified for use tank car facility must comply with the
if it successfully passes the following requirements of appendix R of the AAR
inspections and tests conducted in ac- Specifications for Tank Cars (IBR, see
cordance with this subpart: 171.7 of this subchapter).
(a) Visual inspection. A tank car suc- (b) Unless the exterior tank car shell
cessfully passes the visual inspection or interior tank car jacket has a pro-
when the inspection shows no struc- tective coating, after a repair that re-
tural defect that may cause leakage quires the complete removal of the
from or failure of the tank before the tank car jacket, the exterior tank car
next inspection and test interval. shell and the interior tank car jacket
(b) Structural integrity inspection and must have a protective coating applied
test. A tank car successfully passes the to prevent the deterioration of the
structural integrity inspection and test tank shell and tank jacket.
when it shows no structural defect that [Amdt. 1802, 54 FR 25032, June 12, 1989, as
may initiate cracks or propagate amended at 68 FR 75765, Dec. 31, 2003]
cracks and cause failure of the tank be-
fore the next inspection and test inter- 180.515 Markings.
val. (a) When a tank car passes the re-
(c) Service life shell thickness. A tank quired inspection and test with accept-
car successfully passes the service life able results, the tank car facility shall
shell thickness inspection when the mark the date of the inspection and
tank shell and heads show no thickness test and the due date of the next in-
reduction below that allowed in spection and test on the tank car in ac-
180.509(g). cordance with appendix C of the AAR
(d) Safety system inspection. A tank Specifications for Tank Cars (IBR, see
car successfully passes the safety sys- 171.7 of this subchapter). When a tank
tem inspection when each thermal pro- car facility performs multiple inspec-
tection system, tank head puncture re- tion and test at the same time, one
sistance system, coupler vertical re- date may be used to satisfy the re-
straint system, and system used to pro- quirements of this section. One date
tect discontinuities (e.g., breakage also may be shown when multiple in-
grooves on bottom outlets and protec- spection and test have the same due
tive housings) on the tank car conform date.
to this subchapter. (b) Pressure converted tank cars
(e) Lining and coating inspection. A must have the new specification and
tank car successfully passes the lining conversion date permanently marked
and coating inspection and test when in letters and figures at least 0.95 cm
the lining or coating conforms to the (0.375 inch) high on the outside of the
owners acceptance criteria. manway nozzle or the edge of the
(f) Leakage pressure test. A tank car manway nozzle flange on the left side
wreier-aviles on DSK3TPTVN1PROD with CFR
successfully passes the leakage pres- of the car. The marking may have the
sure test when all product piping, fit- last numeral of the specification num-
tings and closures show no indication ber omitted (e.g., DOT 111A100W in-
of leakage. stead of DOT 111A100W1).
362
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Pipeline and Hazardous Materials Safety Admin., DOT 180.519
(c) When pressure tested within six 180.519 Periodic retest and inspec-
months of installation and protected tion of tank cars other than single-
from deterioration, the test date mark- unit tank car tanks.
ing of a reclosing pressure relief device
(a) General. Unless otherwise pro-
is the installation date on the tank
vided in this subpart, tanks designed to
car.
be removed from cars for filling and
[Amdt. 1808, 60 FR 49079, Sept. 21, 1995, as emptying and tanks built to a Class
amended by Amdt. 17950, 61 FR 33256, June DOT 107A specification and their safety
26, 1996; 63 FR 52851, Oct. 1, 1998; 66 FR 45391,
Aug. 28, 2001; 68 FR 75765, Dec. 31, 2003]
relief devices must be retested periodi-
cally as specified in Retest Table 1 of
180.517 Reporting and record reten- paragraph (b)(5) of this section. Retests
tion requirements. may be made at any time during the
(a) Certification and representation. calendar year the retest falls due.
Each owner of a specification tank car (b) Pressure test. (1) Each tank must
shall retain the certificate of construc- be subjected to the specified hydro-
tion (AAR Form 42) and related papers static pressure and its permanent ex-
certifying that the manufacture of the pansion determined. Pressure must be
specification tank car identified in the maintained for 30 seconds and for as
documents is in accordance with the long as necessary to secure complete
applicable specification. The owner expansion of the tank. Before testing,
shall retain the documents throughout the pressure gauge must be shown to be
the period of ownership of the speci- accurate within 1 percent at test meas-
fication tank car and for one year ure. The expansion gauge must be
thereafter. Upon a change of owner-
shown to be accurate, at test pressure,
ship, the requirements in Section 1.3.15
to within 1 percent. Expansion must be
of the AAR Specifications for Tank
Cars (IBR, see 171.7 of this subchapter) recorded in cubic cm. Permanent volu-
apply. metric expansion may not exceed 10
(b) Inspection and test reporting. Each percent of total volumetric expansion
tank car that is inspected as specified at test pressure and the tank must not
in 180.509 must have a written report, leak or show evidence of distress.
in English, prepared according to this (2) Each tank, except tanks built to
paragraph. The owner must retain a specification DOT 107A, must also be
copy of the inspection and test reports subjected to interior air pressure test
until successfully completing the next of at least 100 psig under conditions fa-
inspection and test of the same type. vorable to detection of any leakage. No
The inspection and test report must in- leaks may appear.
clude the following: (3) Safety relief valves must be re-
(1) Type of inspection and test per- tested by air or gas, must start-to-dis-
formed (a checklist is acceptable); charge at or below the prescribed pres-
(2) The results of each inspection and
sure and must be vapor tight at or
test performed;
above the prescribed pressure.
(3) Owners reporting mark;
(4) DOT Specification; (4) Rupture discs and fusible plugs
(5) Inspection and test date (month must be removed from the tank and
and year); visually inspected.
(6) Location and description of de- (5) Tanks must be retested as speci-
fects found and method used to repair fied in Retest Table 1 of this paragraph
each defect; (b)(5), and before returning to service
(7) The name and address of the tank after repairs involving welding or heat
car facility and the signature of inspec- treatment:
tor.
[Amdt. 1802, 54 FR 25032, June 12, 1989, as
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363
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180.519 49 CFR Ch. I (10111 Edition)
RETEST TABLE 1
Retest intervalyears Minimum Retest Pressure relief valve
pressurepsig pressurepsig
Specification Pressure re- Tank hydro-
Tank Start-to-
lief devices d static Tank air test Vapor tight
discharge
expansion c
(6) The month and year of test, fol- sheet. Completed copies of these re-
lowed by a V if visually inspected as ports must be retained by the owner
described in paragraph (c) of this sec- and by the person performing the pres-
tion, must be plainly and permanently sure test and visual inspection as long
stamped into the metal of one head or as the tank is in service. The informa-
chime of each tank with successful test tion to be recorded and checked on
results; for example, 0190 for January these data sheets are: Date of test and
1990. On DOT 107A**** tanks, the date inspection; DOT specification number;
must be stamped into the metal of the tank identification (registered symbol
marked end, except that if all tanks and serial number, date of manufacture
mounted on a car have been tested, the and ownership symbol); type of protec-
date may be stamped into the metal of tive coating (painted, etc., and state-
a plate permanently applied to the ment as to need for refinishing or re-
bulkhead on the A end of the car. coating); conditions checked (leakage,
Dates of previous tests and all pre- corrosion, gouges, dents or digs, broken
scribed markings must be kept legible. or damaged chime or protective ring,
(c) Visual inspection. Tanks of Class fire, fire damage, internal condition);
DOT 106A and DOT 110A-W specifica- test pressure; results of tests; and dis-
tions ( 179.300 and 179.301 of this sub- position of tank (returned to service,
chapter) used exclusively for trans- returned to manufacturer for repair, or
porting fluorinated hydrocarbons and scrapped); and identification of the per-
mixtures thereof, and that are free son conducting the retest or inspec-
from corroding components, may be tion.
given a periodic complete internal and [Amdt. 1808, 60 FR 49079, Sept. 21, 1995, as
external visual inspection in place of amended by Amdt. 17950, 61 FR 33257, June
the periodic hydrostatic retest. Visual 26, 1996; 65 FR 58633, Sept. 29, 2000; 66 FR
inspections shall be made only by com- 45187, 45392, Aug. 28, 2001; 68 FR 75765, Dec. 31,
petent persons. The tank must be ac- 2003]
cepted or rejected in accordance with
the criteria in CGA C6 (IBR, see 171.7 Subpart GQualification and
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364
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Pipeline and Hazardous Materials Safety Admin., DOT 180.605
ing the period the portable tank is in (2) Each Specification 51 portable
service, and for one year thereafter, tank must be given a periodic inspec-
the owner of the portable tank must tion and test at least once every five
retain on file, at its principal place of years.
365
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180.605 49 CFR Ch. I (10111 Edition)
(3) Each Specification 56 or 57 port- Portable tanks used for the transpor-
able tank must be given a periodic in- tation of refrigerated, liquefied gases
spection and test at least once every are excepted from the requirement for
2.5 years. internal inspection and the hydraulic
(4) Each Specification 60 portable pressure test during the 5-year periodic
tank must be given a periodic inspec- inspection and test, if the portable
tion and test at the end of the first 4- tanks were pressure tested to a min-
year period after the original test; at imum test pressure of 1.3 times the de-
least once every 2 years thereafter up sign pressure using an inert gas as pre-
to a total of 12 years of service; and at scribed in 178.33816(a) and (b) of this
least once annually thereafter. Re- subchapter before putting the portable
testing is not required on a rubber- tank into service initially and after
lined tank except before each relining. any exceptional inspections and tests
(d) Intermediate periodic inspection and specified in paragraph (f) of this sec-
test. For IM and UN portable tanks the tion.
intermediate 2.5 year periodic inspec- (f) Exceptional inspection and test. The
tion and test must include at least an exceptional inspection and test is nec-
internal and external examination of essary when a portable tank shows evi-
the portable tank and its fittings tak- dence of damaged or corroded areas, or
ing into account the hazardous mate- leakage, or other conditions that indi-
rials intended to be transported; a cate a deficiency that could affect the
leakage test; and a test of the satisfac- integrity of the portable tank. The ex-
tory operation of all service equip- tent of the exceptional inspection and
ment. Sheathing, thermal insulation, test must depend on the amount of
etc. need only be removed to the extent damage or deterioration of the portable
required for reliable appraisal of the tank. It must include at least the in-
condition of the portable tank. For spection and a pressure test according
portable tanks intended for the trans- to paragraph (e) of this section. Pres-
portation of a single hazardous mate- sure relief devices need not be tested or
rial, the internal examination may be replaced unless there is reason to be-
waived if it is leakage tested in accord- lieve the relief devices have been af-
ance with the procedures in paragraph fected by the damage or deterioration.
(h) of this section prior to each filling,
(g) Internal and external examination.
or if approved by the Associate Admin-
The internal and external examina-
istrator. Portable tanks used for dedi-
tions must ensure that:
cated transportation of refrigerated
liquefied gases that are not fitted with (1) The shell is inspected for pitting,
inspection openings are excepted from corrosion, or abrasions, dents, distor-
the internal inspection requirement. tions, defects in welds or any other
(e) Periodic inspection and test. The 5 conditions, including leakage, that
year periodic inspection and test must might render the portable tank unsafe
include an internal and external exam- for transportation;
ination and, unless excepted, a pressure (2) The piping, valves, and gaskets
test as specified in this section. are inspected for corroded areas, de-
Sheathing, thermal insulation, etc. fects, and other conditions, including
need only to be removed to the extent leakage, that might render the port-
required for reliable appraisal of the able tank unsafe for filling, discharge
condition of the portable tank. Except or transportation;
for DOT Specification 56 and 57 port- (3) Devices for tightening manhole
able tanks, reclosing pressure relief de- covers are operative and there is no
vices must be removed from the tank leakage at manhole covers or gaskets;
and tested separately unless they can (4) Missing or loose bolts or nuts on
be tested while installed on the port- any flanged connection or blank flange
able tank. For portable tanks where are replaced or tightened;
the shell and equipment have been (5) All emergency devices and valves
wreier-aviles on DSK3TPTVN1PROD with CFR
pressure-tested separately, after as- are free from corrosion, distortion and
sembly they must be subjected to- any damage or defect that could pre-
gether to a leakage test and effectively vent their normal operation. Remote
tested and inspected for corrosion. closure devices and self-closing stop-
366
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Pipeline and Hazardous Materials Safety Admin., DOT 180.605
impending failure, or failure. All clo- service. A portable tank fails to meet
sures shall be in place while the test is the requirements of the pressure test
made and the pressure shall be gauged if, during the test, there is permanent
at the top of the tank. Safety devices distortion of the tank exceeding that
367
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180.605 49 CFR Ch. I (10111 Edition)
permitted by the applicable specifica- (k) Inspection and test markings. (1)
tion; if there is any leakage; or if there Each IM or UN portable tank must be
are any deficiencies that would render durably and legibly marked, in
the portable tank unsafe for transpor- English, with the date (month and
tation. Any portable tank that fails year) of the last pressure test, the iden-
must be rejected and may not be used tification markings of the approval
again for the transportation of a haz- agency witnessing the test, when re-
ardous material unless the tank is ade- quired, and the date of the last visual
quately repaired, and, thereafter, a inspection. The marking must be
successful test is conducted in accord- placed on or near the metal identifica-
ance with the requirements of this tion plate, in letters and numerals of
paragraph. An approval agency shall not less than 3 mm (0.118 inches) high
witness the hydrostatic or pneumatic when on the metal identification plate,
test. Any damage or deficiency that and 12 mm (0.47 inches) high when on
might render the portable tank unsafe the portable tank.
for service shall be repaired to the sat- (2) Each Specification DOT 51, 56, 57
isfaction of the witnessing approval or 60 portable tank must be durably
agency. The repaired tank must be re- and legibly marked, in English, with
tested to the original pressure test re- the date (month and year) of the most
quirements. Upon successful comple- recent periodic retest. The marking
tion of the hydrostatic or pneumatic must be placed on or near the metal
test, as applicable, the witnessing ap- certification plate and must be in ac-
proval agency shall apply its name, cordance with 178.3 of this subchapter.
identifying mark or identifying num- The letters and numerals must not be
ber in accordance with paragraph (k) of less than 3 mm (0.118 inches) high when
this section. on the metal certification plate, and 12
(i) Rejection criteria. When evidence of mm (0.47 inches) high when on the
any unsafe condition is discovered, the portable tank, except that a portable
portable tank may not be returned to tank manufactured under a previously
service until it has been repaired and authorized specification may continue
the pressure test is repeated and to be marked with smaller markings if
passed.
originally authorized under that speci-
(j) Repair. The repair of a portable fication (for example, DOT Specifica-
tank is authorized, provided such re- tion 57 portable tanks).
pairs are made in accordance with the
(l) Record retention. The owner of each
requirements prescribed in the speci-
portable tank or his authorized agent
fication for the tanks original design
shall retain a written record of the
and construction. In addition to any
date and results of all required inspec-
other provisions of the specification,
tions and tests, including an ASME
no portable tank may be repaired so as
manufacturers date report, if applica-
to cause leakage or cracks or so as to
ble, and the name and address of the
increase the likelihood of leakage or
person performing the inspection or
cracks near areas of stress concentra-
tion due to cooling metal shrinkage in test, in accordance with the applicable
welding operations, sharp fillets, rever- specification. The manufacturers data
sal of stresses, or otherwise. No field report, including a certificate(s) signed
welding may be done except to non- by the manufacturer, and the author-
pressure parts. Any cutting, burning or ized design approval agency, as appli-
welding operations on the shell of an cable, indicating compliance with the
IM or UN portable tank must be done applicable specification of the portable
with the approval of the approval agen- tank, must be retained in the files of
cy and be done in accordance with the the owner, or his authorized agent,
requirements of this subchapter, tak- during the time that such portable
ing into account the pressure vessel tank is used for such service, except for
wreier-aviles on DSK3TPTVN1PROD with CFR
code used for the construction of the Specifications 56 and 57 portable tanks.
shell. A pressure test to the original [Amdt. 1802, 54 FR 25032, June 12, 1989, as
test pressure must be performed after amended at 67 FR 15744, Apr. 3, 2002; 68 FR
the work is completed. 45042, July 31, 2003; 74 FR 53189, Oct. 16, 2009]
368
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Pipeline and Hazardous Materials Safety Admin., DOT Pt. 180, App. C
369
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Pt. 180, App. C 49 CFR Ch. I (10111 Edition)
eddy current examinations must be main- (iv) Date of eddy current examination.
tained by the person who performs the re- (vi) Acceptance/condemnation results (e.g.
qualification until either the expiration of pass or fail).
the requalification period or until the cyl- (vii) Retester identification number.
inder is again requalified, whichever occurs 8. Personnel Qualification Requirements.
first. These records shall be made available Each person who performs eddy current and
for inspection by a representative of the De- visual examinations, and evaluates and cer-
partment on request. Eddy current examina- tifies retest results must be certified by the
tion records shall contain the following in- employer that he/she has been properly
formation: trained and tested in the eddy current and
(i) Specification of each standard reference visual examination procedures.
ring used to perform the eddy current exam- 9. Training Records. A record of current
ination. training must be maintained for each em-
(ii) DOT specification or exemption num- ployee who performs eddy current and visual
ber of the cylinder; manufacturers name or examinations in accordance with 172.704(d).
symbol; owners name or symbol, if present;
[71 FR 51129, Aug. 29, 2006]
serial number; and, date of manufacture.
(iii) Name of test operator performing the
eddy current examination. PARTS 181185 [RESERVED]
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370
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SUBCHAPTER DPIPELINE SAFETY
190.311 General.
190.313 Initiation of rulemaking. Safety, which is part of the Pipeline
190.315 Contents of notices of proposed rule- and Hazardous Materials Safety Ad-
making. ministration, U.S. Department of
190.317 Participation by interested persons. Transportation.
371
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190.5 49 CFR Ch. I (10111 Edition)
Person means any individual, firm, firmation, constitutes prima facie evi-
joint venture, partnership, corporation, dence of service.
association, State, municipality, coop-
[45 FR 20413, Mar. 27, 1980, as amended at 73
erative association, or joint stock asso- FR 16567, Mar. 28, 2008]
ciation, and includes any trustee, re-
ceiver, assignee, or personal represent- 190.7 Subpoenas; witness fees.
ative thereof.
(a) The Administrator, PHMSA, the
Presiding Official means the person
Chief Counsel, PHMSA, or the official
who conducts any hearing relating to designated by the Administrator,
civil penalty assessments, compliance PHMSA, to preside over a hearing con-
orders or hazardous facility orders. vened in accordance with this part,
Regional Director means the head of may sign and issue subpoenas individ-
any one of the Regional Offices of the ually on their own initiative or, upon
Office of Pipeline Safety, or a designee request and adequate showing by any
appointed by the Regional Director. person participating in the proceeding
Regional Offices are located in Tren- that the information sought will mate-
ton, NJ (Eastern Region); Atlanta, rially advance the proceeding.
Georgia (Southern Region); Kansas (b) A subpoena may require the at-
City, Missouri (Central Region); Hous- tendance of a witness, or the produc-
ton, Texas (Southwest Region); and tion of documentary or other tangible
Lakewood, Colorado (Western Region). evidence in the possession or under the
Respondent means a person upon control of person served, or both.
whom the OPS has served a notice of (c) A subpoena may be served person-
probable violation. ally by any person who is not an inter-
PHMSA means the Pipeline and Haz- ested person and is not less than 18
ardous Materials Safety Administra- years of age, or by certified or reg-
tion of the United States Department istered mail.
of Transportation. (d) Service of a subpoena upon the
State means a State of the United person named therein shall be made by
States, the District of Columbia and delivering a copy of the subpoena to
the Commonwealth of Puerto Rico. such person and by tendering the fees
for one days attendance and mileage
[Amdt. 1906, 61 FR 18513, Apr. 26, 1996, as
as specified by paragraph (g) of this
amended at 68 FR 11749, Mar. 12, 2003; 70 FR
11137, Mar. 8, 2005; Amdt. 19015, 74 FR 62505,
section. When a subpoena is issued at
Nov. 30, 2009] the instance of any officer or agency of
the United States, fees and mileage
190.5 Service. need not be tendered at the time of
service. Delivery of a copy of a sub-
(a) Each order, notice, or other docu- poena and tender of the fees to a nat-
ment required to be served under this ural person may be made by handing
part shall be served personally, by reg- them to the person, leaving them at
istered or certified mail, overnight the persons office with the person in
courier, or electronic transmission by charge thereof, leaving them at the
facsimile or other electronic means persons dwelling place or usual place
that includes reliable acknowledge- of abode with some person of suitable
ment of actual receipt. age and discretion then residing there-
(b) Service upon a persons duly au- in, by mailing them by registered or
thorized representative or agent con- certified mail to the person at the last
stitutes service upon that person. known address, or by any method
(c) Service by registered or certified whereby actual notice is given to the
mail or overnight courier is complete person and the fees are made available
upon mailing. Service by electronic prior to the return date.
transmission is complete upon trans- (e) When the person to be served is
mission and acknowledgement of re- not a natural person, delivery of a copy
wreier-aviles on DSK3TPTVN1PROD with CFR
ceipt. An official receipt for the mail- of the subpoena and tender of the fees
ing from the U.S. Postal Service or may be effected by handing them to a
overnight courier, or a facsimile or designated agent or representative for
other electronic transmission con- service, or to any officer, director, or
372
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Pipeline and Hazardous Materials Safety Admin., DOT 190.9
agent in charge of any office of the per- found to compel that person, after no-
son, or by mailing them by registered tice, to appear and give testimony, or
or certified mail to that agent or rep- to appear and produce the subpoenaed
resentative and the fees are made documents before the PHMSA, or both.
available prior to the return date.
[45 FR 20413, Mar. 27, 1980, as amended by
(f) The original subpoena bearing a Amdt. 1906, 61 FR 18513, Apr. 26, 1996; Amdt.
certificate of service shall be filed with 1907, 63 FR 7722, Feb. 17, 1998; 70 FR 11137,
the official having responsibility for Mar. 8, 2005]
the proceeding in connection with
which the subpoena was issued. 190.9 Petitions for finding or ap-
(g) A subpoenaed witness shall be proval.
paid the same fees and mileage as (a) In circumstances where a rule
would be paid to a witness in a pro- contained in parts 192, 193 and 195 of
ceeding in the district courts of the this chapter authorizes the Adminis-
United States. The witness fees and trator to make a finding or approval,
mileage shall be paid by the person at an operator may petition the Adminis-
whose instance the subpoena was trator for such a finding or approval.
issued.
(b) Each petition must refer to the
(h) Notwithstanding the provisions of
rule authorizing the action sought and
paragraph (g) of this section, and upon
contain information or arguments that
request, the witness fees and mileage
justify the action. Unless otherwise
may be paid by the PHMSA if the offi-
specified, no public proceeding is held
cial who issued the subpoena deter-
on a petition before it is granted or de-
mines on the basis of good cause
nied. After a petition is received, the
shown, that:
Administrator or participating state
(1) The presence of the subpoenaed
agency notifies the petitioner of the
witness will materially advance the
disposition of the petition or, if the re-
proceeding; and
quest requires more extensive consider-
(2) The person at whose instance the
ation or additional information or
subpoena was issued would suffer a se-
comments are requested and delay is
rious hardship if required to pay the
expected, of the date by which action
witness fees and mileage.
will be taken.
(i) Any person to whom a subpoena is
(1) For operators seeking a finding or
directed may, prior to the time speci-
approval involving intrastate pipeline
fied therein for compliance, but in no
transportation, petitions must be sent
event more than 10 days after the date
to:
of service of such subpoena, apply to
the official who issued the subpoena, or (i) The State agency certified to par-
if the person is unavailable, to the Ad- ticipate under 49 U.S.C. 60105.
ministrator, PHMSA to quash or mod- (ii) Where there is no state agency
ify the subpoena. The application shall certified to participate, the Adminis-
contain a brief statement of the rea- trator, Pipeline and Hazardous Mate-
sons relied upon in support of the ac- rials Safety Administration, 1200 New
tion sought therein. The Adminis- Jersey Avenue, SE, Washington, DC
trator, PHMSA, or this issuing official, 20590.
as the case may be, may: (2) For operators seeking a finding or
(1) Deny the application; approval involving interstate pipeline
(2) Quash or modify the subpoena; or transportation, petitions must be sent
(3) Condition a grant or denial of the to the Administrator, Pipeline and
application to quash or modify the sub- Hazardous Materials Safety Adminis-
poena upon the satisfaction of certain tration, 1200 New Jersey Avenue, SE,
just and reasonable requirements. The Washington, DC 20590.
denial may be summary. (c) All petitions must be received at
(j) Upon refusal to obey a subpoena least 90 days prior to the date by which
served upon any person under the pro- the operator requests the finding or ap-
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373
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190.11 49 CFR Ch. I (10111 Edition)
state agency receiving petitions initi- line Safety (PHP30), PHMSA, U.S. De-
ated under this section shall provide partment of Transportation, 1200 New
the Administrator a written rec- Jersey Avenue, SE, Washington, DC
ommendation as to the disposition of 205900001. The requestor must include
any petition received by them. Where his or her return address and should
the Administrator does not reverse or also include a daytime telephone num-
modify a recommendation made by a ber. Written requests should be sub-
state agency within 10 business days of mitted at least 120 days before the time
its receipt, the recommended disposi- the requestor needs the response.
tion shall constitute the Administra- (2) A written interpretation regard-
tors decision on the petition. ing Federal pipeline safety law, 49
[Amdt. 1905, 59 FR 17280, Apr. 12, 1994, as U.S.C 60101 et seq., may be obtained
amended by Amdt. 1906, 61 FR 18513, Apr. 26, from the Office of the Chief Counsel,
1996; 70 FR 11137, Mar. 8, 2005; 73 FR 16566, PHMSA, U.S. Department of Transpor-
Mar. 28, 2008] tation, 1200 New Jersey Avenue, SE,
Washington, DC 205900001. The re-
190.11 Availability of informal guid- questor must include his or her return
ance and interpretive assistance.
address and should also include a day-
(a) Availability of telephonic and Inter- time telephone number.
net assistance. (1) PHMSA has estab-
lished a website on the Internet and a [62 FR 24057, May 2, 1997; 62 FR 34415, June 26,
telephone line at the Office of Pipeline 1997, as amended at 70 FR 11137, Mar. 8, 2005;
73 FR 16566, Mar. 28, 2008; 73 FR 16567, Mar.
Safety headquarters where small oper-
28, 2008]
ators and others can obtain informa-
tion on and advice about compliance
with pipeline safety regulations, 49 Subpart BEnforcement
CFR parts 190199. The website and
telephone line are staffed by personnel 190.201 Purpose and scope.
from PHMSAs Office of Pipeline Safe- (a) This subpart describes the en-
ty from 9:00 a.m. through 5:00 p.m., forcement authority and sanctions ex-
Eastern time, Monday through Friday, ercised by the Associate Adminis-
except Federal holidays. When the trator, OPS for achieving and main-
lines are not staffed, individuals may taining pipeline safety. It also pre-
leave a recorded voicemail message, or scribes the procedures governing the
post a message at the OPS website. All exercise of that authority and the im-
messages will receive a response by the position of those sanctions.
following business day. The telephone (b) A person who is the subject of ac-
number for the OPS information line is tion pursuant to this subpart may be
(202) 3664595 and the OPS website can represented by legal counsel at all
be accessed via the Internet at http:// stages of the proceeding.
ops.dot.gov.
(2) PHMSAs Office of the Chief Coun- [45 FR 20413, Mar. 27, 1980, as amended by
sel (OCC) is available to answer ques- Amdt. 1906, 61 FR 18513, Apr. 26, 1996]
tions concerning Federal pipeline safe-
ty law, 49 U.S.C. 60101 et seq. OCC may 190.203 Inspections and investiga-
tions.
be contacted by telephone (2023664400)
from 9:00 a.m. to 4:00 p.m. Eastern (a) Officers, employees, or agents au-
time, Monday through Friday, except thorized by the Associate Adminis-
Federal holidays. Information and trator for Pipeline Safety, PHMSA,
guidance concerning Federal pipeline upon presenting appropriate creden-
safety law may also be obtained by tials, are authorized to enter upon, in-
contacting OCC via the Internet at spect, and examine, at reasonable
http://rspa-atty.dot.gov. times and in a reasonable manner, the
(b) Availability of Written Interpreta- records and properties of persons to the
tions. (1) A written regulatory interpre- extent such records and properties are
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374
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Pipeline and Hazardous Materials Safety Admin., DOT 190.207
propriate sources indicates that fur- amendment includes any new material
ther OPS action is warranted, the OPS allegations of fact or proposes an in-
may issue a warning letter under creased civil penalty amount or new or
190.205 or initiate one or more of the additional remedial action under
375
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190.209 49 CFR Ch. I (10111 Edition)
190.217, the respondent shall have the the second copy but must provide an
opportunity to respond under 190.209. explanation for each redaction.
[45 FR 20413, Mar. 27, 1980, as amended by [45 FR 20413, Mar. 27, 1980, as amended by
Amdt. 1906, 61 FR 18513, Apr. 26, 1996] Amdt. 1901, 53 FR 1635, Jan. 21, 1988; Amdt.
1906, 61 FR 18513, Apr. 26, 1996; Amdt. 1907,
190.209 Response options. 61 FR 27792, June 3, 1996; Amdt. 1907, 63 FR
7722, Feb. 17, 1998; 73 FR 16567, Mar. 28, 2008]
Within 30 days of receipt of a notice
of probable violation, the respondent 190.211 Hearing.
shall respond to the Regional Director (a) A request for a hearing provided
who issued the notice in the following for in this part must be accompanied
way: by a statement of the issues that the
(a) When the notice contains a pro- respondent intends to raise at the hear-
posed civil penalty ing. The issues may relate to the alle-
(1) Pay the proposed civil penalty as gations in the notice, the proposed cor-
provided in 190.227 and close the case rective action (including a proposed
with prejudice to the respondent; amendment, a proposed compliance
(2) Submit written explanations, in- order, or a proposed hazardous facility
formation or other materials in answer order), or the proposed civil penalty
to the allegations or in mitigation of amount. A respondents failure to
the proposed civil penalty; or specify an issue may result in waiver of
(3) Request a hearing under 190.211. the respondents right to raise that
issue at the hearing. The respondents
(b) When the notice contains a pro-
request must also indicate whether or
posed compliance order
not the respondent will be represented
(1) Agree to the proposed compliance by counsel at the hearing.
order; (b) A telephone hearing will be held if
(2) Request the execution of a con- the amount of the proposed civil pen-
sent order under 190.219; alty or the cost of the proposed correc-
(3) Object to the proposed compliance tive action is less than $10,000, unless
order and submit written explanations, the respondent submits a written re-
information or other materials in an- quest for an in-person hearing. Hear-
swer to the allegations in the notice of ings are held in a location agreed upon
probable violation; or by the presiding official, OPS and the
(4) Request a hearing under 190.211. respondent.
(c) Failure of the respondent to re- (c) An attorney from the Office of the
spond in accordance with paragraph (a) Chief Counsel, Pipeline and Hazardous
of this section or, when applicable, Materials Safety Administration,
paragraph (c) of this section, con- serves as the presiding official at the
stitutes a waiver of the right to con- hearing.
test the allegations in the notice of (d) The hearing is conducted infor-
probable violation and authorizes the mally without strict adherence to rules
of evidence. The respondent may sub-
Associate Administrator, OPS, without
mit any relevant information and ma-
further notice to the respondent, to
terial and call witnesses on the re-
find facts to be as alleged in the notice
spondents behalf. The respondent may
of probable violation and to issue a
also examine the evidence and wit-
final order under 190.213. nesses presented by the government.
(d) All materials submitted by opera- No detailed record of a hearing is pre-
tors in response to enforcement actions pared.
may be placed on publicly accessible (e) Upon request by respondent, and
Web sites. A Respondent that seeks whenever practicable, the material in
confidential treatment under 5 U.S.C. the case file pertinent to the issues to
552(b) for any portion of its responsive be determined is provided to the re-
materials must provide a second copy spondent 30 days before the hearing.
wreier-aviles on DSK3TPTVN1PROD with CFR
of such materials along with the com- The respondent may respond to or
plete original document. A Respondent rebut this material at the hearing.
may redact the portions it believes (f) During the hearing, the respond-
qualify for confidential treatment in ent may offer any facts, statements,
376
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Pipeline and Hazardous Materials Safety Admin., DOT 190.215
(3) Material submitted by the re- no later than 20 days after service of
spondent in accord with 190.209 in re- the final order upon the respondent.
sponse to the notice of probable viola- Petitions received after that time will
tion; not be considered. The petition must
377
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190.217 49 CFR Ch. I (10111 Edition)
contain a brief statement of the com- lations and to issue an order directing
plaint and an explanation as to why compliance.
the effectiveness of the final order
[Amdt. 1906, 61 FR 18514, Apr. 26, 1996]
should be stayed.
(b) If the respondent requests the 190.219 Consent order.
consideration of additional facts or ar-
(a) At any time before the issuance of
guments, the respondent must submit
a compliance order under 190.213 the
the reasons they were not presented
Associate Administrator, OPS and the
prior to issuance of the final order.
respondent may agree to dispose of the
(c) The Associate Administrator, case by joint execution of a consent
OPS does not consider repetitious in- order. Upon such joint execution, the
formation, arguments, or petitions. consent order shall be considered a
(d) The filing of a petition under this final order under 190.213.
section stays the payment of any civil (b) A consent order executed under
penalty assessed. However, unless the paragraph (a) of this section shall in-
Associate Administrator, OPS other- clude:
wise provides, the order, including any (1) An admission by the respondent of
required corrective action, is not all jurisdictional facts;
stayed.
(2) An express waiver of further pro-
(e) The Associate Administrator, cedural steps and of all right to seek
OPS may grant or deny, in whole or in judicial review or otherwise challenge
part, any petition for reconsideration or contest the validity of that order;
without further proceedings. In the (3) An acknowledgement that the no-
event the Associate Administrator, tice of probable violation may be used
OPS reconsiders a final order, a final to construe the terms of the consent
decision on reconsideration may be order; and
issued without further proceedings, or,
(4) A statement of the actions re-
in the alternative, additional informa-
quired of the respondent and the time
tion, data, and comment may be re-
by which such actions shall be accom-
quested by the Associate Adminis-
plished.
trator, OPS as deemed appropriate.
(f) It is the policy of the Associate [45 FR 20413, Mar. 27, 1980, as amended by
Administrator, OPS to issue notice of Amdt. 1906, 61 FR 18514, Apr. 26, 1996]
the action taken on a petition for re-
consideration expeditiously. In cases CIVIL PENALTIES
where a substantial delay is expected, 190.221 Civil penalties generally.
notice of that fact and the date by
which it is expected that action will be When the Associate Administrator,
taken is provided to the respondent OPS has reason to believe that a per-
upon request and whenever practicable. son has committed an act which is a
violation of any provision of the 49
[Amdt. 1906, 61 FR 18514, Apr. 26, 1996, as U.S.C. 60101 et seq. or any regulation or
amended by Amdt 1907, 61 FR 27792, June 3, order issued thereunder, proceedings
1996; 70 FR 11137, Mar. 8, 2005]
under 190.207 through 190.213 may be
COMPLIANCE ORDERS conducted to determine the nature and
extent of the violations and to assess
190.217 Compliance orders generally. and, if appropriate, compromise a civil
penalty.
When the Associate Administrator,
OPS has reason to believe that a per- [Amdt. 1906, 61 FR 18515, Apr. 26, 1996]
son is engaging in conduct which in-
volves a violation of the 49 U.S.C. 60101 190.223 Maximum penalties.
et seq. or any regulation issued there- (a) Any person who is determined to
under, and if the nature of the viola- have violated a provision of 49 U.S.C.
tion, and the public interest warrant, 60101 et seq., or any regulation or order
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378
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Pipeline and Hazardous Materials Safety Admin., DOT 190.229
civil penalty may not exceed $1,000,000 (1) The economic benefit gained from
for any related series of violations. violation, if readily ascertainable,
(b) Any person who knowingly vio- without any reduction because of sub-
lates a regulation or order under this sequent damages; and
subchapter applicable to offshore gas (2) Such other matters as justice may
gathering lines issued under the au- require.
thority of 49 U.S.C. 5101 et seq is liable [70 FR 11137, Mar. 8, 2005]
for a civil penalty of not more than
$25,000 for each violation, and if any 190.227 Payment of penalty.
such violation is a continuing one, (a) Except for payments exceeding
each day of violation constitutes a sep- $10,000, payment of a civil penalty pro-
arate offense. posed or assessed under this subpart
(c) Any person who is determined to may be made by certified check or
have violated any standard or order money order (containing the CPF Num-
under 49 U.S.C. 60103 shall be subjected ber for the case), payable to U.S. De-
to a civil penalty of not to exceed partment of Transportation, to the
$50,000, which penalty shall be in addi- Federal Aviation Administration, Mike
tion to any other penalties to which Monroney Aeronautical Center, Finan-
such person may be subject under para- cial Operations Division (AMZ341),
graph (a) of this section. P.O. Box 25770, Oklahoma City, OK
(d) Any person who is determined to 73125, or by wire transfer through the
have violated any standard or order Federal Reserve Communications Sys-
under 49 U.S.C. 60129 shall be subject to tem (Fedwire) to the account of the
a civil penalty not to exceed $1,000, U.S. Treasury. Payments exceeding
which shall be in addition to any other $10,000 must be made by wire transfer.
penalties to which such person may be (b) Payment of a civil penalty as-
subject under paragraph (a) of this sec- sessed in a final order issued under
tion. 190.213 or affirmed in a decision on a
(e) No person shall be subject to a petition for reconsideration must be
civil penalty under this section for the made within 20 days after receipt of the
violation of any requirement of this final order or decision. Failure to do so
subchapter and an order issued under will result in the initiation of collec-
190.217, 190.219 or 190.233 if both vio- tion action, including the accrual of in-
lations are based on the same act. terest and penalties, in accordance
with 31 U.S.C. 3717 and 49 CFR part 89.
[45 FR 20413, Mar. 27, 1980, as amended by
Amdt. 1902, 54 FR 32344, Aug. 7, 1989; Amdt. [Amdt. 1907, 61 FR 27792, June 3, 1996, as
1906, 61 FR 18515, Apr. 26, 1996; 61 FR 38403, amended at 70 FR 11138, Mar. 8, 2005; 73 FR
July 24, 1996; 70 FR 11137, Mar. 8, 2005] 16567, Mar. 28, 2008]
(6) The effect on the respondents conviction be subject for each offense
ability to continue in business; and to a fine of not more than $25,000, im-
(b) The Associate Administrator, prisonment for a term not to exceed 5
OPS may consider: years, or both.
379
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190.231 49 CFR Ch. I (10111 Edition)
(c) Any person who willfully and 190.229 if both violations are based on
knowingly injures or destroys, or at- the same act.
tempts to injure or destroy, any inter- [45 FR 20413, Mar. 27, 1980, as amended by
state transmission facility, any inter- Amdt. 1902, 54 FR 32344, Aug. 7, 1989; Amdt.
state pipeline facility, or any intra- 1904, 56 FR 63770, Dec. 5, 1991; Amdt. 1906, 61
state pipeline facility used in inter- FR 18515, Apr. 26, 1996; 70 FR 11138, Mar. 8,
state or foreign commerce or in any ac- 2005]
tivity affecting interstate or foreign 190.231 Referral for prosecution.
commerce (as those terms are defined
in 49 U.S.C. 60101 et seq.) shall, upon If an employee of the Pipeline and
Hazardous Materials Safety Adminis-
conviction, be subject for each offense
tration becomes aware of any actual or
to a fine of not more than $25,000, im-
possible activity subject to criminal
prisonment for a term not to exceed 15 penalties under 190.229, the employee
years, or both. reports it to the Office of the Chief
(d) Any person who willfully and Counsel, Pipeline and Hazardous Mate-
knowingly defaces, damages, removes, rials Safety Administration, U.S. De-
destroys any pipeline sign, right-of- partment of Transportation, Wash-
way marker, or marine buoy required ington, DC 20590. The Chief Counsel re-
by 49 U.S.C. 60101 et seq. or 49 U.S.C. fers the report to OPS for investiga-
5101 et seq., or any regulation or order tion. Upon completion of the investiga-
issued thereunder shall, upon convic- tion and if appropriate, the Chief Coun-
tion, be subject for each offense to a sel refers the report to the Department
fine of not more than $5,000, imprison- of Justice for criminal prosecution of
ment for a term not to exceed 1 year, the offender.
or both. [Amdt. 1906, 61 FR 18515, Apr. 26, 1996, as
(e) Any person who willfully and amended at 70 FR 11137, Mar. 8, 2005]
knowingly engages in excavation activ-
ity without first using an available SPECIFIC RELIEF
one-call notification system to estab- 190.233 Corrective action orders.
lish the location of underground facili-
ties in the excavation area; or without (a) Except as provided by paragraph
(b) of this section, if the Associate Ad-
considering location information or
ministrator, OPS finds, after reason-
markings established by a pipeline fa-
able notice and opportunity for hearing
cility operator; and
in accord with paragraph (c) of this
(1) Subsequently damages a pipeline section and 190.211(a), a particular
facility resulting in death, serious bod- pipeline facility to be hazardous to life,
ily harm, or property damage exceed- property, or the environment, the As-
ing $50,000; sociate Administrator, OPS shall issue
(2) Subsequently damages a pipeline an order pursuant to this section re-
facility and knows or has reason to quiring the owner or operator of the fa-
know of the damage but fails to cility to take corrective action. Cor-
promptly report the damage to the op- rective action may include suspended
erator and to the appropriate authori- or restricted use of the facility, phys-
ties; or ical inspection, testing, repair, replace-
(3) Subsequently damages a haz- ment, or other appropriate action.
ardous liquid pipeline facility that re- (b) The Associate Administrator,
sults in the release of more than 50 bar- OPS may waive the requirement for
rels of product; shall, upon conviction, notice and opportunity for hearing
be subject for each offense to a fine of under paragraph (a) of this section be-
not more than $5,000, imprisonment for fore issuing an order pursuant to this
section when the Associate Adminis-
a term not to exceed 5 years, or both.
trator, OPS determines that the failure
(f) No person shall be subject to
to do so would result in the likelihood
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criminal penalties under paragraph (a) of serious harm to life, property, or the
of this section for violation of any reg- environment. However, the Associate
ulation and the violation of any order Administrator, OPS shall provide an
issued under 190.217, 190.219 or opportunity for a hearing as soon as is
380
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Pipeline and Hazardous Materials Safety Admin., DOT 190.233
381
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190.235 49 CFR Ch. I (10111 Edition)
the sequence in which such materials enforce orders issued under this section
are transported, and the pressure re- by appropriate means.
quired for such transportation; [70 FR 11138, Mar. 8, 2005]
(3) The characteristics of the geo-
graphical areas in which the pipeline 190.235 Civil actions generally.
facility is located, in particular the cli-
Whenever it appears to the Associate
matic and geologic conditions (includ-
Administrator, OPS that a person has
ing soil characteristics) associated
engaged, is engaged, or is about to en-
with such areas, and the population
gage in any act or practice consti-
density and population and growth pat-
tuting a violation of any provision of 49
terns of such areas;
U.S.C. 60101 et seq., or any regulations
(4) Any recommendation of the Na-
issued thereunder, the Administrator,
tional Transportation Safety Board
PHMSA, or the person to whom the au-
issued in connection with any inves-
thority has been delegated, may re-
tigation conducted by the Board; and
quest the Attorney General to bring an
(5) Such other factors as the Asso-
action in the appropriate U.S. District
ciate Administrator, OPS may consider
Court for such relief as is necessary or
appropriate.
appropriate, including mandatory or
(f) A corrective action order shall
prohibitive injunctive relief, interim
contain the following information:
equitable relief, civil penalties, and pu-
(1) A finding that the pipeline facility
nitive damages as provided under 49
is hazardous to life, property, or the
U.S.C. 60120 and 49 U.S.C. 5123.
environment.
(2) The relevant facts which form the [70 FR 11139, Mar. 8, 2005]
basis of that finding.
(3) The legal basis for the order. 190.237 Amendment of plans or pro-
(4) The nature and description of any cedures.
particular corrective action required of (a) A Regional Director begins a pro-
the respondent. ceeding to determine whether an opera-
(5) The date by which the required tors plans or procedures required
corrective action must be taken or under parts 192, 193, 195, and 199 of this
completed and, where appropriate, the subchapter are inadequate to assure
duration of the order. safe operation of a pipeline facility by
(6) If the opportunity for a hearing issuing a notice of amendment. The no-
was waived pursuant to paragraph (b) tice shall provide an opportunity for a
of this section, a statement that an op- hearing under 190.211 of this part and
portunity for a hearing will be avail- shall specify the alleged inadequacies
able at a particular time and location and the proposed action for revision of
after issuance of the order. the plans or procedures. The notice
(g) The Associate Administrator, shall allow the operator 30 days after
OPS shall rescind or suspend a correc- receipt of the notice to submit written
tive action order whenever the Asso- comments or request a hearing. After
ciate Administrator, OPS determines considering all material presented in
that the facility is no longer hazardous writing or at the hearing, the Asso-
to life, property, or the environment. ciate Administrator, OPS shall deter-
When appropriate, however, such a re- mine whether the plans or procedures
scission or suspension may be accom- are inadequate as alleged and order the
panied by a notice of probable viola- required amendment if they are inad-
tion issued under 190.207. equate, or withdraw the notice if they
(h) At any time after a corrective ac- are not. In determining the adequacy
tion order issued under this section has of an operators plans or procedures,
become effective, the Associate Admin- the Associate Administrator, OPS shall
istrator, OPS may request the Attor- consider:
ney General to bring an action for ap- (1) Relevant available pipeline safety
propriate relief in accordance with data;
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382
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Pipeline and Hazardous Materials Safety Admin., DOT 190.239
the PHMSA official who issued the no- ceipt of the notice or within 10 days
tice. following the conclusion of informal
(2) Informal consultation. Upon timely consultation that did not result in a
request by the operator, PHMSA will consent agreement, as applicable. In
383
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190.239 49 CFR Ch. I (10111 Edition)
384
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Pipeline and Hazardous Materials Safety Admin., DOT 190.307
385
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190.309 49 CFR Ch. I (10111 Edition)
Regulations of the Office of the Sec- (1) A statement of the time, place,
retary of Transportation (part 7 of this and nature of the proposed rulemaking
title). proceeding;
(2) A reference to the authority under
[Amdt. 1908, 61 FR 50909, Sept. 27, 1996, as
which it is issued;
amended at 70 FR 11137, Mar. 8, 2005]
(3) A description of the subjects and
190.309 Where to file petitions. issues involved or the substance and
terms of the proposed regulation;
Petitions for extension of time to (4) A statement of the time within
comment submitted under 190.319, pe- which written comments must be sub-
titions for hearings submitted under mitted; and
190.327, petitions for rulemaking sub- (5) A statement of how and to what
mitted under 190.331, and petitions for extent interested persons may partici-
reconsideration submitted under pate in the proceeding.
190.335 must be submitted to: Admin-
istrator, Pipeline and Hazardous Mate- 190.317 Participation by interested
rials Safety Administration, U.S. De- persons.
partment of Transportation, 1200 New (a) Any interested person may par-
Jersey Avenue, SE, Washington, D.C. ticipate in rulemaking proceedings by
205900001. submitting comments in writing con-
taining information, views or argu-
[Amdt. 1908, 61 FR 50909, Sept. 27, 1996, as ments in accordance with instructions
amended at 70 FR 11137, Mar. 8, 2005; 73 FR for participation in the rulemaking
16566, Mar. 28, 2008]
document.
190.311 General. (b) The Administrator may invite
any interested person to participate in
Unless the Administrator, for good the rulemaking proceedings described
cause, finds that notice is impracti- in 190.325.
cable, unnecessary, or contrary to the (c) For the purposes of this subpart,
public interest, and incorporates that an interested person includes any Fed-
finding and a brief statement of the eral or State government agency or
reasons for it in the rule, a notice of any political subdivision of a State.
proposed rulemaking is issued and in-
terested persons are invited to partici- 190.319 Petitions for extension of
pate in the rulemaking proceedings time to comment.
with respect to each substantive rule. A petition for extension of the time
to submit comments must be received
190.313 Initiation of rulemaking. not later than 10 days before expiration
The Administrator initiates rule- of the time stated in the notice. It is
making on his or her own motion; how- requested, but not required, that three
ever, in so doing, the Administrator copies be submitted. The filing of the
petition does not automatically extend
may use discretion to consider the rec-
the time for petitioners comments. A
ommendations of other agencies of the
petition is granted only if the peti-
United States or of other interested
tioner shows good cause for the exten-
persons including those of any tech-
sion, and if the extension is consistent
nical advisory body established by
with the public interest. If an exten-
statute for that purpose. sion is granted, it is granted to all per-
190.315 Contents of notices of pro- sons, and it is published in the FED-
posed rulemaking. ERAL REGISTER.
386
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Pipeline and Hazardous Materials Safety Admin., DOT 190.331
387
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190.333 49 CFR Ch. I (10111 Edition)
(2) The direct effects (including pre- petitions filed under 190.331. The peti-
emption effects) of the proposed action tion must contain a brief statement of
on States, on the relationship between the complaint and an explanation as to
the Federal Government and the why compliance with the rule is not
States, and on the distribution of practicable, is unreasonable, or is not
power and responsibilities among the in the public interest.
various levels of government; (b) If the petitioner requests the con-
(3) The regulatory burden on small sideration of additional facts, the peti-
businesses, small organizations and tioner must state the reason they were
small governmental jurisdictions; not presented to the Associate Admin-
(4) The recordkeeping and reporting istrator or the Chief Counsel within
requirements and to whom they would the prescribed time.
apply; and (c) The Associate Administrator or
(5) Impacts on the quality of the nat- the Chief Counsel does not consider
ural and social environments. repetitious petitions.
(d) The Associate Administrator or
(d) Unless the Associate Adminis-
Chief Counsel may return a petition
trator or the Chief Counsel otherwise
that does not comply with the require-
provides, the filing of a petition under
ments of this section, accompanied by
this section does not stay the effective-
a written statement indicating the de-
ness of the rule.
ficiencies in the petition.
190.333 Processing of petition. 190.337 Proceedings on petitions for
reconsideration.
(a) General. Unless the Associate Ad-
ministrator or the Chief Counsel other- (a) The Associate Administrator or
wise specifies, no public hearing, argu- the Chief Counsel may grant or deny,
ment, or other proceeding is held di- in whole or in part, any petition for re-
rectly on a petition before its disposi- consideration without further pro-
tion under this section. ceedings, except where a grant of the
(b) Grants. If the Associate Adminis- petition would result in issuance of a
trator or the Chief Counsel determines new final rule. In the event that the
that the petition contains adequate Associate Administrator or the Chief
justification, he or she initiates rule- Counsel determines to reconsider any
making action under this subpart. regulation, a final decision on recon-
(c) Denials. If the Associate Adminis- sideration may be issued without fur-
trator or the Chief Counsel determines ther proceedings, or an opportunity to
that the petition does not justify rule- submit comment or information and
making, the petition is denied. data as deemed appropriate, may be
(d) Notification. The Associate Admin- provided. Whenever the Associate Ad-
istrator or the Chief Counsel will no- ministrator or the Chief Counsel deter-
tify a petitioner, in writing, of the de- mines that a petition should be granted
cision to grant or deny a petition for or denied, the Office of the Chief Coun-
rulemaking. sel prepares a notice of the grant or de-
nial of a petition for reconsideration,
190.335 Petitions for reconsideration. for issuance to the petitioner, and the
(a) Except as provided in 190.339(d), Associate Administrator or the Chief
any interested person may petition the Counsel issues it to the petitioner. The
Associate Administrator for reconsid- Associate Administrator or the Chief
eration of any regulation issued under Counsel may consolidate petitions re-
this subpart, or may petition the Chief lating to the same rules.
Counsel for reconsideration of any pro- (b) It is the policy of the Associate
cedural regulation issued under this Administrator or the Chief Counsel to
subpart and contained in this subpart. issue notice of the action taken on a
It is requested, but not required, that petition for reconsideration within 90
three copies be submitted. The petition days after the date on which the regu-
wreier-aviles on DSK3TPTVN1PROD with CFR
must be received not later than 30 days lation in question is published in the
after publication of the rule in the FEDERAL REGISTER, unless it is found
FEDERAL REGISTER. Petitions filed impracticable to take action within
after that time will be considered as that time. In cases where it is so found
388
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Pipeline and Hazardous Materials Safety Admin., DOT 190.341
and the delay beyond that period is ex- rect final rule will either become effec-
pected to be substantial, notice of that tive on the date stated in the direct
fact and the date by which it is ex- final rule or at least 30 days after the
pected that action will be taken is publication date of the confirmation
issued to the petitioner and published document, whichever is later.
in the FEDERAL REGISTER. (c) For purposes of this section, an
adverse comment is one which explains
190.338 Appeals. why the rule would be inappropriate,
(a) Any interested person may appeal including a challenge to the rules un-
a denial of the Associate Administrator derlying premise or approach, or would
or the Chief Counsel, issued under be ineffective or unacceptable without
190.333 or 190.337, to the Adminis- a change. Comments that are frivolous
trator. or insubstantial will not be considered
(b) An appeal must be received within adverse under this procedure. A com-
20 days of service of written notice to ment recommending a rule change in
petitioner of the Associate Administra- addition to the rule will not be consid-
tors or the Chief Counsels decision, or ered an adverse comment, unless the
within 20 days from the date of publica- commenter states why the rule would
tion of the decision in the FEDERAL be ineffective without the additional
REGISTER, and should set forth the con- change.
tested aspects of the decision as well as (d) Only parties who filed comments
any new arguments or information. to a direct final rule issued under this
(c) It is requested, but not required, section may petition under 190.335 for
that three copies of the appeal be sub- reconsideration of that direct final
mitted to the Administrator. rule.
(d) Unless the Administrator other-
(e) If an adverse comment or notice
wise provides, the filing of an appeal
of intent to file an adverse comment is
under this section does not stay the ef-
received, a timely document will be
fectiveness of any rule.
published in the FEDERAL REGISTER ad-
190.339 Direct final rulemaking. vising the public and withdrawing the
direct final rule in whole or in part.
(a) Where practicable, the Adminis-
The Administrator may then incor-
trator will use direct final rulemaking
porate the adverse comment into a sub-
to issue the following types of rules:
sequent direct final rule or may pub-
(1) Minor, substantive changes to reg-
ulations; lish a notice of proposed rulemaking. A
(2) Incorporation by reference of the notice of proposed rulemaking will pro-
latest edition of technical or industry vide an opportunity for public com-
standards; ment, generally a minimum of 60 days,
(3) Extensions of compliance dates; and will be processed in accordance
and with 190.311190.329.
(4) Other noncontroversial rules
190.341 Special permits.
where the Administrator determines
that use of direct final rulemaking is (a) What is a special permit? A spe-
in the public interest, and that a regu- cial permit is an order by which
lation is unlikely to result in adverse PHMSA waives compliance with one or
comment. more of the Federal pipeline safety reg-
(b) The direct final rule will state an ulations under the standards set forth
effective date. The direct final rule will in 49 U.S.C. 60118(c) and subject to con-
also state that unless an adverse com- ditions set forth in the order. A special
ment or notice of intent to file an ad- permit is issued to a pipeline operator
verse comment is received within the (or prospective operator) for specified
specified comment period, generally 60 facilities that are or, absent waiver,
days after publication of the direct would be subject to the regulation.
final rule in the FEDERAL REGISTER, (b) How do I apply for a special per-
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the Administrator will issue a con- mit? Applications for special permits
firmation document, generally within must be submitted at least 120 days be-
15 days after the close of the comment fore the requested effective date using
period, advising the public that the di- any of the following methods:
389
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190.341 49 CFR Ch. I (10111 Edition)
(1) Direct fax to PHMSA at: 202366 quested special permit would not be in-
4566; or consistent with pipeline safety;
(2) Mail, express mail, or overnight (8) If the application is for a renewal
courier to the Associate Administrator of a previously granted waiver or spe-
for Pipeline Safety, Pipeline and Haz- cial permit, a copy of the original
ardous Materials Safety Administra- grant of the waiver or permit; and
tion, 1200 New Jersey Avenue, SE., East (9) Any other information PHMSA
Building, Washington, DC 20590. may need to process the application in-
(c) What information must be con- cluding environmental analysis where
tained in the application? Applications necessary.
must contain the following informa- (d) How does PHMSA handle special
tion: permit applications? (1) Public notice.
(1) The name, mailing address, and Upon receipt of an application for a
telephone number of the applicant and special permit, PHMSA will provide
whether the applicant is an operator; notice to the public of its intent to
(2) A detailed description of the pipe- consider the application and invite
line facilities for which the special per- comment. In addition, PHMSA may
mit is sought, including: consult with other Federal agencies be-
(i) The beginning and ending points fore granting or denying an application
of the pipeline mileage to be covered on matters that PHMSA believes may
and the Counties and States in which it have significance for proceedings under
is located; their areas of responsibility.
(ii) Whether the pipeline is interstate (2) Grants and denials. If the Asso-
or intrastate and a general description ciate Administrator determines that
of the right-of-way including proximity the application complies with the re-
of the affected segments to populated quirements of this section and that the
areas and unusually sensitive areas; waiver of the relevant regulation or
(iii) Relevant pipeline design and standard is not inconsistent with pipe-
construction information including the line safety, the Associate Adminis-
year of installation, the material, trator may grant the application, in
grade, diameter, wall thickness, and whole or in part, on a temporary or
coating type; and permanent basis. Conditions may be
(iv) Relevant operating information imposed on the grant if the Associate
including operating pressure, leak his- Administrator concludes they are nec-
tory, and most recent testing or assess- essary to assure safety, environmental
ment results; protection, or are otherwise in the pub-
(3) A list of the specific regulation(s) lic interest. If the Associate Adminis-
from which the applicant seeks relief; trator determines that the application
(4) An explanation of the unique cir- does not comply with the requirements
cumstances that the applicant believes of this section or that a waiver is not
make the applicability of that regula- justified, the application will be de-
tion or standard (or portion thereof) nied. Whenever the Associate Adminis-
unnecessary or inappropriate for its fa- trator grants or denies an application,
cility; notice of the decision will be provided
(5) A description of any measures or to the applicant. PHMSA will post all
activities the applicant proposes to un- special permits on its Web site at http://
dertake as an alternative to compli- www.phmsa.dot.gov/.
ance with the relevant regulation, in- (e) Can a special permit be requested
cluding an explanation of how such on an emergency basis? Yes. PHMSA
measures will mitigate any safety or may grant an application for an emer-
environmental risks; gency special permit without notice
(6) A description of any positive or and comment or hearing if the Asso-
negative impacts on affected stake- ciate Administrator determines that
holders and a statement indicating how such action is in the public interest, is
operating the pipeline pursuant to a not inconsistent with pipeline safety,
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391
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Pt. 191 49 CFR Ch. I (10111 Edition)
392
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Pipeline and Hazardous Materials Safety Admin., DOT 191.3
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191.5 49 CFR Ch. I (10111 Edition)
394
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Pipeline and Hazardous Materials Safety Admin., DOT 191.17
section, the operator shall make sup- shall submit separate reports for these
plementary reports as deemed nec- pipelines as required by 191.15 and
essary with a clear reference by date 191.17. Each operator, primarily en-
and subject to the original report. gaged in gas transmission or gathering,
(c) Master meter operators are not who also operates gas distribution
required to submit an incident report pipelines shall submit separate reports
as required by this section. for these pipelines as required by
[Amdt. 1915, 49 FR 18960, May 3, 1984, as 191.9 and 191.11.
amended at 75 FR 72905, Nov. 26, 2010] [Amdt. 1915, 49 FR 18961, May 3, 1984]
191.11 Distribution system: Annual 191.15 Transmission systems; gath-
report. ering systems; and liquefied natural
(a) General. Except as provided in gas facilities: Incident report.
paragraph (b) of this section, each op- (a) Transmission or Gathering. Each
erator of a distribution pipeline system operator of a transmission or a gath-
must submit an annual report for that ering pipeline system must submit
system on DOT Form PHMSA F 7100.1 DOT Form PHMSA F 7100.2 as soon as
1. This report must be submitted each practicable but not more than 30 days
year, not later than March 15, for the
after detection of an incident required
preceding calendar year.
to be reported under 191.5 of this part.
(b) Not required. The annual report re-
(b) LNG. Each operator of a liquefied
quirement in this section does not
apply to a master meter system or to a natural gas plant or facility must sub-
petroleum gas system that serves fewer mit DOT Form PHMSA F 7100.3 as soon
than 100 customers from a single as practicable but not more than 30
source. days after detection of an incident re-
quired to be reported under 191.5 of
[75 FR 72905, Nov. 26, 2010] this part.
(c) Supplemental report. Where addi-
191.12 Distribution Systems: Mechan-
ical Fitting Failure Reports tional related information is obtained
after a report is submitted under para-
Each mechanical fitting failure, as graph (a) or (b) of this section, the op-
required by 192.1009, must be sub- erator must make a supplemental re-
mitted on a Mechanical Fitting Failure port as soon as practicable with a clear
Report Form PHMSA F7100.12. An op- reference by date to the original re-
erator must submit a mechanical fit- port.
ting failure report for each mechanical
fitting failure that occurs within a cal- [75 FR 72905, Nov. 26, 2010]
endar year not later than March 15 of
the following year (for example, all me- 191.17 Transmission systems; gath-
chanical failure reports for calendar ering systems; and liquefied natural
gas facilities: Annual report.
year 2011 must be submitted no later
than March 15, 2012). Alternatively, an (a) Transmission or Gathering. Each
operator may elect to submit its re- operator of a transmission or a gath-
ports throughout the year. In addition, ering pipeline system must submit an
an operator must also report this infor- annual report for that system on DOT
mation to the State pipeline safety au- Form PHMSA 7100.2.1. This report
thority if a State has obtained regu- must be submitted each year, not later
latory authority over the operators than March 15, for the preceding cal-
pipeline. endar year, except that for the 2010 re-
[76 FR 5499, Feb. 1, 2011]
porting year the report must be sub-
mitted by June 15, 2011.
191.13 Distribution systems reporting (b) LNG. Each operator of a liquefied
transmission pipelines; trans- natural gas facility must submit an an-
mission or gathering systems re- nual report for that system on DOT
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191.21 49 CFR Ch. I (10111 Edition)
year the report must be submitted by agement and Budget (OMB) to the in-
June 15, 2011. formation collection requirements in
[75 FR 72905, Nov. 26, 2010] this part. The Paperwork Reduction
Act requires agencies to display a cur-
191.21 OMB control number assigned rent control number assigned by the
to information collection. Director of OMB for each agency infor-
This section displays the control mation collection requirement.
number assigned by the Office of Man-
OMB CONTROL NUMBER 21370522
Section of 49 CFR Part 191 where identified Form No.
396
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Pipeline and Hazardous Materials Safety Admin., DOT 191.25
397
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191.27 49 CFR Ch. I (10111 Edition)
steel pipe.
block number tract. 192.115 Temperature derating factor (T) for
(b) The report shall be mailed to the steel pipe.
Office of Pipeline Safety, Pipeline and 192.117 [Reserved]
Hazardous Materials Safety Adminis- 192.119 [Reserved]
398
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Pipeline and Hazardous Materials Safety Admin., DOT Pt. 192
192.121 Design of plastic pipe. 192.245 Repair or removal of defects.
192.123 Design limitations for plastic pipe.
192.125 Design of copper pipe. Subpart FJoining of Materials Other Than
by Welding
Subpart DDesign of Pipeline Components
192.271 Scope.
192.141 Scope. 192.273 General.
192.143 General requirements. 192.275 Cast iron pipe.
192.144 Qualifying metallic components. 192.277 Ductile iron pipe.
192.145 Valves. 192.279 Copper pipe.
192.147 Flanges and flange accessories. 192.281 Plastic pipe.
192.149 Standard fittings. 192.283 Plastic pipe: Qualifying joining pro-
192.150 Passage of internal inspection de- cedures.
vices. 192.285 Plastic pipe: Qualifying persons to
192.151 Tapping. make joints.
192.153 Components fabricated by welding. 192.287 Plastic pipe: Inspection of joints.
192.155 Welded branch connections.
192.157 Extruded outlets. Subpart GGeneral Construction Require-
192.159 Flexibility. ments for Transmission Lines and Mains
192.161 Supports and anchors.
192.163 Compressor stations: Design and 192.301 Scope.
construction. 192.303 Compliance with specifications or
192.165 Compressor stations: Liquid re- standards.
moval. 192.305 Inspection: General.
192.167 Compressor stations: Emergency 192.307 Inspection of materials.
shutdown. 192.309 Repair of steel pipe.
192.169 Compressor stations: Pressure lim- 192.311 Repair of plastic pipe.
iting devices. 192.313 Bends and elbows.
192.171 Compressor stations: Additional 192.315 Wrinkle bends in steel pipe.
safety equipment. 192.317 Protection from hazards.
192.173 Compressor stations: Ventilation. 192.319 Installation of pipe in a ditch.
192.175 Pipe-type and bottle-type holders. 192.321 Installation of plastic pipe.
192.177 Additional provisions for bottle-type 192.323 Casing.
holders. 192.325 Underground clearance.
192.179 Transmission line valves. 192.327 Cover.
192.181 Distribution line valves. 192.328 Additional construction require-
192.183 Vaults: Structural design require- ments for steel pipe using alternative
ments. maximum allowable operating pressure.
192.185 Vaults: Accessibility.
192.187 Vaults: Sealing, venting, and ven- Subpart HCustomer Meters, Service
tilation. Regulators, and Service Lines
192.189 Vaults: Drainage and waterproofing.
192.191 Design pressure of plastic fittings. 192.351 Scope.
192.193 Valve installation in plastic pipe. 192.353 Customer meters and regulators: Lo-
192.195 Protection against accidental over- cation.
pressuring. 192.355 Customer meters and regulators:
192.197 Control of the pressure of gas deliv- Protection from damage.
ered from high-pressure distribution sys- 192.357 Customer meters and regulators: In-
tems. stallation.
192.199 Requirements for design of pressure 192.359 Customer meter installations: Oper-
relief and limiting devices. ating pressure.
192.201 Required capacity of pressure reliev- 192.361 Service lines: Installation.
ing and limiting stations. 192.363 Service lines: Valve requirements.
192.203 Instrument, control, and sampling 192.365 Service lines: Location of valves.
pipe and components. 192.367 Service lines: General requirements
for connections to main piping.
Subpart EWelding of Steel in Pipelines 192.369 Service lines: Connections to cast
iron or ductile iron mains.
192.221 Scope. 192.371 Service lines: Steel.
192.225 Welding procedures. 192.373 Service lines: Cast iron and ductile
192.227 Qualification of welders. iron.
192.229 Limitations on welders. 192.375 Service lines: Plastic.
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Pipeline and Hazardous Materials Safety Admin., DOT Pt. 192
192.717 Transmission lines: Permanent field 192.919 What must be in the baseline assess-
repair of leaks. ment plan?
192.719 Transmission lines: Testing of re- 192.921 How is the baseline assessment to be
pairs. conducted?
192.721 Distribution systems: Patrolling. 192.923 How is direct assessment used and
192.723 Distribution systems: Leakage sur- for what threats?
veys. 192.925 What are the requirements for using
192.725 Test requirements for reinstating External Corrosion Direct Assessment
service lines. (ECDA)?
192.727 Abandonment or deactivation of fa- 192.927 What are the requirements for using
cilities. Internal Corrosion Direct Assessment
192.731 Compressor stations: Inspection and (ICDA)?
testing of relief devices. 192.929 What are the requirements for using
192.735 Compressor stations: Storage of Direct Assessment for Stress Corrosion
combustible materials. Cracking (SCCDA)?
192.736 Compressor stations: Gas detection. 192.931 How may Confirmatory Direct As-
192.739 Pressure limiting and regulating sessment (CDA) be used?
stations: Inspection and testing. 192.933 What actions must be taken to ad-
192.741 Pressure limiting and regulating dress integrity issues?
stations: Telemetering or recording 192.935 What additional preventive and
gauges. mitigative measures must an operator
192.743 Pressure limiting and regulating take?
stations: Capacity of relief devices. 192.937 What is a continual process of eval-
192.745 Valve maintenance: Transmission uation and assessment to maintain a
lines. pipelines integrity?
192.747 Valve maintenance: Distribution 192.939 What are the required reassessment
systems. intervals?
192.749 Vault maintenance. 192.941 What is a low stress reassessment?
192.751 Prevention of accidental ignition. 192.943 When can an operator deviate from
192.753 Caulked bell and spigot joints. these reassessment intervals?
192.755 Protecting cast-iron pipelines. 192.945 What methods must an operator use
to measure program effectiveness?
Subpart NQualification of Pipeline 192.947 What records must an operator
Personnel keep?
192.949 How does an operator notify
192.801 Scope. PHMSA?
192.803 Definitions. 192.951 Where does an operator file a report?
192.805 Qualification Program.
192.807 Recordkeeping. Subpart PGas Distribution Pipeline
192.809 General. Integrity Management (IM)
Subpart OGas Transmission Pipeline 192.1001 What definitions apply to this sub-
Integrity Management part?
192.1003 What do the regulations in this sub-
192.901 What do the regulations in this sub- part cover?
part cover? 192.1005 What must a gas distribution oper-
192.903 What definitions apply to this sub- ator (other than a master meter or small
part? LPG operator) do to implement this sub-
192.905 How does an operator identify a high part?
consequence area? 192.1007 What are the required elements of
192.907 What must an operator do to imple- an integrity management plan?
ment this subpart? 192.1009 What must an operator report when
192.909 How can an operator change its in- a mechanical fitting fails?
tegrity management program? 192.1011 What records must an operator
192.911 What are the elements of an integ- keep?
rity management program? 192.1013 When may an operator deviate from
192.913 When may an operator deviate its required periodic inspections of this
program from certain requirements of part?
this subpart? 192.1015 What must a master meter or small
192.915 What knowledge and training must liquefied petroleum gas (LPG) operator
personnel have to carry out an integrity do to implement this subpart?
management program?
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192.1 49 CFR Ch. I (10111 Edition)
APPENDIX D TO PART 192CRITERIA FOR CA- (i) Through a pipeline that operates
THODIC PROTECTION AND DETERMINATION at less than 0 psig (0 kPa);
OF MEASUREMENTS (ii) Through a pipeline that is not a
APPENDIX E TO PART 192GUIDANCE ON DE- regulated onshore gathering line (as
TERMINING HIGH CONSEQUENCE AREAS AND
determined in 192.8); and
ON CARRYING OUT REQUIREMENTS IN THE
INTEGRITY MANAGEMENT RULE (iii) Within inlets of the Gulf of Mex-
ico, except for the requirements in
AUTHORITY: 49 U.S.C. 5103, 60102, 60104, 192.612; or
60108, 60109, 60110, 60113, 60116, 60118, and 60137; (5) Any pipeline system that trans-
and 49 CFR 1.53. ports only petroleum gas or petroleum
SOURCE: 35 FR 13257, Aug. 19, 1970, unless gas/air mixtures to
otherwise noted. (i) Fewer than 10 customers, if no
EDITORIAL NOTE: Nomenclature changes to portion of the system is located in a
part 192 appear at 71 FR 33406, June 9, 2006. public place; or
(ii) A single customer, if the system
is located entirely on the customers
Subpart AGeneral premises (no matter if a portion of the
system is located in a public place).
192.1 What is the scope of this part?
[35 FR 13257, Aug. 19, 1970, as amended by
(a) This part prescribes minimum Amdt. 19227, 41 FR 34605, Aug. 16, 1976;
safety requirements for pipeline facili- Amdt. 19267, 56 FR 63771, Dec. 5, 1991; Amdt.
ties and the transportation of gas, in- 19278, 61 FR 28782, June 6, 1996; Amdt. 19281,
cluding pipeline facilities and the 62 FR 61695, Nov. 19, 1997; Amdt. 19292, 68 FR
transportation of gas within the limits 46112, Aug. 5, 2003; 70 FR 11139, Mar. 8, 2005;
of the outer continental shelf as that Amdt. 192102, 71 FR 13301, Mar. 15, 2006;
term is defined in the Outer Conti- Amdt. 192103, 72 FR 4656, Feb. 1, 2007]
nental Shelf Lands Act (43 U.S.C. 1331). 192.3 Definitions.
(b) This part does not apply to
(1) Offshore gathering of gas in State As used in this part:
waters upstream from the outlet flange Abandoned means permanently re-
moved from service.
of each facility where hydrocarbons are
Active corrosion means continuing
produced or where produced hydro-
corrosion that, unless controlled, could
carbons are first separated, dehy-
result in a condition that is detri-
drated, or otherwise processed, which-
mental to public safety.
ever facility is farther downstream;
Administrator means the Adminis-
(2) Pipelines on the Outer Conti- trator, Pipeline and Hazardous Mate-
nental Shelf (OCS) that are producer- rials Safety Administration or his or
operated and cross into State waters her delegate.
without first connecting to a trans- Alarm means an audible or visible
porting operators facility on the OCS, means of indicating to the controller
upstream (generally seaward) of the that equipment or processes are out-
last valve on the last production facil- side operator-defined, safety-related
ity on the OCS. Safety equipment pro- parameters.
tecting PHMSA-regulated pipeline seg- Control room means an operations
ments is not excluded. Producing oper- center staffed by personnel charged
ators for those pipeline segments up- with the responsibility for remotely
stream of the last valve of the last pro- monitoring and controlling a pipeline
duction facility on the OCS may peti- facility.
tion the Administrator, or designee, for Controller means a qualified indi-
approval to operate under PHMSA reg- vidual who remotely monitors and con-
ulations governing pipeline design, trols the safety-related operations of a
construction, operation, and mainte- pipeline facility via a SCADA system
nance under 49 CFR 190.9; from a control room, and who has oper-
(3) Pipelines on the Outer Conti- ational authority and accountability
nental Shelf upstream of the point at for the remote operational functions of
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Pipeline and Hazardous Materials Safety Admin., DOT 192.3
403
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192.5 49 CFR Ch. I (10111 Edition)
Pipeline environment includes soil re- customer that is not down-stream from
sistivity (high or low), soil moisture a distribution center; (2) operates at a
(wet or dry), soil contaminants that hoop stress of 20 percent or more of
may promote corrosive activity, and SMYS; or (3) transports gas within a
other known conditions that could af- storage field.
fect the probability of active corrosion. NOTE: A large volume customer may re-
Pipeline facility means new and exist- ceive similar volumes of gas as a distribu-
ing pipelines, rights-of-way, and any tion center, and includes factories, power
equipment, facility, or building used in plants, and institutional users of gas.
the transportation of gas or in the Transportation of gas means the gath-
treatment of gas during the course of ering, transmission, or distribution of
transportation. gas by pipeline or the storage of gas, in
Service line means a distribution line or affecting interstate or foreign com-
that transports gas from a common merce.
source of supply to an individual cus-
[Amdt. 19213, 38 FR 9084, Apr. 10, 1973, as
tomer, to two adjacent or adjoining amended by Amdt. 19227, 41 FR 34605, Aug.
residential or small commercial cus- 16, 1976; Amdt. 19258, 53 FR 1635, Jan. 21,
tomers, or to multiple residential or 1988; Amdt. 19267, 56 FR 63771, Dec. 5, 1991;
small commercial customers served Amdt. 19272, 59 FR 17281, Apr. 12, 1994; Amdt.
through a meter header or manifold. A 19278, 61 FR 28783, June 6, 1996; Amdt. 19281,
service line ends at the outlet of the 62 FR 61695, Nov. 19, 1997; Amdt. 19285, 63 FR
customer meter or at the connection to 37501, July 13, 1998; Amdt. 19289, 65 FR 54443,
a customers piping, whichever is fur- Sept. 8, 2000; 68 FR 11749, Mar. 12, 2003; Amdt.
19293, 68 FR 53900, Sept. 15, 2003; Amdt. 192
ther downstream, or at the connection 98, 69 FR 48406, Aug. 10, 2004; Amdt. 19294, 69
to customer piping if there is no meter. FR 54592, Sept. 9, 2004; 70 FR 3148, Jan. 21,
Service regulator means the device on 2005; 70 FR 11139, Mar. 8, 2005; Amdt. 192112,
a service line that controls the pres- 74 FR 63326, Dec. 3, 2009; Amdt. 192114, 75 FR
sure of gas delivered from a higher 48601, Aug. 11, 2010]
pressure to the pressure provided to
the customer. A service regulator may 192.5 Class locations.
serve one customer or multiple cus- (a) This section classifies pipeline lo-
tomers through a meter header or cations for purposes of this part. The
manifold. following criteria apply to classifica-
SMYS means specified minimum tions under this section.
yield strength is: (1) A class location unit is an on-
(1) For steel pipe manufactured in ac- shore area that extends 220 yards (200
cordance with a listed specification, meters) on either side of the centerline
the yield strength specified as a min- of any continuous 1- mile (1.6 kilo-
imum in that specification; or meters) length of pipeline.
(2) For steel pipe manufactured in ac- (2) Each separate dwelling unit in a
cordance with an unknown or unlisted multiple dwelling unit building is
specification, the yield strength deter- counted as a separate building intended
mined in accordance with 192.107(b). for human occupancy.
State means each of the several (b) Except as provided in paragraph
States, the District of Columbia, and (c) of this section, pipeline locations
the Commonwealth of Puerto Rico. are classified as follows:
Supervisory Control and Data Acquisi- (1) A Class 1 location is:
tion (SCADA) system means a computer- (i) An offshore area; or
based system or systems used by a con- (ii) Any class location unit that has
troller in a control room that collects 10 or fewer buildings intended for
and displays information about a pipe- human occupancy.
line facility and may have the ability (2) A Class 2 location is any class lo-
to send commands back to the pipeline cation unit that has more than 10 but
facility. fewer than 46 buildings intended for
Transmission line means a pipeline, human occupancy.
wreier-aviles on DSK3TPTVN1PROD with CFR
other than a gathering line, that: (1) (3) A Class 3 location is:
Transports gas from a gathering line or (i) Any class location unit that has 46
storage facility to a distribution cen- or more buildings intended for human
ter, storage facility, or large volume occupancy; or
404
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Pipeline and Hazardous Materials Safety Admin., DOT 192.7
(ii) An area where the pipeline lies tion, the incorporated materials are
within 100 yards (91 meters) of either a available from the respective organiza-
building or a small, well-defined out- tions listed in paragraph (c) (1) of this
side area (such as a playground, recre- section.
ation area, outdoor theater, or other (c) The full titles of documents incor-
place of public assembly) that is occu- porated by reference, in whole or in
pied by 20 or more persons on at least part, are provided herein. The numbers
5 days a week for 10 weeks in any 12- in parentheses indicate applicable edi-
month period. (The days and weeks tions. For each incorporated document,
need not be consecutive.) citations of all affected sections are
(4) A Class 4 location is any class lo- provided. Earlier editions of currently
cation unit where buildings with four listed documents or editions of docu-
or more stories above ground are prev- ments listed in previous editions of 49
alent. CFR part 192 may be used for materials
(c) The length of Class locations 2, 3, and components designed, manufac-
and 4 may be adjusted as follows: tured, or installed in accordance with
(1) A Class 4 location ends 220 yards these earlier documents at the time
(200 meters) from the nearest building they were listed. The user must refer
with four or more stories above ground. to the appropriate previous edition of
(2) When a cluster of buildings in- 49 CFR part 192 for a listing of the ear-
tended for human occupancy requires a lier listed editions or documents.
Class 2 or 3 location, the class location (1) Incorporated by reference (IBR).
ends 220 yards (200 meters) from the
nearest building in the cluster. List of Organizations and Addresses:
[Amdt. 19278, 61 FR 28783, June 6, 1996; 61 FR A. Pipeline Research Council Inter-
35139, July 5, 1996, as amended by Amdt. 192 national, Inc. (PRCI), c/o Technical
85, 63 FR 37502, July 13, 1998] Toolboxes, 3801 Kirby Drive, Suite 520,
Houston, TX 77098.
192.7 What documents are incor- B. American Petroleum Institute
porated by reference partly or
wholly in this part? (API), 1220 L Street, NW., Washington,
DC 20005.
(a) Any documents or portions there- C. American Society for Testing and
of incorporated by reference in this Materials (ASTM), 100 Barr Harbor
part are included in this part as though Drive, West Conshohocken, PA 19428.
set out in full. When only a portion of
D. ASME International (ASME),
a document is referenced, the remain-
Three Park Avenue, New York, NY
der is not incorporated in this part.
100165990.
(b) All incorporated materials are
available for inspection in the Office of E. Manufacturers Standardization
Pipeline Safety, Pipeline and Haz- Society of the Valve and Fittings In-
ardous Materials Safety Administra- dustry, Inc. (MSS), 127 Park Street,
tion, 1200 New Jersey Avenue, SE., NE., Vienna, VA 22180.
Washington, DC, 205900001, 202366 F. National Fire Protection Associa-
4595, or at the National Archives and tion (NFPA), 1 Batterymarch Park,
Records Administration (NARA). For P.O. Box 9101, Quincy, MA 022699101.
information on the availability of this G. Plastics Pipe Institute, Inc. (PPI),
material at NARA, call 2027416030 or 1825 Connecticut Avenue, NW., Suite
go to: http://www.archives.gov/ 680, Washington, DC 20009.
federallregister/ H. NACE International (NACE), 1440
codeloflfederallregulations/ South Creek Drive, Houston, TX 77084.
ibrllocations.html. These materials I. Gas Technology Institute (GTI),
have been approved for incorporation 1700 South Mount Prospect Road, Des
by reference by the Director of the Plaines, IL 60018.
Federal Register in accordance with 5 (2) Documents incorporated by ref-
U.S.C. 552(a) and 1 CFR part 51. In addi- erence.
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405
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192.7 49 CFR Ch. I (10111 Edition)
(1) AGA Pipeline Research Committee, Project PR3805, A Modi- 192.485(c);.192.933(a)(1); 192.933(d)(1)(i).
fied Criterion for Evaluating the Remaining Strength of Corroded
Pipe, (December 22, 1989). The RSTRENG program may be
used for calculating remaining strength.
B. American Petroleum Institute (API):
(1) ANSI/API Specification 5L/ISO 3183 Specification for Line Pipe 192.55(e); 192.112; 192.113; Item I, Appen-
(44th edition, 2007), includes errata (January 2009) and addendum dix B to Part 192.
(February 2009).
(2) API Recommended Practice 5L1 Recommended Practice for 192.65(a)(1).
Railroad Transportation of Line Pipe, (6th Edition, July 2002).
(3) API Recommended Practice 5LW, Transportation of Line Pipe 192.65(b).
on Barges and Marine Vessels (2nd edition, December 1996, ef-
fective March 1, 1997).
(4) ANSI/API Specification 6D, Specification for Pipeline Valves 192.145(a).
(23rd edition (April 2008, effective October 1, 2008) and errata 3
(includes 1 and 2, February 2009)).
(5) API Recommended Practice 80, Guidelines for the Definition of 192.8(a); 192.8(a)(1); 192.8(a)(2);
Onshore Gas Gathering Lines, (1st edition, April 2000). 192.8(a)(3); 192.8(a)(4).
(6) API Standard 1104, Welding of Pipelines and Related Facilities 192.225; 192.227(a); 192.229(c)(1);
(20th edition, October 2005, errata/addendum, (July 2007) and er- 192.241(c); Item II, Appendix B.
rata 2 (2008)).
(7) API Recommended Practice 1162, Public Awareness Programs 192.616(a); 192.616(b); 192.616(c).
for Pipeline Operators, (1st edition, December 2003).
(8) API Recommended Practice 1165 Recommended Practice 1165 192.631(c)(1).
Recommended Practice for Pipeline SCADA Displays, (API RP
1165) (First edition (January 2007)).
C. American Society for Testing and Materials (ASTM):
(1) ASTM A53/A53M07, Standard Specification for Pipe, Steel, 192.113; Item I, Appendix B to Part 192.
Black and Hot-Dipped, Zinc-Coated, Welded and Seamless (Sep-
tember 1, 2007).
(2) ASTM A106/A106M08, Standard Specification for Seamless 192.113; Item I, Appendix B to Part 192.
Carbon Steel Pipe for High-Temperature Service (July 15, 2008).
(3) ASTM A333/A333M05 (2005) Standard Specification for Seam- 192.113; Item I, Appendix B to Part 192.
less and Welded Steel Pipe for Low-Temperature Service.
(4) ASTM A372/A372M03 (reapproved 2008), Standard Specifica- 192.177(b)(1).
tion for Carbon and Alloy Steel Forgings for Thin-Walled Pressure
Vessels (March 1, 2008).
(5) ASTM A38196 (reapproved 2005), Standard Specification for 192.113; Item I, Appendix B to Part 192.
Metal-Arc Welded Steel Pipe for Use With High-Pressure Trans-
mission Systems (October 1, 2005).
(6) ASTM A578/A578M96 (re-approved 2001) Standard Specifica- 192.112(c)(2)(iii).
tion for Straight-Beam Ultrasonic Examination of Plain and Clad
Steel Plates for Special Applications..
(7) ASTM A67106, Standard Specification for Electric-Fusion- 192.113; Item I, Appendix B to Part 192.
Welded Steel Pipe for Atmospheric and Lower Temperatures
(May 1, 2006).
(8) ASTM A67208, Standard Specification for Electric-Fusion- 192.113; Item I, Appendix B to Part 192.
Welded Steel Pipe for High-Pressure Service at Moderate Tem-
peratures (May 1, 2008).
(9) ASTM A69198 (reapproved 2007), Standard Specification for 192.113; Item I, Appendix B to Part 192.
Carbon and Alloy Steel Pipe, Electric-Fusion-Welded for High-
Pressure Service at High Temperatures (November 1, 2007).
(10) ASTM D63803 Standard Test Method for Tensile Properties 192.283(a)(3); 192.283(b)(1).
of Plastics..
(11) ASTM D251387 Standard Specification for Thermoplastic Gas 192.63(a)(1).
Pressure Pipe, Tubing, and Fittings..
(12) ASTM D251399 Standard Specification for Thermoplastic Gas 192.123(e)(2); 192.191(b); 192.281(b)(2);
Pressure Pipe, Tubing, and Fittings.. 192.283(a)(1)(i); Item 1, Appendix B to Part
192.
(13) ASTM D251700 Standard Specification for Reinforced Epoxy 192.191(a); 192.281(d)(1); 192.283(a)(1)(ii);
Resin Gas Pressure Pipe and Fittings.. Item I, Appendix B to Part 192.
(14) ASTM F10551998, Standard Specification for Electrofusion 192.283(a)(1)(iii).
Type Polyethylene Fittings for Outside Diameter Controller Poly-
ethylene Pipe and Tubing..
D. ASME International (ASME):
(1) ASME/ANSI B16.12005, Gray Iron Pipe Flanges and Flanged 192.147(c).
Fittings: (Classes 25, 125, and 250) (August 31, 2006).
(2) ASME/ANSI B16.52003, Pipe Flanges and Flanged Fittings. 192.147(a); 192.279.
wreier-aviles on DSK3TPTVN1PROD with CFR
(October 2004).
(3) ASME/ANSI B31G1991 (Reaffirmed, 2004), Manual for Deter- 192.485(c); 192.933(a).
mining the Remaining Strength of Corroded Pipelines..
(4) ASME/ANSI B31.82007, Gas Transmission and Distribution 192.619(a)(1)(i).
Piping Systems (November 30, 2007).
406
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Pipeline and Hazardous Materials Safety Admin., DOT 192.8
(5) ASME/ANSI B31.8S2004, Supplement to B31.8 on Managing 192.903(c); 192.907(b); 192.911 Introductory
System Integrity of Gas Pipelines.. text; 192.911(i); 192.911(k); 192.911(l);
192.911(m); 192.913(a) Introductory text;
192.913(b)(1); 192.917(a) Introductory text;
192.917(b); 192.917(c); 192.917(e)(1);
192.917(e)(4); 192.921(a)(1); 192.923(b)(1);
192.923(b)(2); 192.923(b)(3); 192.925(b) In-
troductory text; 192.925(b)(1); 192.925(b)(2);
192.925(b)(3); 192.925(b)(4); 192.927(b);
192.927(c)(1)(i); 192.929(b)(1); 192.929(b)(2);
192.933(a); 192.933(d)(1); 192.933(d)(1)(i);
192.935(a); 192.935(b)(1)(iv); 192.937(c)(1);
192.939(a)(1)(i); 192.939(a)(1)(ii);
192.939(a)(3); 192.945(a).
(6) 2007 ASME Boiler & Pressure Vessel Code, Section I, Rules for 192.153(b).
Construction of Power Boilers 2007 (2007 edition, July 1, 2007).
(7) 2007 ASME Boiler & Pressure Vessel Code, Section VIII, Division 192.153(a); 192.153(b); 192.153(d);
1, Rules for Construction of Pressure Vessels 2 (2007 edition, 192.165(b)(3).
July 1, 2007).
(8) 2007 ASME Boiler & Pressure Vessel Code, Section VIII, Division 192.153(b); 192.165(b)(3).
2, Alternative Rules, Rules for Construction of Pressure Vessels
(2007 edition, July 1, 2007).
(9) 2007 ASME Boiler & Pressure Vessel Code, Section IX, Welding 192.227(a); Item II, Appendix B to Part 192.
and Brazing Procedures, Welders, Brazers, and Welding and Braz-
ing Operators (2007 edition, July 1, 2007).
E. Manufacturers Standardization Society of the Valve and Fittings Industry,
Inc. (MSS):
(1) MSS SP442006, Standard Practice, Steel Pipeline Flanges 192.147(a).
(2006 edition).
(2) [Reserved].
F. National Fire Protection Association (NFPA):
(1) NFPA 30 (2008 edition, August 15, 2007), Flammable and Com- 192.735(b).
bustible Liquids Code (2008 edition; approved August 15, 2007).
(2) NFPA 58 (2004), Liquefied Petroleum Gas Code (LP-Gas 192.11(a); 192.11(b); 192.11(c).
Code)..
(3) NFPA 59 (2004), Utility LP-Gas Plant Code. ............................... 192.11(a); 192.11(b); 192.11(c).
(4) NFPA 70 (2008), National Electrical Code (NEC 2008) (Ap- 192.163(e); 192.189(c).
proved August 15, 2007).
G. Plastics Pipe Institute, Inc. (PPI):
(1) PPI TR3/2008 HDB/HDS/PDB/SDB/MRS Policies (2008), Poli- 192.121.
cies and Procedures for Developing Hydrostatic Design Basis
(HDB), Pressure Design Basis (PDB), Strength Design Basis
(SDB), and Minimum Required Strength (MRS) Ratings for Ther-
moplastic Piping Materials or Pipe (May 2008).
H. NACE International (NACE):
(1) NACE Standard SP05022008, Standard Practice, Pipeline Ex- 192.923(b)(1); 192.925(b) Introductory text;
ternal Corrosion Direct Assessment Methodology (reaffirmed 192.925(b)(1); 192.925(b)(1)(ii); 192.925(b)(2)
March 20, 2008). Introductory text; 192.925(b)(3) Introductory
text; 192.925(b)(3)(ii); 192.925(b)(3)(iv);
192.925(b)(4) Introductory text;
192.925(b)(4)(ii); 192.931(d);
192.935(b)(1)(iv); 192.939(a)(2).
I. Gas Technology Institute (GTI):
(1) GRI 02/0057 (2002) Internal Corrosion Direct Assessment of 192.927(c)(2).
Gas Transmission Pipelines Methodology..
407
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192.9 49 CFR Ch. I (10111 Edition)
A ......... Metallic and the MAOP produces a Class 2, 3, or 4 location (see 192.5) None.
hoop stress of 20 percent or more
of SMYS. If the stress level is un-
known, an operator must determine
the stress level according to the
applicable provisions in subpart C
of this part.
Non-metallic and the MAOP is
more than 125 psig (862 kPa).
B ......... Metallic and the MAOP produces a Area 1. Class 3 or 4 location ............. If the gathering line is in Area 2(b) or
hoop stress of less than 20 percent Area 2. An area within a Class 2 lo- 2(c), the additional lengths of line
of SMYS. If the stress level is un- cation the operator determines by extend upstream and downstream
known, an operator must determine using any of the following three from the area to a point where the
the stress level according to the methods: line is at least 150 feet (45.7 m)
applicable provisions in subpart C (a) A Class 2 location. ........................ from the nearest dwelling in the
of this part. (b) An area extending 150 feet (45.7 area. However, if a cluster of dwell-
Non-metallic and the MAOP is 125 m) on each side of the centerline of ings in Area 2 (b) or 2(c) qualifies a
psig (862 kPa) or less. any continuous 1 mile (1.6 km) of line as Type B, the Type B classi-
pipeline and including more than 10 fication ends 150 feet (45.7 m)
but fewer than 46 dwellings. from the nearest dwelling in the
(c) An area extending 150 feet (45.7 cluster.
m) on each side of the centerline of
any continous 1000 feet (305 m) of
pipeline and including 5 or more
dwellings.
[Amdt. 192102, 71 FR 13302, Mar. 15, 2006] quirements in 192.150 and in subpart O
of this part.
192.9 What requirements apply to (c) Type A lines. An operator of a
gathering lines? Type A regulated onshore gathering
(a) Requirements. An operator of a line must comply with the require-
gathering line must follow the safety ments of this part applicable to trans-
requirements of this part as prescribed mission lines, except the requirements
by this section. in 192.150 and in subpart O of this
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Pipeline and Hazardous Materials Safety Admin., DOT 192.11
409
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192.13 49 CFR Ch. I (10111 Edition)
[35 FR 13257, Aug. 19, 1970, as amended by (2) Words importing the plural in-
Amdt. 19227, 41 FR 34605, Aug. 16, 1976; clude the singular; and
Amdt. 19230, 42 FR 60148, Nov. 25, 1977; (3) Words importing the masculine
Amdt. 192102, 71 FR 13303, Mar. 15, 2006] gender include the feminine.
410
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Pipeline and Hazardous Materials Safety Admin., DOT 192.55
411
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192.57 49 CFR Ch. I (10111 Edition)
(ii) If it was manufactured before No- (4) Its dimensions are still within the
vember 12, 1970, either section II or III tolerances of the specification to which
of appendix B to this part; it was manufactured; and
(3) It has been used in an existing (5) It is free of visible defects.
line of the same or higher pressure and (c) For the purpose of paragraphs
meets the requirements of paragraph (a)(1) and (b)(1) of this section, where
II-C of appendix B to this part; or pipe of a diameter included in a listed
(4) It is used in accordance with para- specification is impractical to use, pipe
graph (c) of this section. of a diameter between the sizes in-
(c) New or used steel pipe may be cluded in a listed specification may be
used at a pressure resulting in a hoop used if it:
stress of less than 6,000 p.s.i. (41 MPa) (1) Meets the strength and design cri-
where no close coiling or close bending teria required of pipe included in that
is to be done, if visual examination in- listed specification; and
dicates that the pipe is in good condi- (2) Is manufactured from plastic com-
tion and that it is free of split seams
pounds which meet the criteria for ma-
and other defects that would cause
terial required of pipe included in that
leakage. If it is to be welded, steel pipe
listed specification.
that has not been manufactured to a
listed specification must also pass the [35 FR 13257, Aug. 19, 1970, as amended by
weldability tests prescribed in para- Amdt. 19219, 40 FR 10472, Mar. 6, 1975; Amdt.
graph II-B of appendix B to this part. 19258, 53 FR 1635, Jan. 21, 1988]
(d) Steel pipe that has not been pre-
viously used may be used as replace- 192.61 [Reserved]
ment pipe in a segment of pipeline if it
192.63 Marking of materials.
has been manufactured prior to Novem-
ber 12, 1970, in accordance with the (a) Except as provided in paragraph
same specification as the pipe used in (d) of this section, each valve, fitting,
constructing that segment of pipeline. length of pipe, and other component
(e) New steel pipe that has been cold must be marked
expanded must comply with the man- (1) As prescribed in the specification
datory provisions of API Specification or standard to which it was manufac-
5L. tured, except that thermoplastic fit-
[35 FR 13257, Aug. 19, 1970, as amended by
tings must be marked in accordance
Amdt. 1911, 35 FR 17660, Nov. 17, 1970; Amdt. with ASTM D251387 (incorporated by
19212, 38 FR 4761, Feb. 22, 1973; Amdt. 19251, reference, see 192.7);
51 FR 15335, Apr. 23, 1986; 58 FR 14521, Mar. 18, (2) To indicate size, material, manu-
1993; Amdt. 19285, 63 FR 37502, July 13, 1998] facturer, pressure rating, and tempera-
ture rating, and as appropriate, type,
192.57 [Reserved]
grade, and model.
192.59 Plastic pipe. (b) Surfaces of pipe and components
that are subject to stress from internal
(a) New plastic pipe is qualified for pressure may not be field die stamped.
use under this part if:
(c) If any item is marked by die
(1) It is manufactured in accordance stamping, the die must have blunt or
with a listed specification; and
rounded edges that will minimize
(2) It is resistant to chemicals with stress concentrations.
which contact may be anticipated.
(d) Paragraph (a) of this section does
(b) Used plastic pipe is qualified for
not apply to items manufactured be-
use under this part if:
fore November 12, 1970, that meet all of
(1) It was manufactured in accord- the following:
ance with a listed specification;
(1) The item is identifiable as to type,
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Pipeline and Hazardous Materials Safety Admin., DOT 192.107
413
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192.109 49 CFR Ch. I (10111 Edition)
tion, the design factor to be used in the ating pressure (MAOP) calculated
design formula in 192.105 is deter- under 192.620, a segment must meet
mined in accordance with the following the following additional design require-
table: ments. Records for alternative MAOP
414
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Pipeline and Hazardous Materials Safety Admin., DOT 192.112
(a) General standards for the (1) The plate, skelp, or coil used for the pipe must be micro-alloyed, fine grain, fully killed, con-
steel pipe. tinuously cast steel with calcium treatment.
(2) The carbon equivalents of the steel used for pipe must not exceed 0.25 percent by weight,
as calculated by the Ito-Bessyo formula (Pcm formula) or 0.43 percent by weight, as cal-
culated by the International Institute of Welding (IIW) formula.
(3) The ratio of the specified outside diameter of the pipe to the specified wall thickness must
be less than 100. The wall thickness or other mitigative measures must prevent denting and
ovality anomalies during construction, strength testing and anticipated operational stresses.
(4) The pipe must be manufactured using API Specification 5L, product specification level 2
(incorporated by reference, see 192.7) for maximum operating pressures and minimum
and maximum operating temperatures and other requirements under this section.
(b) Fracture control ................... (1) The toughness properties for pipe must address the potential for initiation, propagation and
arrest of fractures in accordance with:
(i) API Specification 5L (incorporated by reference, see 192.7); or
(ii) American Society of Mechanical Engineers (ASME) B31.8 (incorporated by reference, see
192.7); and
(iii) Any correction factors needed to address pipe grades, pressures, temperatures, or gas
compositions not expressly addressed in API Specification 5L, product specification level 2
or ASME B31.8 (incorporated by reference, see 192.7).
(2) Fracture control must:
(i) Ensure resistance to fracture initiation while addressing the full range of operating tempera-
tures, pressures, gas compositions, pipe grade and operating stress levels, including max-
imum pressures and minimum temperatures for shut-in conditions, that the pipeline is ex-
pected to experience. If these parameters change during operation of the pipeline such that
they are outside the bounds of what was considered in the design evaluation, the evaluation
must be reviewed and updated to assure continued resistance to fracture initiation over the
operating life of the pipeline;
(ii) Address adjustments to toughness of pipe for each grade used and the decompression be-
havior of the gas at operating parameters;
(iii) Ensure at least 99 percent probability of fracture arrest within eight pipe lengths with a
probability of not less than 90 percent within five pipe lengths; and
(iv) Include fracture toughness testing that is equivalent to that described in supplementary re-
quirements SR5A, SR5B, and SR6 of API Specification 5L (incorporated by reference, see
192.7) and ensures ductile fracture and arrest with the following exceptions:
(A) The results of the Charpy impact test prescribed in SR5A must indicate at least 80 percent
minimum shear area for any single test on each heat of steel; and
(B) The results of the drop weight test prescribed in SR6 must indicate 80 percent average
shear area with a minimum single test result of 60 percent shear area for any steel test
samples. The test results must ensure a ductile fracture and arrest.
(3) If it is not physically possible to achieve the pipeline toughness properties of paragraphs
(b)(1) and (2) of this section, additional design features, such as mechanical or composite
crack arrestors and/or heavier walled pipe of proper design and spacing, must be used to
ensure fracture arrest as described in paragraph (b)(2)(iii) of this section.
(c) Plate/coil quality control ...... (1) There must be an internal quality management program at all mills involved in producing
steel, plate, coil, skelp, and/or rolling pipe to be operated at alternative MAOP. These pro-
grams must be structured to eliminate or detect defects and inclusions affecting pipe quality.
(2) A mill inspection program or internal quality management program must include (i) and ei-
ther (ii) or (iii):
(i) An ultrasonic test of the ends and at least 35 percent of the surface of the plate/coil or pipe
to identify imperfections that impair serviceability such as laminations, cracks, and inclu-
sions. At least 95 percent of the lengths of pipe manufactured must be tested. For all pipe-
lines designed after December 22, 2008, the test must be done in accordance with ASTM
A578/A578M Level B, or API 5L Paragraph 7.8.10 (incorporated by reference, see 192.7)
or equivalent method, and either
(ii) A macro etch test or other equivalent method to identify inclusions that may form centerline
segregation during the continuous casting process. Use of sulfur prints is not an equivalent
method. The test must be carried out on the first or second slab of each sequence graded
with an acceptance criteria of one or two on the Mannesmann scale or equivalent; or
(iii) A quality assurance monitoring program implemented by the operator that includes audits
of: (a) all steelmaking and casting facilities, (b) quality control plans and manufacturing pro-
cedure specifications, (c) equipment maintenance and records of conformance, (d) applica-
ble casting superheat and speeds, and (e) centerline segregation monitoring records to en-
sure mitigation of centerline segregation during the continuous casting process.
wreier-aviles on DSK3TPTVN1PROD with CFR
(d) Seam quality control ........... (1) There must be a quality assurance program for pipe seam welds to assure tensile strength
provided in API Specification 5L (incorporated by reference, see 192.7) for appropriate
grades.
(2) There must be a hardness test, using Vickers (Hv10) hardness test method or equivalent
test method, to assure a maximum hardness of 280 Vickers of the following:
415
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192.113 49 CFR Ch. I (10111 Edition)
To address this design issue: The pipeline segment must meet these additional requirements:
(i) A cross section of the weld seam of one pipe from each heat plus one pipe from each
welding line per day; and
(ii) For each sample cross section, a minimum of 13 readings (three for each heat affected
zone, three in the weld metal, and two in each section of pipe base metal).
(3) All of the seams must be ultrasonically tested after cold expansion and mill hydrostatic
testing.
(e) Mill hydrostatic test ............. (1) All pipe to be used in a new pipeline segment must be hydrostatically tested at the mill at a
test pressure corresponding to a hoop stress of 95 percent SMYS for 10 seconds. The test
pressure may include a combination of internal test pressure and the allowance for end
loading stresses imposed by the pipe mill hydrostatic testing equipment as allowed by API
Specification 5L, Appendix K (incorporated by reference, see 192.7).
(2) Pipe in operation prior to December 22, 2008, must have been hydrostatically tested at the
mill at a test pressure corresponding to a hoop stress of 90 percent SMYS for 10 seconds.
(f) Coating ................................. (1) The pipe must be protected against external corrosion by a non-shielding coating.
(2) Coating on pipe used for trenchless installation must be non-shielding and resist abrasions
and other damage possible during installation.
(3) A quality assurance inspection and testing program for the coating must cover the surface
quality of the bare pipe, surface cleanliness and chlorides, blast cleaning, application tem-
perature control, adhesion, cathodic disbondment, moisture permeation, bending, coating
thickness, holiday detection, and repair.
(g) Fittings and flanges ............. (1) There must be certification records of flanges, factory induction bends and factory weld
ells. Certification must address material properties such as chemistry, minimum yield
strength and minimum wall thickness to meet design conditions.
(2) If the carbon equivalents of flanges, bends and ells are greater than 0.42 percent by
weight, the qualified welding procedures must include a pre-heat procedure.
(3) Valves, flanges and fittings must be rated based upon the required specification rating
class for the alternative MAOP.
(h) Compressor stations ........... (1) A compressor station must be designed to limit the temperature of the nearest downstream
segment operating at alternative MAOP to a maximum of 120 degrees Fahrenheit (49 de-
grees Celsius) or the higher temperature allowed in paragraph (h)(2) of this section unless a
long-term coating integrity monitoring program is implemented in accordance with paragraph
(h)(3) of this section.
(2) If research, testing and field monitoring tests demonstrate that the coating type being used
will withstand a higher temperature in long-term operations, the compressor station may be
designed to limit downstream piping to that higher temperature. Test results and acceptance
criteria addressing coating adhesion, cathodic disbondment, and coating condition must be
provided to each PHMSA pipeline safety regional office where the pipeline is in service at
least 60 days prior to operating above 120 degrees Fahrenheit (49 degrees Celsius). An op-
erator must also notify a State pipeline safety authority when the pipeline is located in a
State where PHMSA has an interstate agent agreement, or an intrastate pipeline is regu-
lated by that State.
(3) Pipeline segments operating at alternative MAOP may operate at temperatures above 120
degrees Fahrenheit (49 degrees Celsius) if the operator implements a long-term coating in-
tegrity monitoring program. The monitoring program must include examinations using direct
current voltage gradient (DCVG), alternating current voltage gradient (ACVG), or an equiva-
lent method of monitoring coating integrity. An operator must specify the periodicity at which
these examinations occur and criteria for repairing identified indications. An operator must
submit its long-term coating integrity monitoring program to each PHMSA pipeline safety re-
gional office in which the pipeline is located for review before the pipeline segments may be
operated at temperatures in excess of 120 degrees Fahrenheit (49 degrees Celsius). An op-
erator must also notify a State pipeline safety authority when the pipeline is located in a
State where PHMSA has an interstate agent agreement, or an intrastate pipeline is regu-
lated by that State.
[73 FR 62175, Oct. 17, 2008, as amended by Amdt. 192111, 74 FR 62505, Nov. 30, 2009]
416
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Pipeline and Hazardous Materials Safety Admin., DOT 192.121
Longitudinal joint
Specification Pipe class factor (E)
t
P = 2S (DF)
(D t)
2S
P= (DF)
(SDR 1)
mining a design pressure rating at the speci- responding to a value from a common num-
fied temperature by arithmetic interpolation bering system that was derived from the
using the procedure in Part D.2 of PPI TR3/ American National Standards Institute pre-
2008, HDB/PDB/SDB/MRS Policies (incor- ferred number series 10.
417
ER30NO09.008</MATH>
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192.123 49 CFR Ch. I (10111 Edition)
D F = 0.32 or D251399 (incorporated by reference, see
= 0.40 for PA11 pipe produced after January 192.7);
23, 2009 with a nominal pipe size (IPS or CTS)
4-inch or less, and a SDR of 11 or greater (i.e. (3) The pipe size is nominal pipe size
thicker pipe wall). (IPS) 12 or less; and
[Amdt. 192111, 74 FR 62505, Nov. 30, 2009, as
(4) The design pressure is determined
amended by Amdt. 192114, 75 FR 48603, Aug. in accordance with the design equation
11, 2010] defined in 192.121.
(f) The design pressure for poly-
192.123 Design limitations for plastic amide-11 (PA11) pipe produced after
pipe. January 23, 2009 may exceed a gauge
(a) Except as provided in paragraph pressure of 100 psig (689 kPa) provided
(e) and paragraph (f) of this section, that:
the design pressure may not exceed a (1) The design pressure does not ex-
gauge pressure of 100 psig (689 kPa) for ceed 200 psig (1379 kPa);
plastic pipe used in:
(2) The pipe size is nominal pipe size
(1) Distribution systems; or
(IPS or CTS) 4-inch or less; and
(2) Classes 3 and 4 locations.
(b) Plastic pipe may not be used (3) The pipe has a standard dimension
where operating temperatures of the ratio of SDR11 or greater (i.e., thicker
pipe will be: pipe wall).
(1) Below 20 F (20 C), or 40 F [35 FR 13257, Aug. 19, 1970, as amended by
(40 C) if all pipe and pipeline compo- Amdt. 19231, 43 FR 13883, Apr. 3, 1978; Amdt.
nents whose operating temperature 19278, 61 FR 28783, June 6, 1996; Amdt. 19285,
will be below 29 C (20 F) have a 63 FR 37502, July 13, 1998; Amdt. 19293, 68 FR
temperature rating by the manufac- 53900, Sept. 15, 2003; 69 FR 32894, June 14, 2004;
turer consistent with that operating Amdt. 19294, 69 FR 54592, Sept. 9, 2004; Amdt.
temperature; or 192103, 71 FR 33407, June 9, 2006; 73 FR 79005,
(2) Above the following applicable Dec. 24, 2008; Amdt. 192114, 75 FR 48603, Aug.
temperatures: 11, 2010]
(i) For thermoplastic pipe, the tem-
perature at which the HDB used in the 192.125 Design of copper pipe.
design formula under 192.121 is deter- (a) Copper pipe used in mains must
mined. have a minimum wall thickness of 0.065
(ii) For reinforced thermosetting inches (1.65 millimeters) and must be
plastic pipe, 150 F (66 C). hard drawn.
(c) The wall thickness for thermo- (b) Copper pipe used in service lines
plastic pipe may not be less than 0.062 must have wall thickness not less than
inches (1.57 millimeters).
that indicated in the following table:
(d) The wall thickness for reinforced
thermosetting plastic pipe may not be Wall thickness inch (milli-
Standard Nominal
less than that listed in the following meter)
size inch O.D. inch
table: (millimeter) (millimeter) Nominal Tolerance
Minimum
12 (13) .625 (16) .040 (1.06) .0035 (.0889)
wall thick-
Nominal size in inches (millimeters). ness inches
58 (16) .750 (19) .042 (1.07) .0035 (.0889)
(millime-
34 (19) .875 (22) .045 (1.14) .004 (.102)
ters). 1 (25) 1.125 (29) .050 (1.27) .004 (.102)
1 4
1 (32) 1.375 (35) .055 (1.40) .0045 (.1143)
2 (51) ................................................................. 0.060 (1.52)
1 2
1 (38) 1.625 (41) .060 (1.52) .0045 (.1143)
3 (76) ................................................................. 0.060 (1.52)
4 (102) ............................................................... 0.070 (1.78)
6 (152) ............................................................... 0.100 (2.54) (c) Copper pipe used in mains and
service lines may not be used at pres-
(e) The design pressure for thermo- sures in excess of 100 p.s.i. (689 kPa)
plastic pipe produced after July 14, 2004 gage.
may exceed a gauge pressure of 100 psig
(d) Copper pipe that does not have an
(689 kPa) provided that:
internal corrosion resistant lining may
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Pipeline and Hazardous Materials Safety Admin., DOT 192.145
419
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192.147 49 CFR Ch. I (10111 Edition)
pressure ratings for comparable steel for the pipeline to which it is being
valves at their listed temperature, if: added.
(1) The temperature-adjusted service
pressure does not exceed 1,000 p.s.i. (7 192.150 Passage of internal inspec-
Mpa) gage; and tion devices.
(2) Welding is not used on any ductile (a) Except as provided in paragraphs
iron component in the fabrication of (b) and (c) of this section, each new
the valve shells or their assembly. transmission line and each replace-
(e) No valve having shell (body, bon- ment of line pipe, valve, fitting, or
net, cover, and/or end flange) compo- other line component in a transmission
nents made of cast iron, malleable
line must be designed and constructed
iron, or ductile iron may be used in the
to accommodate the passage of instru-
gas pipe components of compressor sta-
mented internal inspection devices.
tions.
(b) This section does not apply to: (1)
[35 FR 13257, Aug. 19, 1970, as amended by Manifolds;
Amdt. 19262, 54 FR 5628, Feb. 6, 1989; Amdt.
(2) Station piping such as at com-
19285, 63 FR 37502, July 13, 1998; Amdt. 192
94, 69 FR 32894, June 14, 2004; Amdt. 192114, pressor stations, meter stations, or
75 FR 48603, Aug. 11, 2010] regulator stations;
(3) Piping associated with storage fa-
192.147 Flanges and flange acces- cilities, other than a continuous run of
sories. transmission line between a com-
(a) Each flange or flange accessory pressor station and storage facilities;
(other than cast iron) must meet the (4) Cross-overs;
minimum requirements of ASME/ANSI (5) Sizes of pipe for which an instru-
B16.5, MSS SP44, or the equivalent. mented internal inspection device is
(b) Each flange assembly must be not commercially available;
able to withstand the maximum pres- (6) Transmission lines, operated in
sure at which the pipeline is to be oper- conjunction with a distribution system
ated and to maintain its physical and which are installed in Class 4 locations;
chemical properties at any tempera- (7) Offshore transmission lines, ex-
ture to which it is anticipated that it
cept transmission lines 1034 inches (273
might be subjected in service.
millimeters) or more in outside diame-
(c) Each flange on a flanged joint in
ter on which construction begins after
cast iron pipe must conform in dimen-
sions, drilling, face and gasket design December 28, 2005, that run from plat-
to ASME/ANSI B16.1 and be cast inte- form to platform or platform to shore
grally with the pipe, valve, or fitting. unless
(i) Platform space or configuration is
[35 FR 13257, Aug. 19, 1970, as amended by incompatible with launching or re-
Amdt. 19262, 54 FR 5628, Feb. 6, 1989; 58 FR
trieving instrumented internal inspec-
14521, Mar. 18, 1993]
tion devices; or
192.149 Standard fittings. (ii) If the design includes taps for lat-
(a) The minimum metal thickness of eral connections, the operator can
threaded fittings may not be less than demonstrate, based on investigation or
specified for the pressures and tem- experience, that there is no reasonably
peratures in the applicable standards practical alternative under the design
referenced in this part, or their equiva- circumstances to the use of a tap that
lent. will obstruct the passage of instru-
(b) Each steel butt-welding fitting mented internal inspection devices;
must have pressure and temperature and
ratings based on stresses for pipe of the (8) Other piping that, under 190.9 of
same or equivalent material. The ac- this chapter, the Administrator finds
tual bursting strength of the fitting in a particular case would be impracti-
must at least equal the computed cable to design and construct to ac-
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420
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Pipeline and Hazardous Materials Safety Admin., DOT 192.155
only on 6-inch (152 millimeters) or larg- to ensure that the strength of the pipe-
er pipe. line system is not reduced, taking into
[35 FR 13257, Aug. 19, 1970, as amended by account the stresses in the remaining
Amdt. 19285, 63 FR 37502, July 13, 1998] pipe wall due to the opening in the pipe
421
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192.157 49 CFR Ch. I (10111 Edition)
or header, the shear stresses produced (1) A structural support may not be
by the pressure acting on the area of welded directly to the pipe.
the branch opening, and any external (2) The support must be provided by a
loadings due to thermal movement, member that completely encircles the
weight, and vibration. pipe.
(3) If an encircling member is welded
192.157 Extruded outlets. to a pipe, the weld must be continuous
Each extruded outlet must be suit- and cover the entire circumference.
able for anticipated service conditions (e) Each underground pipeline that is
and must be at least equal to the de- connected to a relatively unyielding
sign strength of the pipe and other fit- line or other fixed object must have
tings in the pipeline to which it is at- enough flexibility to provide for pos-
tached. sible movement, or it must have an an-
chor that will limit the movement of
192.159 Flexibility. the pipeline.
Each pipeline must be designed with (f) Except for offshore pipelines, each
enough flexibility to prevent thermal underground pipeline that is being con-
expansion or contraction from causing nected to new branches must have a
excessive stresses in the pipe or compo- firm foundation for both the header
nents, excessive bending or unusual and the branch to prevent detrimental
loads at joints, or undesirable forces or lateral and vertical movement.
moments at points of connection to [35 FR 13257, Aug. 19, 1970, as amended by
equipment, or at anchorage or guide Amdt. 19258, 53 FR 1635, Jan. 21, 1988]
points.
192.163 Compressor stations: Design
192.161 Supports and anchors. and construction.
(a) Each pipeline and its associated (a) Location of compressor building. Ex-
equipment must have enough anchors cept for a compressor building on a
or supports to: platform located offshore or in inland
(1) Prevent undue strain on con- navigable waters, each main com-
nected equipment; pressor building of a compressor sta-
(2) Resist longitudinal forces caused tion must be located on property under
by a bend or offset in the pipe; and the control of the operator. It must be
(3) Prevent or damp out excessive vi- far enough away from adjacent prop-
bration. erty, not under control of the operator,
(b) Each exposed pipeline must have to minimize the possibility of fire
enough supports or anchors to protect being communicated to the compressor
the exposed pipe joints from the max- building from structures on adjacent
imum end force caused by internal property. There must be enough open
pressure and any additional forces space around the main compressor
caused by temperature expansion or building to allow the free movement of
contraction or by the weight of the fire-fighting equipment.
pipe and its contents. (b) Building construction. Each build-
(c) Each support or anchor on an ex- ing on a compressor station site must
posed pipeline must be made of dura- be made of noncombustible materials if
ble, noncombustible material and must it contains either
be designed and installed as follows: (1) Pipe more than 2 inches (51 milli-
(1) Free expansion and contraction of meters) in diameter that is carrying
the pipeline between supports or an- gas under pressure; or
chors may not be restricted. (2) Gas handling equipment other
(2) Provision must be made for the than gas utilization equipment used for
service conditions involved. domestic purposes.
(3) Movement of the pipeline may not (c) Exits. Each operating floor of a
cause disengagement of the support main compressor building must have at
equipment. least two separated and unobstructed
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Pipeline and Hazardous Materials Safety Admin., DOT 192.167
a type which can be readily opened tion must have an emergency shut-
from the inside without a key. Each down system that meets the following:
swinging door located in an exterior (1) It must be able to block gas out of
wall must be mounted to swing out- the station and blow down the station
ward. piping.
(d) Fenced areas. Each fence around a (2) It must discharge gas from the
compressor station must have at least blowdown piping at a location where
two gates located so as to provide a the gas will not create a hazard.
convenient opportunity for escape to a (3) It must provide means for the
place of safety, or have other facilities shutdown of gas compressing equip-
affording a similarly convenient exit ment, gas fires, and electrical facilities
from the area. Each gate located with- in the vicinity of gas headers and in
in 200 feet (61 meters) of any com- the compressor building, except that:
pressor plant building must open out- (i) Electrical circuits that supply
ward and, when occupied, must be emergency lighting required to assist
openable from the inside without a station personnel in evacuating the
key. compressor building and the area in
(e) Electrical facilities. Electrical the vicinity of the gas headers must re-
equipment and wiring installed in com- main energized; and
pressor stations must conform to the (ii) Electrical circuits needed to pro-
National Electrical Code, ANSI/NFPA tect equipment from damage may re-
70, so far as that code is applicable. main energized.
[35 FR 13257, Aug. 19, 1970, as amended by (4) It must be operable from at least
Amdt. 19227, 41 FR 34605, Aug. 16, 1976; two locations, each of which is:
Amdt. 19237, 46 FR 10159, Feb. 2, 1981; 58 FR (i) Outside the gas area of the sta-
14521, Mar. 18, 1993; Amdt. 19285, 63 FR 37502, tion;
37503, July 13, 1998]
(ii) Near the exit gates, if the station
192.165 Compressor stations: Liquid is fenced, or near emergency exits, if
removal. not fenced; and
(iii) Not more than 500 feet (153 me-
(a) Where entrained vapors in gas
ters) from the limits of the station.
may liquefy under the anticipated pres-
sure and temperature conditions, the (b) If a compressor station supplies
compressor must be protected against gas directly to a distribution system
the introduction of those liquids in with no other adequate source of gas
quantities that could cause damage. available, the emergency shutdown
(b) Each liquid separator used to re- system must be designed so that it will
move entrained liquids at a compressor not function at the wrong time and
station must: cause an unintended outage on the dis-
(1) Have a manually operable means tribution system.
of removing these liquids. (c) On a platform located offshore or
(2) Where slugs of liquid could be car- in inland navigable waters, the emer-
ried into the compressors, have either gency shutdown system must be de-
automatic liquid removal facilities, an signed and installed to actuate auto-
automatic compressor shutdown de- matically by each of the following
vice, or a high liquid level alarm; and events:
(3) Be manufactured in accordance (1) In the case of an unattended com-
with section VIII of the ASME Boiler pressor station:
and Pressure Vessel Code, except that (i) When the gas pressure equals the
liquid separators constructed of pipe maximum allowable operating pressure
and fittings without internal welding plus 15 percent; or
must be fabricated with a design factor (ii) When an uncontrolled fire occurs
of 0.4, or less. on the platform; and
(2) In the case of a compressor sta-
192.167 Compressor stations: Emer- tion in a building:
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192.169 49 CFR Ch. I (10111 Edition)
compressor station must have vent under field conditions must comply
slots or holes in the baffles of each with the following:
compartment to prevent gas from (1) A bottle-type holder made from
being trapped in the muffler. alloy steel must meet the chemical and
424
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Pipeline and Hazardous Materials Safety Admin., DOT 192.183
tensile requirements for the various tween main line valves must have a
grades of steel in ASTM A 372/A 372M. blowdown valve with enough capacity
(2) The actual yield-tensile ratio of to allow the transmission line to be
the steel may not exceed 0.85. blown down as rapidly as practicable.
(3) Welding may not be performed on Each blowdown discharge must be lo-
the holder after it has been heat treat- cated so the gas can be blown to the at-
ed or stress relieved, except that cop- mosphere without hazard and, if the
per wires may be attached to the small transmission line is adjacent to an
diameter portion of the bottle end clo- overhead electric line, so that the gas
sure for cathodic protection if a local- is directed away from the electrical
ized thermit welding process is used. conductors.
(4) The holder must be given a mill (d) Offshore segments of transmission
hydrostatic test at a pressure that pro- lines must be equipped with valves or
duces a hoop stress at least equal to 85 other components to shut off the flow
percent of the SMYS. of gas to an offshore platform in an
(5) The holder, connection pipe, and emergency.
components must be leak tested after
installation as required by subpart J of [35 FR 13257, Aug. 19, 1970, as amended by
Amdt. 19227, 41 FR 34606, Aug. 16, 1976;
this part. Amdt. 19278, 61 FR 28784, June 6, 1996; Amdt.
[35 FR 13257, Aug. 19, 1970, as amended by 19285, 63 FR 37503, July 13, 1998]
Amdt. 19258, 53 FR 1635, Jan. 21, 1988; Amdt
19262, 54 FR 5628, Feb. 6, 1989; 58 FR 14521, 192.181 Distribution line valves.
Mar. 18, 1993; Amdt. 19285, 63 FR 37503, July
13, 1998]
(a) Each high-pressure distribution
system must have valves spaced so as
192.179 Transmission line valves. to reduce the time to shut down a sec-
tion of main in an emergency. The
(a) Each transmission line, other
valve spacing is determined by the op-
than offshore segments, must have sec-
erating pressure, the size of the mains,
tionalizing block valves spaced as fol-
and the local physical conditions.
lows, unless in a particular case the
Administrator finds that alternative (b) Each regulator station control-
spacing would provide an equivalent ling the flow or pressure of gas in a dis-
level of safety: tribution system must have a valve in-
(1) Each point on the pipeline in a stalled on the inlet piping at a distance
Class 4 location must be within 212 from the regulator station sufficient to
miles (4 kilometers)of a valve. permit the operation of the valve dur-
(2) Each point on the pipeline in a ing an emergency that might preclude
Class 3 location must be within 4 miles access to the station.
(6.4 kilometers) of a valve. (c) Each valve on a main installed for
(3) Each point on the pipeline in a operating or emergency purposes must
Class 2 location must be within 712 comply with the following:
miles (12 kilometers) of a valve. (1) The valve must be placed in a
(4) Each point on the pipeline in a readily accessible location so as to fa-
Class 1 location must be within 10 cilitate its operation in an emergency.
miles (16 kilometers) of a valve. (2) The operating stem or mechanism
(b) Each sectionalizing block valve must be readily accessible.
on a transmission line, other than off- (3) If the valve is installed in a buried
shore segments, must comply with the box or enclosure, the box or enclosure
following: must be installed so as to avoid trans-
(1) The valve and the operating de- mitting external loads to the main.
vice to open or close the valve must be
readily accessible and protected from 192.183 Vaults: Structural design re-
tampering and damage. quirements.
(2) The valve must be supported to (a) Each underground vault or pit for
prevent settling of the valve or move- valves, pressure relieving, pressure
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192.185 49 CFR Ch. I (10111 Edition)
(b) There must be enough working and there must be a means for testing
space so that all of the equipment re- the internal atmosphere before remov-
quired in the vault or pit can be prop- ing the cover;
erly installed, operated, and main- (2) If the vault or pit is vented, there
tained. must be a means of preventing external
(c) Each pipe entering, or within, a sources of ignition from reaching the
regulator vault or pit must be steel for vault atmosphere; or
sizes 10 inch (254 millimeters), and less, (3) If the vault or pit is ventilated,
except that control and gage piping paragraph (a) or (c) of this section ap-
may be copper. Where pipe extends plies.
through the vault or pit structure, pro- (c) If a vault or pit covered by para-
vision must be made to prevent the graph (b) of this section is ventilated
passage of gases or liquids through the by openings in the covers or gratings
opening and to avert strains in the and the ratio of the internal volume, in
pipe. cubic feet, to the effective ventilating
[35 FR 13257, Aug. 19, 1970, as amended by area of the cover or grating, in square
Amdt. 19285, 63 FR 37503, July 13, 1998] feet, is less than 20 to 1, no additional
ventilation is required.
192.185 Vaults: Accessibility.
[35 FR 13257, Aug. 19, 1970, as amended by
Each vault must be located in an ac- Amdt. 19285, 63 FR 37503, July 13, 1998]
cessible location and, so far as prac-
tical, away from: 192.189 Vaults: Drainage and water-
(a) Street intersections or points proofing.
where traffic is heavy or dense;
(a) Each vault must be designed so as
(b) Points of minimum elevation,
to minimize the entrance of water.
catch basins, or places where the ac-
cess cover will be in the course of sur- (b) A vault containing gas piping
face waters; and may not be connected by means of a
(c) Water, electric, steam, or other drain connection to any other under-
facilities. ground structure.
(c) Electrical equipment in vaults
192.187 Vaults: Sealing, venting, and must conform to the applicable re-
ventilation. quirements of Class 1, Group D, of the
Each underground vault or closed top National Electrical Code, ANSI/NFPA
pit containing either a pressure regu- 70.
lating or reducing station, or a pres- [35 FR 13257, Aug. 19, 1970, as amended by
sure limiting or relieving station, must Amdt. 19276, 61 FR 26122, May 24, 1996]
be sealed, vented or ventilated as fol-
lows: 192.191 Design pressure of plastic fit-
(a) When the internal volume exceeds tings.
200 cubic feet (5.7 cubic meters): (a) Thermosetting fittings for plastic
(1) The vault or pit must be venti- pipe must conform to ASTM D 2517,
lated with two ducts, each having at (incorporated by reference, see 192.7).
least the ventilating effect of a pipe 4 (b) Thermoplastic fittings for plastic
inches (102 millimeters) in diameter; pipe must conform to ASTM D 251399,
(2) The ventilation must be enough to (incorporated by reference, see 192.7).
minimize the formation of combustible
atmosphere in the vault or pit; and [Amdt. 192114, 75 FR 48603, Aug. 11, 2010]
(3) The ducts must be high enough
above grade to disperse any gas-air 192.193 Valve installation in plastic
mixtures that might be discharged. pipe.
(b) When the internal volume is more Each valve installed in plastic pipe
than 75 cubic feet (2.1 cubic meters) but must be designed so as to protect the
less than 200 cubic feet (5.7 cubic me- plastic material against excessive tor-
ters): sional or shearing loads when the valve
wreier-aviles on DSK3TPTVN1PROD with CFR
(1) If the vault or pit is sealed, each or shutoff is operated, and from any
opening must have a tight fitting cover other secondary stresses that might be
without open holes through which an exerted through the valve or its enclo-
explosive mixture might be ignited, sure.
426
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Pipeline and Hazardous Materials Safety Admin., DOT 192.197
the necessary limits of accuracy and to stream from the service regulator. This
limit the build-up of pressure under no- combination may be used alone only in
flow conditions to prevent a pressure those cases where the inlet pressure on
that would cause the unsafe operation the service regulator does not exceed
427
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192.199 49 CFR Ch. I (10111 Edition)
the manufacturers safe working pres- (h) Except for a valve that will iso-
sure rating of the service regulator, late the system under protection from
and may not be used where the inlet its source of pressure, be designed to
pressure on the service regulator ex- prevent unauthorized operation of any
ceeds 125 p.s.i. (862 kPa) gage. For high- stop valve that will make the pressure
er inlet pressures, the methods in para- relief valve or pressure limiting device
graph (c) (1) or (2) of this section must inoperative.
be used. [35 FR 13257, Aug. 19, 1970, as amended by
(4) A service regulator and an auto- Amdt. 1921, 35 FR 17660, Nov. 17, 1970]
matic shutoff device that closes upon a
rise in pressure downstream from the 192.201 Required capacity of pres-
regulator and remains closed until sure relieving and limiting stations.
manually reset. (a) Each pressure relief station or
[35 FR 13257, Aug. 19, 1970, as amended by pressure limiting station or group of
Amdt. 1921, 35 FR 17660, Nov. 7, 1970; Amdt those stations installed to protect a
19285, 63 FR 37503, July 13, 1998; Amdt. 192 pipeline must have enough capacity,
93, 68 FR 53900, Sept. 15, 2003] and must be set to operate, to insure
the following:
192.199 Requirements for design of (1) In a low pressure distribution sys-
pressure relief and limiting devices. tem, the pressure may not cause the
Except for rupture discs, each pres- unsafe operation of any connected and
sure relief or pressure limiting device properly adjusted gas utilization equip-
must: ment.
(a) Be constructed of materials such (2) In pipelines other than a low pres-
that the operation of the device will sure distribution system:
not be impaired by corrosion; (i) If the maximum allowable oper-
(b) Have valves and valve seats that ating pressure is 60 p.s.i. (414 kPa) gage
are designed not to stick in a position or more, the pressure may not exceed
that will make the device inoperative; the maximum allowable operating
(c) Be designed and installed so that pressure plus 10 percent, or the pres-
it can be readily operated to determine sure that produces a hoop stress of 75
if the valve is free, can be tested to de- percent of SMYS, whichever is lower;
termine the pressure at which it will (ii) If the maximum allowable oper-
operate, and can be tested for leakage ating pressure is 12 p.s.i. (83 kPa) gage
when in the closed position; or more, but less than 60 p.s.i. (414 kPa)
(d) Have support made of noncombus- gage, the pressure may not exceed the
tible material; maximum allowable operating pressure
(e) Have discharge stacks, vents, or plus 6 p.s.i. (41 kPa) gage; or
outlet ports designed to prevent accu- (iii) If the maximum allowable oper-
mulation of water, ice, or snow, located ating pressure is less than 12 p.s.i. (83
where gas can be discharged into the kPa) gage, the pressure may not exceed
atmosphere without undue hazard; the maximum allowable operating
(f) Be designed and installed so that pressure plus 50 percent.
the size of the openings, pipe, and fit- (b) When more than one pressure reg-
tings located between the system to be ulating or compressor station feeds
protected and the pressure relieving de- into a pipeline, relief valves or other
vice, and the size of the vent line, are protective devices must be installed at
adequate to prevent hammering of the each station to ensure that the com-
valve and to prevent impairment of re- plete failure of the largest capacity
lief capacity; regulator or compressor, or any single
(g) Where installed at a district regu- run of lesser capacity regulators or
lator station to protect a pipeline sys- compressors in that station, will not
tem from overpressuring, be designed impose pressures on any part of the
and installed to prevent any single in- pipeline or distribution system in ex-
cident such as an explosion in a vault cess of those for which it was designed,
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Pipeline and Hazardous Materials Safety Admin., DOT 192.227
near each regulator station in a low- suitable for the anticipated pressure
pressure distribution system, with a and temperature condition. Slip type
capacity to limit the maximum pres- expansion joints may not be used. Ex-
sure in the main to a pressure that will pansion must be allowed for by pro-
not exceed the safe operating pressure viding flexibility within the system
for any connected and properly ad- itself.
justed gas utilization equipment. (9) Each control line must be pro-
tected from anticipated causes of dam-
[35 FR 13257, Aug. 19, 1970, as amended by
Amdt. 1929, 37 FR 20827, Oct. 4, 1972; Amdt age and must be designed and installed
19285, 63 FR 37503, July 13, 1998] to prevent damage to any one control
line from making both the regulator
192.203 Instrument, control, and sam- and the over-pressure protective device
pling pipe and components. inoperative.
(a) Applicability. This section applies [35 FR 13257, Aug. 19, 1970, as amended by
to the design of instrument, control, Amdt. 19278, 61 FR 28784, June 6, 1996; Amdt.
and sampling pipe and components. It 19285, 63 FR 37503, July 13, 1998]
does not apply to permanently closed
systems, such as fluid-filled tempera- Subpart EWelding of Steel in
ture-responsive devices. Pipelines
(b) Materials and design. All materials
employed for pipe and components 192.221 Scope.
must be designed to meet the par- (a) This subpart prescribes minimum
ticular conditions of service and the requirements for welding steel mate-
following: rials in pipelines.
(1) Each takeoff connection and at- (b) This subpart does not apply to
taching boss, fitting, or adapter must welding that occurs during the manu-
be made of suitable material, be able to facture of steel pipe or steel pipeline
withstand the maximum service pres- components.
sure and temperature of the pipe or
equipment to which it is attached, and 192.225 Welding procedures.
be designed to satisfactorily withstand
(a) Welding must be performed by a
all stresses without failure by fatigue.
qualified welder in accordance with
(2) Except for takeoff lines that can
welding procedures qualified under sec-
be isolated from sources of pressure by
tion 5 of API 1104 (incorporated by ref-
other valving, a shutoff valve must be
erence, see 192.7) or section IX of the
installed in each takeoff line as near as
ASME Boiler and Pressure Vessel Code
practicable to the point of takeoff.
Welding and Brazing Qualifications
Blowdown valves must be installed
(incorporated by reference, see 192.7)
where necessary.
to produce welds meeting the require-
(3) Brass or copper material may not
ments of this subpart. The quality of
be used for metal temperatures greater
the test welds used to qualify welding
than 400 F (204C).
procedures shall be determined by de-
(4) Pipe or components that may con-
structive testing in accordance with
tain liquids must be protected by heat-
the applicable welding standard(s).
ing or other means from damage due to
(b) Each welding procedure must be
freezing.
recorded in detail, including the results
(5) Pipe or components in which liq-
of the qualifying tests. This record
uids may accumulate must have drains
must be retained and followed when-
or drips.
(6) Pipe or components subject to ever the procedure is used.
clogging from solids or deposits must [Amdt. 19252, 51 FR 20297, June 4, 1986;
have suitable connections for cleaning. Amdt. 19294, 69 FR 32894, June 14, 2004]
(7) The arrangement of pipe, compo-
nents, and supports must provide safe- 192.227 Qualification of welders.
ty under anticipated operating (a) Except as provided in paragraph
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192.229 49 CFR Ch. I (10111 Edition)
Boiler and Pressure Vessel Code (incor- stress of less than 20 percent of SMYS
porated by reference, see 192.7). How- unless the welder is tested in accord-
ever, a welder qualified under an ear- ance with paragraph (c)(1) of this sec-
lier edition than listed in 192.7 of this tion or requalifies under paragraph
part may weld but may not requalify (d)(1) or (d)(2) of this section.
under that earlier edition. (d) A welder qualified under
(b) A welder may qualify to perform 192.227(b) may not weld unless
welding on pipe to be operated at a (1) Within the preceding 15 calendar
pressure that produces a hoop stress of months, but at least once each cal-
less than 20 percent of SMYS by per- endar year, the welder has requalified
forming an acceptable test weld, for under 192.227(b); or
the process to be used, under the test (2) Within the preceding 712 calendar
set forth in section I of Appendix C of months, but at least twice each cal-
this part. Each welder who is to make endar year, the welder has had
a welded service line connection to a (i) A production weld cut out, tested,
main must first perform an acceptable and found acceptable in accordance
test weld under section II of Appendix with the qualifying test; or
C of this part as a requirement of the (ii) For welders who work only on
qualifying test. service lines 2 inches (51 millimeters)
or smaller in diameter, two sample
[35 FR 13257, Aug. 19, 1970, as amended by
welds tested and found acceptable in
Amdt. 19243, 47 FR 46851, Oct. 21, 1982; Amdt.
19252, 51 FR 20297, June 4, 1986; Amdt. 19278, accordance with the test in section III
61 FR 28784, June 6, 1996; Amdt. 19294, 69 FR of Appendix C of this part.
32894, June 14, 2004; Amdt. 192103, 72 FR 4656, [35 FR 13257, Aug. 19, 1970, as amended by
Feb. 1, 2007] Amdt. 19237, 46 FR 10159, Feb. 2, 1981; Amdt.
19278, 61 FR 28784, June 6, 1996; Amdt. 19285,
192.229 Limitations on welders. 63 FR 37503, July 13, 1998; Amdt. 19294, 69 FR
(a) No welder whose qualification is 32895, June 14, 2004]
based on nondestructive testing may
weld compressor station pipe and com- 192.231 Protection from weather.
ponents. The welding operation must be pro-
(b) No welder may weld with a par- tected from weather conditions that
ticular welding process unless, within would impair the quality of the com-
the preceding 6 calendar months, he pleted weld.
has engaged in welding with that proc-
ess. 192.233 Miter joints.
(c) A welder qualified under (a) A miter joint on steel pipe to be
192.227(a) operated at a pressure that produces a
(1) May not weld on pipe to be oper- hoop stress of 30 percent or more of
ated at a pressure that produces a hoop SMYS may not deflect the pipe more
stress of 20 percent or more of SMYS than 3.
unless within the preceding 6 calendar (b) A miter joint on steel pipe to be
months the welder has had one weld operated at a pressure that produces a
tested and found acceptable under the hoop stress of less than 30 percent, but
sections 6 or 9 of API Standard 1104 (in- more than 10 percent, of SMYS may
corporated by reference, see 192.7). Al- not deflect the pipe more than 1212 and
ternatively, welders may maintain an must be a distance equal to one pipe di-
ongoing qualification status by per- ameter or more away from any other
forming welds tested and found accept- miter joint, as measured from the
able under the above acceptance cri- crotch of each joint.
teria at least twice each calendar year, (c) A miter joint on steel pipe to be
but at intervals not exceeding 712 operated at a pressure that produces a
months. A welder qualified under an hoop stress of 10 percent or less of
earlier edition of a standard listed in SMYS may not deflect the pipe more
192.7 of this part may weld but may than 90.
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Pipeline and Hazardous Materials Safety Admin., DOT 192.245
431
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192.271 49 CFR Ch. I (10111 Edition)
repaired. Except for welds on an off- dium. Each gasket must be suitably
shore pipeline being installed from a confined and retained under compres-
pipeline vessel, a weld must be re- sion by a separate gland or follower
moved if it has a crack that is more ring.
than 8 percent of the weld length. (c) Cast iron pipe may not be joined
(b) Each weld that is repaired must by threaded joints.
have the defect removed down to sound (d) Cast iron pipe may not be joined
metal and the segment to be repaired by brazing.
must be preheated if conditions exist [35 FR 13257, Aug. 19, 1970, as amended by
which would adversely affect the qual- Amdt. 19262, 54 FR 5628, Feb. 6, 1989]
ity of the weld repair. After repair, the
segment of the weld that was repaired 192.277 Ductile iron pipe.
must be inspected to ensure its accept- (a) Ductile iron pipe may not be
ability. joined by threaded joints.
(c) Repair of a crack, or of any defect (b) Ductile iron pipe may not be
in a previously repaired area must be joined by brazing.
in accordance with written weld repair
procedures that have been qualified [35 FR 13257, Aug. 19, 1970, as amended by
under 192.225. Repair procedures must Amdt. 19262, 54 FR 5628, Feb. 6, 1989]
provide that the minimum mechanical 192.279 Copper pipe.
properties specified for the welding
procedure used to make the original Copper pipe may not be threaded ex-
weld are met upon completion of the cept that copper pipe used for joining
final weld repair. screw fittings or valves may be thread-
ed if the wall thickness is equivalent to
[Amdt. 19246, 48 FR 48674, Oct. 20, 1983] the comparable size of Schedule 40 or
heavier wall pipe listed in Table C1 of
Subpart FJoining of Materials ASME/ANSI B16.5.
Other Than by Welding [Amdt. 19262, 54 FR 5628, Feb. 6, 1989, as
amended at 58 FR 14521, Mar. 18, 1993]
192.271 Scope.
(a) This subpart prescribes minimum 192.281 Plastic pipe.
requirements for joining materials in (a) General. A plastic pipe joint that
pipelines, other than by welding. is joined by solvent cement, adhesive,
(b) This subpart does not apply to or heat fusion may not be disturbed
joining during the manufacture of pipe until it has properly set. Plastic pipe
or pipeline components. may not be joined by a threaded joint
or miter joint.
192.273 General.
(b) Solvent cement joints. Each solvent
(a) The pipeline must be designed and cement joint on plastic pipe must com-
installed so that each joint will sustain ply with the following:
the longitudinal pullout or thrust (1) The mating surfaces of the joint
forces caused by contraction or expan- must be clean, dry, and free of material
sion of the piping or by anticipated ex- which might be detrimental to the
ternal or internal loading. joint.
(b) Each joint must be made in ac- (2) The solvent cement must conform
cordance with written procedures that to ASTM D251399, (incorporated by
have been proven by test or experience reference, see 192.7).
to produce strong gastight joints. (3) The joint may not be heated to ac-
(c) Each joint must be inspected to celerate the setting of the cement.
insure compliance with this subpart. (c) Heat-fusion joints. Each heat-fu-
sion joint on plastic pipe must comply
192.275 Cast iron pipe. with the following:
(a) Each caulked bell and spigot joint (1) A butt heat-fusion joint must be
in cast iron pipe must be sealed with joined by a device that holds the heater
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432
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Pipeline and Hazardous Materials Safety Admin., DOT 192.283
Static pressure Test) of ASTM D251399 less than 25 percent or failure initiates
(incorporated by reference, see 192.7); outside the joint area.
(ii) In the case of thermosetting plas- (5) Pipe specimens 4 inches (102 mm)
tic pipe, paragraph 8.5 (Minimum Hy- and larger in diameter shall be pulled
433
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192.285 49 CFR Ch. I (10111 Edition)
until the pipe is subjected to a tensile cable to the type of joint and material
stress equal to or greater than the being tested;
maximum thermal stress that would be (ii) Examined by ultrasonic inspec-
produced by a temperature change of tion and found not to contain flaws
100 F (38 C) or until the pipe is pulled that would cause failure; or
from the fitting. If the pipe pulls from (iii) Cut into at least 3 longitudinal
the fitting, the lowest value of the five straps, each of which is:
test results or the manufacturers rat- (A) Visually examined and found not
ing, whichever is lower must be used in to contain voids or discontinuities on
the design calculations for stress. the cut surfaces of the joint area; and
(6) Each specimen that fails at the (B) Deformed by bending, torque, or
grips must be retested using new pipe. impact, and if failure occurs, it must
(7) Results obtained pertain only to not initiate in the joint area.
the specific outside diameter, and ma- (c) A person must be requalified
terial of the pipe tested, except that under an applicable procedure, if dur-
testing of a heavier wall pipe may be ing any 12-month period that person:
used to qualify pipe of the same mate-
(1) Does not make any joints under
rial but with a lesser wall thickness.
that procedure; or
(c) A copy of each written procedure
being used for joining plastic pipe must (2) Has 3 joints or 3 percent of the
be available to the persons making and joints made, whichever is greater,
inspecting joints. under that procedure that are found
(d) Pipe or fittings manufactured be- unacceptable by testing under 192.513.
fore July 1, 1980, may be used in ac- (d) Each operator shall establish a
cordance with procedures that the method to determine that each person
manufacturer certifies will produce a making joints in plastic pipelines in
joint as strong as the pipe. the operators system is qualified in ac-
cordance with this section.
[Amdt. 19234A, 45 FR 9935, Feb. 14, 1980, as
amended by Amdt. 19234B, 46 FR 39, Jan. 2, [Amdt. 19234A, 45 FR 9935, Feb. 14, 1980, as
1981; 47 FR 32720, July 29, 1982; 47 FR 49973, amended by Amdt. 19234B, 46 FR 39, Jan. 2,
Nov. 4, 1982; 58 FR 14521, Mar. 18, 1993; Amdt. 1981; Amdt. 19293, 68 FR 53900, Sept. 15, 2003]
19278, 61 FR 28784, June 6, 1996; Amdt. 19285,
63 FR 37503, July 13, 1998; Amdt. 19294, 69 FR 192.287 Plastic pipe: Inspection of
32895, June 14, 2004; Amdt. 19294, 69 FR 54592, joints.
Sept. 9, 2004; Amdt. 192114, 75 FR 48603, Aug.
No person may carry out the inspec-
11, 2010]
tion of joints in plastic pipes required
192.285 Plastic pipe: Qualifying per- by 192.273(c) and 192.285(b) unless that
sons to make joints. person has been qualified by appro-
(a) No person may make a plastic priate training or experience in evalu-
pipe joint unless that person has been ating the acceptability of plastic pipe
qualified under the applicable joining joints made under the applicable join-
procedure by: ing procedure.
(1) Appropriate training or experi- [Amdt. 19234, 44 FR 42974, July 23, 1979]
ence in the use of the procedure; and
(2) Making a specimen joint from Subpart GGeneral Construction
pipe sections joined according to the
procedure that passes the inspection
Requirements for Transmission
and test set forth in paragraph (b) of Lines and Mains
this section.
192.301 Scope.
(b) The specimen joint must be:
(1) Visually examined during and This subpart prescribes minimum re-
after assembly or joining and found to quirements for constructing trans-
have the same appearance as a joint or mission lines and mains.
photographs of a joint that is accept-
able under the procedure; and 192.303 Compliance with specifica-
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434
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Pipeline and Hazardous Materials Safety Admin., DOT 192.313
standards that are consistent with this the lowest point of the dent and a pro-
part. longation of the original contour of the
pipe.
192.305 Inspection: General. (c) Each arc burn on steel pipe to be
Each transmission line or main must operated at a pressure that produces a
be inspected to ensure that it is con- hoop stress of 40 percent, or more, of
structed in accordance with this part. SMYS must be repaired or removed. If
a repair is made by grinding, the arc
192.307 Inspection of materials. burn must be completely removed and
Each length of pipe and each other the remaining wall thickness must be
component must be visually inspected at least equal to either:
at the site of installation to ensure (1) The minimum wall thickness re-
that it has not sustained any visually quired by the tolerances in the speci-
determinable damage that could im- fication to which the pipe was manu-
pair its serviceability. factured; or
(2) The nominal wall thickness re-
192.309 Repair of steel pipe. quired for the design pressure of the
(a) Each imperfection or damage that pipeline.
impairs the serviceability of a length (d) A gouge, groove, arc burn, or dent
of steel pipe must be repaired or re- may not be repaired by insert patching
moved. If a repair is made by grinding, or by pounding out.
the remaining wall thickness must at (e) Each gouge, groove, arc burn, or
least be equal to either: dent that is removed from a length of
(1) The minimum thickness required pipe must be removed by cutting out
by the tolerances in the specification the damaged portion as a cylinder.
to which the pipe was manufactured; or [35 FR 13257, Aug. 19, 1970, as amended by
(2) The nominal wall thickness re- Amdt. 1921, 35 FR 17660, Nov. 17, 1970; Amdt.
quired for the design pressure of the 19285, 63 FR 37503, July 13, 1998; Amdt. 192
pipeline. 88, 64 FR 69664, Dec. 14, 1999]
(b) Each of the following dents must
192.311 Repair of plastic pipe.
be removed from steel pipe to be oper-
ated at a pressure that produces a hoop Each imperfection or damage that
stress of 20 percent, or more, of SMYS, would impair the serviceability of plas-
unless the dent is repaired by a method tic pipe must be repaired or removed.
that reliable engineering tests and [Amdt. 19293, 68 FR 53900, Sept. 15, 2003]
analyses show can permanently restore
the serviceability of the pipe: 192.313 Bends and elbows.
(1) A dent that contains a stress con- (a) Each field bend in steel pipe,
centrator such as a scratch, gouge, other than a wrinkle bend made in ac-
groove, or arc burn. cordance with 192.315, must comply
(2) A dent that affects the longitu- with the following:
dinal weld or a circumferential weld. (1) A bend must not impair the serv-
(3) In pipe to be operated at a pres- iceability of the pipe.
sure that produces a hoop stress of 40 (2) Each bend must have a smooth
percent or more of SMYS, a dent that contour and be free from buckling,
has a depth of: cracks, or any other mechanical dam-
(i) More than 14 inch (6.4 millimeters) age.
in pipe 1234 inches (324 millimeters) or (3) On pipe containing a longitudinal
less in outer diameter; or weld, the longitudinal weld must be as
(ii) More than 2 percent of the nomi- near as practicable to the neutral axis
nal pipe diameter in pipe over 1234 of the bend unless:
inches (324 millimeters) in outer di- (i) The bend is made with an internal
ameter. bending mandrel; or
For the purpose of this section a (ii) The pipe is 12 inches (305 millime-
dent is a depression that produces a ters) or less in outside diameter or has
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192.315 49 CFR Ch. I (10111 Edition)
during bending causes a permanent de- distance from the traffic or by install-
formation in the pipe must be non- ing barricades.
destructively tested either before or (c) Pipelines, including pipe risers, on
after the bending process. each platform located offshore or in in-
(c) Wrought-steel welding elbows and land navigable waters must be pro-
transverse segments of these elbows tected from accidental damage by ves-
may not be used for changes in direc- sels.
tion on steel pipe that is 2 inches (51 [Amdt. 19227, 41 FR 34606, Aug. 16, 1976, as
millimeters) or more in diameter un- amended by Amdt. 19278, 61 FR 28784, June
less the arc length, as measured along 6, 1996]
the crotch, is at least 1 inch (25 milli-
meters). 192.319 Installation of pipe in a
ditch.
[Amdt. No. 19226, 41 FR 26018, June 24, 1976,
as amended by Amdt. 19229, 42 FR 42866, (a) When installed in a ditch, each
Aug. 25, 1977; Amdt. 19229, 42 FR 60148, Nov. transmission line that is to be operated
25, 1977; Amdt. 19249, 50 FR 13225, Apr. 3, at a pressure producing a hoop stress of
1985; Amdt. 19285, 63 FR 37503, July 13, 1998] 20 percent or more of SMYS must be
installed so that the pipe fits the ditch
192.315 Wrinkle bends in steel pipe. so as to minimize stresses and protect
(a) A wrinkle bend may not be made the pipe coating from damage.
on steel pipe to be operated at a pres- (b) When a ditch for a transmission
sure that produces a hoop stress of 30 line or main is backfilled, it must be
percent, or more, of SMYS. backfilled in a manner that:
(b) Each wrinkle bend on steel pipe (1) Provides firm support under the
must comply with the following: pipe; and
(1) The bend must not have any sharp (2) Prevents damage to the pipe and
kinks. pipe coating from equipment or from
(2) When measured along the crotch the backfill material.
of the bend, the wrinkles must be a dis- (c) All offshore pipe in water at least
tance of at least one pipe diameter. 12 feet (3.7 meters) deep but not more
(3) On pipe 16 inches (406 millimeters) than 200 feet (61 meters) deep, as meas-
or larger in diameter, the bend may ured from the mean low tide, except
not have a deflection of more than 112 pipe in the Gulf of Mexico and its inlets
for each wrinkle. under 15 feet (4.6 meters) of water,
(4) On pipe containing a longitudinal must be installed so that the top of the
weld the longitudinal seam must be as pipe is below the natural bottom unless
near as practicable to the neutral axis the pipe is supported by stanchions,
of the bend. held in place by anchors or heavy con-
[35 FR 13257, Aug. 19, 1970, as amended by crete coating, or protected by an equiv-
Amdt. 19285, 63 FR 37503, July 13, 1998] alent means. Pipe in the Gulf of Mexico
and its inlets under 15 feet (4.6 meters)
192.317 Protection from hazards. of water must be installed so that the
(a) The operator must take all prac- top of the pipe is 36 inches (914 milli-
ticable steps to protect each trans- meters) below the seabed for normal
mission line or main from washouts, excavation or 18 inches (457 millime-
floods, unstable soil, landslides, or ters) for rock excavation.
other hazards that may cause the pipe- [35 FR 13257, Aug. 19, 1970, as amended by
line to move or to sustain abnormal Amdt. 19227, 41 FR 34606, Aug. 16, 1976;
loads. In addition, the operator must Amdt. 19278, 61 FR 28784, June 6, 1996; Amdt.
take all practicable steps to protect 19285, 63 FR 37503, July 13, 1998]
offshore pipelines from damage by mud
slides, water currents, hurricanes, ship 192.321 Installation of plastic pipe.
anchors, and fishing operations. (a) Plastic pipe must be installed
(b) Each aboveground transmission below ground level except as provided
line or main, not located offshore or in by paragraphs (g) and (h) of this sec-
wreier-aviles on DSK3TPTVN1PROD with CFR
436
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Pipeline and Hazardous Materials Safety Admin., DOT 192.325
gas-tight metal pipe and fittings that (3) Not allowed to exceed the pipe
are adequately protected from corro- temperature limits specified in
sion. 192.123.
(c) Plastic pipe must be installed so [35 FR 13257, Aug. 19, 1970, as amended by
as to minimize shear or tensile Amdt. 19278, 61 FR 28784, June 6, 1996; Amdt.
stresses. 19285, 63 FR 37503, July 13, 1998; Amdt. 192
(d) Thermoplastic pipe that is not en- 93, 68 FR 53900, Sept. 15, 2003; Amdt. 19294, 69
cased must have a minimum wall FR 32895, June 14, 2004]
thickness of 0.090 inch (2.29 millime-
ters), except that pipe with an outside 192.323 Casing.
diameter of 0.875 inch (22.3 millimeters) Each casing used on a transmission
or less may have a minimum wall line or main under a railroad or high-
thickness of 0.062 inch (1.58 millime- way must comply with the following:
ters). (a) The casing must be designed to
(e) Plastic pipe that is not encased withstand the superimposed loads.
must have an electrically conducting (b) If there is a possibility of water
wire or other means of locating the entering the casing, the ends must be
pipe while it is underground. Tracer sealed.
wire may not be wrapped around the (c) If the ends of an unvented casing
pipe and contact with the pipe must be are sealed and the sealing is strong
minimized but is not prohibited. Tracer enough to retain the maximum allow-
wire or other metallic elements in- able operating pressure of the pipe, the
stalled for pipe locating purposes must casing must be designed to hold this
be resistant to corrosion damage, ei- pressure at a stress level of not more
ther by use of coated copper wire or by than 72 percent of SMYS.
other means. (d) If vents are installed on a casing,
(f) Plastic pipe that is being encased the vents must be protected from the
must be inserted into the casing pipe in weather to prevent water from enter-
a manner that will protect the plastic. ing the casing.
The leading end of the plastic must be
closed before insertion. 192.325 Underground clearance.
(g) Uncased plastic pipe may be tem- (a) Each transmission line must be
porarily installed above ground level installed with at least 12 inches (305
under the following conditions: millimeters) of clearance from any
(1) The operator must be able to dem- other underground structure not asso-
onstrate that the cumulative above- ciated with the transmission line. If
ground exposure of the pipe does not this clearance cannot be attained, the
exceed the manufacturers rec- transmission line must be protected
ommended maximum period of expo- from damage that might result from
sure or 2 years, whichever is less. the proximity of the other structure.
(2) The pipe either is located where (b) Each main must be installed with
damage by external forces is unlikely enough clearance from any other un-
or is otherwise protected against such derground structure to allow proper
damage. maintenance and to protect against
(3) The pipe adequately resists expo- damage that might result from prox-
sure to ultraviolet light and high and imity to other structures.
low temperatures. (c) In addition to meeting the re-
(h) Plastic pipe may be installed on quirements of paragraph (a) or (b) of
bridges provided that it is: this section, each plastic transmission
(1) Installed with protection from line or main must be installed with suf-
mechanical damage, such as installa- ficient clearance, or must be insulated,
tion in a metallic casing; from any source of heat so as to pre-
wreier-aviles on DSK3TPTVN1PROD with CFR
(2) Protected from ultraviolet radi- vent the heat from impairing the serv-
ation; and iceability of the pipe.
437
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192.327 49 CFR Ch. I (10111 Edition)
(a) Quality assurance ............... (1) The construction of the pipeline segment must be done under a quality assurance plan ad-
dressing pipe inspection, hauling and stringing, field bending, welding, non-destructive ex-
wreier-aviles on DSK3TPTVN1PROD with CFR
amination of girth welds, applying and testing field applied coating, lowering of the pipeline
into the ditch, padding and backfilling, and hydrostatic testing.
(2) The quality assurance plan for applying and testing field applied coating to girth welds
must be:
(i) Equivalent to that required under 192.112(f)(3) for pipe; and
438
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Pipeline and Hazardous Materials Safety Admin., DOT 192.355
To address this construction The pipeline segment must meet this additional construction requirement:
issue:
(ii) Performed by an individual with the knowledge, skills, and ability to assure effective coating
application.
(b) Girth welds .......................... (1) All girth welds on a new pipeline segment must be non-destructively examined in accord-
ance with 192.243(b) and (c).
(c) Depth of cover ..................... (1) Notwithstanding any lesser depth of cover otherwise allowed in 192.327, there must be at
least 36 inches (914 millimeters) of cover or equivalent means to protect the pipeline from
outside force damage.
(2) In areas where deep tilling or other activities could threaten the pipeline, the top of the
pipeline must be installed at least one foot below the deepest expected penetration of the
soil.
(d) Initial strength testing .......... (1) The pipeline segment must not have experienced failures indicative of systemic material
defects during strength testing, including initial hydrostatic testing. A root cause analysis, in-
cluding metallurgical examination of the failed pipe, must be performed for any failure expe-
rienced to verify that it is not indicative of a systemic concern. The results of this root cause
analysis must be reported to each PHMSA pipeline safety regional office where the pipe is
in service at least 60 days prior to operating at the alternative MAOP. An operator must also
notify a State pipeline safety authority when the pipeline is located in a State where PHMSA
has an interstate agent agreement, or an intrastate pipeline is regulated by that State.
(e) Interference currents ........... (1) For a new pipeline segment, the construction must address the impacts of induced alter-
nating current from parallel electric transmission lines and other known sources of potential
interference with corrosion control.
439
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192.357 49 CFR Ch. I (10111 Edition)
192.357 Customer meters and regu- so as to drain into the main or into
lators: Installation. drips at the low points in the service
(a) Each meter and each regulator line.
must be installed so as to minimize an- (d) Protection against piping strain and
ticipated stresses upon the connecting external loading. Each service line must
piping and the meter. be installed so as to minimize antici-
(b) When close all-thread nipples are pated piping strain and external load-
used, the wall thickness remaining ing.
after the threads are cut must meet (e) Installation of service lines into
the minimum wall thickness require- buildings. Each underground service
ments of this part. line installed below grade through the
(c) Connections made of lead or other outer foundation wall of a building
easily damaged material may not be must:
used in the installation of meters or (1) In the case of a metal service line,
regulators. be protected against corrosion;
(d) Each regulator that might release (2) In the case of a plastic service
gas in its operation must be vented to line, be protected from shearing action
the outside atmosphere. and backfill settlement; and
(3) Be sealed at the foundation wall
192.359 Customer meter installations:
Operating pressure. to prevent leakage into the building.
(f) Installation of service lines under
(a) A meter may not be used at a buildings. Where an underground serv-
pressure that is more than 67 percent ice line is installed under a building:
of the manufacturers shell test pres-
(1) It must be encased in a gas tight
sure.
conduit;
(b) Each newly installed meter manu-
factured after November 12, 1970, must (2) The conduit and the service line
have been tested to a minimum of 10 must, if the service line supplies the
p.s.i. (69 kPa) gage. building it underlies, extend into a nor-
(c) A rebuilt or repaired tinned steel mally usable and accessible part of the
case meter may not be used at a pres- building; and
sure that is more than 50 percent of the (3) The space between the conduit
pressure used to test the meter after and the service line must be sealed to
rebuilding or repairing. prevent gas leakage into the building
and, if the conduit is sealed at both
[35 FR 13257, Aug. 19, 1970, as amended by ends, a vent line from the annular
Amdt. 1921, 35 FR 17660, Nov. 17, 1970; Amdt.
space must extend to a point where gas
19285, 63 FR 37503, July 13, 1998]
would not be a hazard, and extend
192.361 Service lines: Installation. above grade, terminating in a rain and
insect resistant fitting.
(a) Depth. Each buried service line
must be installed with at least 12 (g) Locating underground service lines.
inches (305 millimeters) of cover in pri- Each underground nonmetallic service
vate property and at least 18 inches line that is not encased must have a
(457 millimeters) of cover in streets and means of locating the pipe that com-
roads. However, where an underground plies with 192.321(e).
structure prevents installation at [35 FR 13257, Aug. 19, 1970, as amended by
those depths, the service line must be Amdt. 19275, 61 FR 18517, Apr. 26, 1996; Amdt.
able to withstand any anticipated ex- 19285, 63 FR 37503, July 13, 1998; Amdt. 192
ternal load. 93, 68 FR 53900, Sept. 15, 2003]
(b) Support and backfill. Each service
line must be properly supported on un- 192.363 Service lines: Valve require-
disturbed or well-compacted soil, and ments.
material used for backfill must be free (a) Each service line must have a
of materials that could damage the service-line valve that meets the appli-
pipe or its coating. cable requirements of subparts B and D
wreier-aviles on DSK3TPTVN1PROD with CFR
(c) Grading for drainage. Where con- of this part. A valve incorporated in a
densate in the gas might cause inter- meter bar, that allows the meter to be
ruption in the gas supply to the cus- bypassed, may not be used as a service-
tomer, the service line must be graded line valve.
440
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Pipeline and Hazardous Materials Safety Admin., DOT 192.375
(b) A soft seat service line valve may 192.369 Service lines: Connections to
not be used if its ability to control the cast iron or ductile iron mains.
flow of gas could be adversely affected (a) Each service line connected to a
by exposure to anticipated heat. cast iron or ductile iron main must be
(c) Each service-line valve on a high- connected by a mechanical clamp, by
pressure service line, installed above drilling and tapping the main, or by
ground or in an area where the blowing another method meeting the require-
of gas would be hazardous, must be de- ments of 192.273.
signed and constructed to minimize the (b) If a threaded tap is being inserted,
possibility of the removal of the core of the requirements of 192.151 (b) and (c)
the valve with other than specialized must also be met.
tools.
192.371 Service lines: Steel.
192.365 Service lines: Location of Each steel service line to be operated
valves.
at less than 100 p.s.i. (689 kPa) gage
(a) Relation to regulator or meter. Each must be constructed of pipe designed
service-line valve must be installed up- for a minimum of 100 p.s.i. (689 kPa)
stream of the regulator or, if there is gage.
no regulator, upstream of the meter. [Amdt. 1921, 35 FR 17660, Nov. 17, 1970, as
(b) Outside valves. Each service line amended by Amdt. 19285, 63 FR 37503, July
must have a shut-off valve in a readily 13, 1998]
accessible location that, if feasible, is
outside of the building. 192.373 Service lines: Cast iron and
(c) Underground valves. Each under- ductile iron.
ground service-line valve must be lo- (a) Cast or ductile iron pipe less than
cated in a covered durable curb box or 6 inches (152 millimeters) in diameter
standpipe that allows ready operation may not be installed for service lines.
of the valve and is supported independ- (b) If cast iron pipe or ductile iron
ently of the service lines. pipe is installed for use as a service
line, the part of the service line which
192.367 Service lines: General re- extends through the building wall must
quirements for connections to main be of steel pipe.
piping. (c) A cast iron or ductile iron service
(a) Location. Each service line con- line may not be installed in unstable
nection to a main must be located at soil or under a building.
the top of the main or, if that is not [35 FR 13257, Aug. 19, 1970, as amended by
practical, at the side of the main, un- Amdt. 19285, 63 FR 37503, July 13, 1998]
less a suitable protective device is in-
stalled to minimize the possibility of 192.375 Service lines: Plastic.
dust and moisture being carried from (a) Each plastic service line outside a
the main into the service line. building must be installed below
(b) Compression-type connection to ground level, except that
main. Each compression-type service (1) It may be installed in accordance
line to main connection must: with 192.321(g); and
(1) Be designed and installed to effec- (2) It may terminate above ground
tively sustain the longitudinal pull-out level and outside the building, if
or thrust forces caused by contraction (i) The above ground level part of the
or expansion of the piping, or by antici- plastic service line is protected against
pated external or internal loading; and deterioration and external damage; and
(2) If gaskets are used in connecting (ii) The plastic service line is not
the service line to the main connection used to support external loads.
fitting, have gaskets that are compat- (b) Each plastic service line inside a
wreier-aviles on DSK3TPTVN1PROD with CFR
ible with the kind of gas in the system. building must be protected against ex-
ternal damage.
[35 FR 13257, Aug. 19, 1970, as amended by
Amdt. 19275, 61 FR 18517, Apr. 26, 1996] [35 FR 13257, Aug. 19, 1970, as amended by
Amdt. 19278, 61 FR 28785, June 6, 1996]
441
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192.377 49 CFR Ch. I (10111 Edition)
192.377 Service lines: Copper. cubic feet per hour (.01 cubic meters
per hour); and
Each copper service line installed
within a building must be protected (4) Not close when the pressure is less
against external damage. than the manufacturers minimum
specified operating pressure and the
192.379 New service lines not in use. flow rate is below the manufacturers
minimum specified closure flow rate.
Each service line that is not placed
in service upon completion of installa- (b) An excess flow valve must meet
tion must comply with one of the fol- the applicable requirements of Sub-
lowing until the customer is supplied parts B and D of this part.
with gas: (c) An operator must mark or other-
(a) The valve that is closed to pre- wise identify the presence of an excess
vent the flow of gas to the customer flow valve in the service line.
must be provided with a locking device (d) An operator shall locate an excess
or other means designed to prevent the flow valve as near as practical to the
opening of the valve by persons other fitting connecting the service line to
than those authorized by the operator. its source of gas supply.
(b) A mechanical device or fitting (e) An operator should not install an
that will prevent the flow of gas must excess flow valve on a service line
be installed in the service line or in the where the operator has prior experi-
meter assembly. ence with contaminants in the gas
(c) The customers piping must be stream, where these contaminants
physically disconnected from the gas could be expected to cause the excess
supply and the open pipe ends sealed. flow valve to malfunction or where the
excess flow valve would interfere with
[Amdt. 1928, 37 FR 20694, Oct. 3, 1972] necessary operation and maintenance
activities on the service, such as blow-
192.381 Service lines: Excess flow
valve performance standards. ing liquids from the line.
(a) Excess flow valves to be used on [Amdt. 19279, 61 FR 31459, June 20, 1996, as
single residence service lines that oper- amended by Amdt. 19280, 62 FR 2619, Jan. 17,
ate continuously throughout the year 1997; Amdt. 19285, 63 FR 37504, July 13, 1998]
at a pressure not less than 10 p.s.i. (69
192.383 Excess flow valve installa-
kPa) gage must be manufactured and tion.
tested by the manufacturer according
to an industry specification, or the (a) Definitions. As used in this sec-
manufacturers written specification, tion:
to ensure that each valve will: Replaced service line means a gas serv-
(1) Function properly up to the max- ice line where the fitting that connects
imum operating pressure at which the the service line to the main is replaced
valve is rated; or the piping connected to this fitting
(2) Function properly at all tempera- is replaced.
tures reasonably expected in the oper- Service line serving single-family resi-
ating environment of the service line; dence means a gas service line that be-
(3) At 10 p.s.i. (69 kPa) gage: gins at the fitting that connects the
(i) Close at, or not more than 50 per- service line to the main and serves
cent above, the rated closure flow rate only one single-family residence.
specified by the manufacturer; and (b) Installation required. An excess
(ii) Upon closure, reduce gas flow flow valve (EFV) installation must
(A) For an excess flow valve designed comply with the performance stand-
to allow pressure to equalize across the ards in 192.381. The operator must in-
valve, to no more than 5 percent of the stall an EFV on any new or replaced
manufacturers specified closure flow service line serving a single-family res-
rate, up to a maximum of 20 cubic feet idence after February 12, 2010, unless
per hour (0.57 cubic meters per hour); one or more of the following conditions
wreier-aviles on DSK3TPTVN1PROD with CFR
or is present:
(B) For an excess flow valve designed (1) The service line does not operate
to prevent equalization of pressure at a pressure of 10 psig or greater
across the valve, to no more than 0.4 throughout the year;
442
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Pipeline and Hazardous Materials Safety Admin., DOT 192.455
(2) The operator has prior experience (b) Regulated onshore gathering lines.
with contaminants in the gas stream For any regulated onshore gathering
that could interfere with the EFVs op- line under 192.9 existing on April 14,
eration or cause loss of service to a res- 2006, that was not previously subject to
idence; this part, and for any onshore gath-
(3) An EFV could interfere with nec- ering line that becomes a regulated on-
essary operation or maintenance ac- shore gathering line under 192.9 after
tivities, such as blowing liquids from April 14, 2006, because of a change in
the line; or class location or increase in dwelling
(4) An EFV meeting performance density:
standards in 192.381 is not commer- (1) The requirements of this subpart
cially available to the operator. specifically applicable to pipelines in-
stalled before August 1, 1971, apply to
(c) Reporting. Each operator must re-
the gathering line regardless of the
port the EFV measures detailed in the
date the pipeline was actually in-
annual report required by 191.11. stalled; and
[Amdt. 192113, 74 FR 63934, Dec. 4, 2009, as (2) The requirements of this subpart
amended at 75 FR 5244, Feb. 2, 2010; 76 FR specifically applicable to pipelines in-
5499, Feb. 1, 2011] stalled after July 31, 1971, apply only if
the pipeline substantially meets those
Subpart IRequirements for requirements.
Corrosion Control [Amdt. 19230, 42 FR 60148, Nov. 25, 1977, as
amended by Amdt. 192102, 71 FR 13303, Mar.
15, 2006]
SOURCE: Amdt. 1924, 36 FR 12302, June 30,
1971, unless otherwise noted. 192.453 General.
192.451 Scope. The corrosion control procedures re-
quired by 192.605(b)(2), including those
(a) This subpart prescribes minimum for the design, installation, operation,
requirements for the protection of me- and maintenance of cathodic protec-
tallic pipelines from external, internal, tion systems, must be carried out by,
and atmospheric corrosion. or under the direction of, a person
(b) [Reserved] qualified in pipeline corrosion control
[Amdt. 1924, 36 FR 12302, June 30, 1971, as methods.
amended by Amdt. 19227, 41 FR 34606, Aug. [Amdt. 19271, 59 FR 6584, Feb. 11, 1994]
16, 1976; Amdt. 19233, 43 FR 39389, Sept. 5,
1978] 192.455 External corrosion control:
Buried or submerged pipelines in-
192.452 How does this subpart apply stalled after July 31, 1971.
to converted pipelines and regu-
lated onshore gathering lines? (a) Except as provided in paragraphs
(b), (c), and (f) of this section, each bur-
(a) Converted pipelines. Notwith- ied or submerged pipeline installed
standing the date the pipeline was in- after July 31, 1971, must be protected
stalled or any earlier deadlines for against external corrosion, including
compliance, each pipeline which quali- the following:
fies for use under this part in accord- (1) It must have an external protec-
ance with 192.14 must meet the re- tive coating meeting the requirements
quirements of this subpart specifically of 192.461.
applicable to pipelines installed before (2) It must have a cathodic protec-
August 1, 1971, and all other applicable tion system designed to protect the
requirements within 1 year after the pipeline in accordance with this sub-
pipeline is readied for service. How- part, installed and placed in operation
ever, the requirements of this subpart within 1 year after completion of con-
specifically applicable to pipelines in- struction.
stalled after July 31, 1971, apply if the (b) An operator need not comply with
wreier-aviles on DSK3TPTVN1PROD with CFR
pipeline substantially meets those re- paragraph (a) of this section, if the op-
quirements before it is readied for serv- erator can demonstrate by tests, inves-
ice or it is a segment which is replaced, tigation, or experience in the area of
relocated, or substantially altered. application, including, as a minimum,
443
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192.457 49 CFR Ch. I (10111 Edition)
soil resistivity measurements and tests (2) The fitting is designed to prevent
for corrosion accelerating bacteria, leakage caused by localized corrosion
that a corrosive environment does not pitting.
exist. However, within 6 months after [Amdt. 1924, 36 FR 12302, June 30, 1971, as
an installation made pursuant to the amended at Amdt. 19228, 42 FR 35654, July
preceding sentence, the operator shall 11, 1977; Amdt. 19239, 47 FR 9844, Mar. 8, 1982;
conduct tests, including pipe-to-soil Amdt. 19278, 61 FR 28785, June 6, 1996; Amdt.
potential measurements with respect 19285, 63 FR 37504, July 13, 1998]
to either a continuous reference elec- 192.457 External corrosion control:
trode or an electrode using close spac- Buried or submerged pipelines in-
ing, not to exceed 20 feet (6 meters), stalled before August 1, 1971.
and soil resistivity measurements at (a) Except for buried piping at com-
potential profile peak locations, to pressor, regulator, and measuring sta-
adequately evaluate the potential pro- tions, each buried or submerged trans-
file along the entire pipeline. If the mission line installed before August 1,
tests made indicate that a corrosive 1971, that has an effective external
condition exists, the pipeline must be coating must be cathodically protected
cathodically protected in accordance along the entire area that is effectively
with paragraph (a)(2) of this section. coated, in accordance with this sub-
(c) An operator need not comply with part. For the purposes of this subpart,
paragraph (a) of this section, if the op- a pipeline does not have an effective
erator can demonstrate by tests, inves- external coating if its cathodic protec-
tigation, or experience that tion current requirements are substan-
(1) For a copper pipeline, a corrosive tially the same as if it were bare. The
environment does not exist; or operator shall make tests to determine
(2) For a temporary pipeline with an the cathodic protection current re-
operating period of service not to ex- quirements.
ceed 5 years beyond installation, corro- (b) Except for cast iron or ductile
iron, each of the following buried or
sion during the 5-year period of service
submerged pipelines installed before
of the pipeline will not be detrimental
August 1, 1971, must be cathodically
to public safety.
protected in accordance with this sub-
(d) Notwithstanding the provisions of part in areas in which active corrosion
paragraph (b) or (c) of this section, if a is found:
pipeline is externally coated, it must (1) Bare or ineffectively coated trans-
be cathodically protected in accord- mission lines.
ance with paragraph (a)(2) of this sec- (2) Bare or coated pipes at com-
tion. pressor, regulator, and measuring sta-
(e) Aluminum may not be installed in tions.
a buried or submerged pipeline if that (3) Bare or coated distribution lines.
aluminum is exposed to an environ-
[Amdt. 1924, 36 FR 12302, June 30, 1971, as
ment with a natural pH in excess of 8, amended by Amdt. 19233, 43 FR 39390, Sept.
unless tests or experience indicate its 5, 1978; Amdt. 19293, 68 FR 53900, Sept. 15,
suitability in the particular environ- 2003]
ment involved.
(f) This section does not apply to 192.459 External corrosion control:
Examination of buried pipeline
electrically isolated, metal alloy fit- when exposed.
tings in plastic pipelines, if:
(1) For the size fitting to be used, an Whenever an operator has knowledge
operator can show by test, investiga- that any portion of a buried pipeline is
exposed, the exposed portion must be
tion, or experience in the area of appli-
examined for evidence of external cor-
cation that adequate corrosion control
rosion if the pipe is bare, or if the coat-
is provided by the alloy composition; ing is deteriorated. If external corro-
wreier-aviles on DSK3TPTVN1PROD with CFR
444
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Pipeline and Hazardous Materials Safety Admin., DOT 192.465
exposed portion (by visual examina- (b) If amphoteric metals are included
tion, indirect method, or both) to de- in a buried or submerged pipeline con-
termine whether additional corrosion taining a metal of different anodic po-
requiring remedial action exists in the tential
vicinity of the exposed portion. (1) The amphoteric metals must be
[Amdt. 19287, 64 FR 56981, Oct. 22, 1999] electrically isolated from the remain-
der of the pipeline and cathodically
192.461 External corrosion control: protected; or
Protective coating. (2) The entire buried or submerged
(a) Each external protective coating, pipeline must be cathodically pro-
whether conductive or insulating, ap- tected at a cathodic potential that
plied for the purpose of external corro- meets the requirements of appendix D
sion control must of this part for amphoteric metals.
(1) Be applied on a properly prepared (c) The amount of cathodic protec-
surface; tion must be controlled so as not to
(2) Have sufficient adhesion to the damage the protective coating or the
metal surface to effectively resist pipe.
underfilm migration of moisture;
(3) Be sufficiently ductile to resist 192.465 External corrosion control:
cracking; Monitoring.
(4) Have sufficient strength to resist (a) Each pipeline that is under ca-
damage due to handling and soil stress; thodic protection must be tested at
and least once each calendar year, but with
(5) Have properties compatible with intervals not exceeding 15 months, to
any supplemental cathodic protection. determine whether the cathodic protec-
(b) Each external protective coating tion meets the requirements of
which is an electrically insulating type 192.463. However, if tests at those in-
must also have low moisture absorp- tervals are impractical for separately
tion and high electrical resistance. protected short sections of mains or
(c) Each external protective coating transmission lines, not in excess of 100
must be inspected just prior to low- feet (30 meters), or separately pro-
ering the pipe into the ditch and back- tected service lines, these pipelines
filling, and any damage detrimental to
may be surveyed on a sampling basis.
effective corrosion control must be re-
At least 10 percent of these protected
paired.
structures, distributed over the entire
(d) Each external protective coating
system must be surveyed each calendar
must be protected from damage result-
year, with a different 10 percent
ing from adverse ditch conditions or
checked each subsequent year, so that
damage from supporting blocks.
the entire system is tested in each 10
(e) If coated pipe is installed by bor-
ing, driving, or other similar method, year period.
precautions must be taken to minimize (b) Each cathodic protection rectifier
damage to the coating during installa- or other impressed current power
tion. source must be inspected six times
each calendar year, but with intervals
192.463 External corrosion control: not exceeding 212 months, to insure
Cathodic protection. that it is operating.
(a) Each cathodic protection system (c) Each reverse current switch, each
required by this subpart must provide a diode, and each interference bond
level of cathodic protection that com- whose failure would jeopardize struc-
plies with one or more of the applicable ture protection must be electrically
criteria contained in appendix D of this checked for proper performance six
part. If none of these criteria is appli- times each calendar year, but with in-
cable, the cathodic protection system tervals not exceeding 212 months. Each
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192.467 49 CFR Ch. I (10111 Edition)
(d) Each operator shall take prompt precautions are taken to prevent arc-
remedial action to correct any defi- ing.
ciencies indicated by the monitoring. (f) Where a pipeline is located in
(e) After the initial evaluation re- close proximity to electrical trans-
quired by 192.455(b) and (c) and mission tower footings, ground cables
192.457(b), each operator must, not less or counterpoise, or in other areas
than every 3 years at intervals not ex- where fault currents or unusual risk of
ceeding 39 months, reevaluate its un- lightning may be anticipated, it must
protected pipelines and cathodically be provided with protection against
protect them in accordance with this damage due to fault currents or light-
subpart in areas in which active corro- ning, and protective measures must
sion is found. The operator must deter- also be taken at insulating devices.
mine the areas of active corrosion by [Amdt. 1924, 36 FR 12302, June 30, 1971, as
electrical survey. However, on distribu- amended by Amdt. 19233, 43 FR 39390, Sept.
tion lines and where an electrical sur- 5, 1978]
vey is impractical on transmission
lines, areas of active corrosion may be 192.469 External corrosion control:
determined by other means that in- Test stations.
clude review and analysis of leak re- Each pipeline under cathodic protec-
pair and inspection records, corrosion tion required by this subpart must
monitoring records, exposed pipe in- have sufficient test stations or other
spection records, and the pipeline envi- contact points for electrical measure-
ronment. ment to determine the adequacy of ca-
[Amdt. 1924, 36 FR 12302, June 30, 1971, as thodic protection.
amended by Amdt. 19233, 43 FR 39390, Sept. [Amdt. 19227, 41 FR 34606, Aug. 16, 1976]
5, 1978; Amdt. 19235A, 45 FR 23441, Apr. 7,
1980; Amdt. 19285, 63 FR 37504, July 13, 1998; 192.471 External corrosion control:
Amdt. 19293, 68 FR 53900, Sept. 15, 2003; Test leads.
Amdt. 192114, 75 FR 48603, Aug. 11, 2010]
(a) Each test lead wire must be con-
192.467 External corrosion control: nected to the pipeline so as to remain
Electrical isolation. mechanically secure and electrically
(a) Each buried or submerged pipe- conductive.
line must be electrically isolated from (b) Each test lead wire must be at-
other underground metallic structures, tached to the pipeline so as to mini-
unless the pipeline and the other struc- mize stress concentration on the pipe.
tures are electrically interconnected (c) Each bared test lead wire and
and cathodically protected as a single bared metallic area at point of connec-
unit. tion to the pipeline must be coated
(b) One or more insulating devices with an electrical insulating material
must be installed where electrical iso- compatible with the pipe coating and
lation of a portion of a pipeline is nec- the insulation on the wire.
essary to facilitate the application of
corrosion control. 192.473 External corrosion control:
Interference currents.
(c) Except for unprotected copper in-
serted in ferrous pipe, each pipeline (a) Each operator whose pipeline sys-
must be electrically isolated from me- tem is subjected to stray currents shall
tallic casings that are a part of the un- have in effect a continuing program to
derground system. However, if isola- minimize the detrimental effects of
tion is not achieved because it is im- such currents.
practical, other measures must be (b) Each impressed current type ca-
taken to minimize corrosion of the thodic protection system or galvanic
pipeline inside the casing. anode system must be designed and in-
(d) Inspection and electrical tests stalled so as to minimize any adverse
must be made to assure that electrical effects on existing adjacent under-
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446
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Pipeline and Hazardous Materials Safety Admin., DOT 192.479
447
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192.481 49 CFR Ch. I (10111 Edition)
(c) Except for cast iron or ductile of the pipeline, or a remaining wall
iron pipe, each segment of buried or thickness less than 30 percent of the
submerged pipe that is required to be nominal wall thickness, must be re-
repaired because of external corrosion placed. However, corroded pipe may be
448
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Pipeline and Hazardous Materials Safety Admin., DOT 192.503
2 In 192.925(b), the provision regarding detection of coat-
repaired by a method that reliable en- ing damage applies only to pipelines subject to subpart O of
gineering tests and analyses show can this part.
permanently restore the serviceability
of the pipe. Corrosion pitting so closely [Amdt. 192101, 70 FR 61575, Oct. 25, 2005]
grouped as to affect the overall
strength of the pipe is considered gen- 192.491 Corrosion control records.
eral corrosion for the purpose of this (a) Each operator shall maintain
paragraph. records or maps to show the location of
(b) Localized corrosion pitting. Except cathodically protected piping, cathodic
for cast iron or ductile iron pipe, each protection facilities, galvanic anodes,
segment of distribution line pipe with and neighboring structures bonded to
localized corrosion pitting to a degree the cathodic protection system.
where leakage might result must be re- Records or maps showing a stated num-
placed or repaired. ber of anodes, installed in a stated
[Amdt. 1924, 36 FR 12302, June 30, 1971, as manner or spacing, need not show spe-
amended by Amdt. 19288, 64 FR 69665, Dec. cific distances to each buried anode.
14, 1999] (b) Each record or map required by
paragraph (a) of this section must be
192.489 Remedial measures: Cast retained for as long as the pipeline re-
iron and ductile iron pipelines. mains in service.
(a) General graphitization. Each seg- (c) Each operator shall maintain a
ment of cast iron or ductile iron pipe record of each test, survey, or inspec-
on which general graphitization is tion required by this subpart in suffi-
found to a degree where a fracture or cient detail to demonstrate the ade-
any leakage might result, must be re- quacy of corrosion control measures or
placed. that a corrosive condition does not
(b) Localized graphitization. Each seg- exist. These records must be retained
ment of cast iron or ductile iron pipe for at least 5 years, except that records
on which localized graphitization is related to 192.465 (a) and (e) and
found to a degree where any leakage 192.475(b) must be retained for as long
might result, must be replaced or re- as the pipeline remains in service.
paired, or sealed by internal sealing
methods adequate to prevent or arrest [Amdt. 19278, 61 FR 28785, June 6, 1996]
any leakage.
Subpart JTest Requirements
192.490 Direct assessment.
Each operator that uses direct as- 192.501 Scope.
sessment as defined in 192.903 on an This subpart prescribes minimum
onshore transmission line made pri- leak-test and strength-test require-
marily of steel or iron to evaluate the ments for pipelines.
effects of a threat in the first column
must carry out the direct assessment 192.503 General requirements.
according to the standard listed in the (a) No person may operate a new seg-
second column. These standards do not ment of pipeline, or return to service a
apply to methods associated with di- segment of pipeline that has been relo-
rect assessment, such as close interval cated or replaced, until
surveys, voltage gradient surveys, or (1) It has been tested in accordance
examination of exposed pipelines, when with this subpart and 192.619 to sub-
used separately from the direct assess- stantiate the maximum allowable oper-
ment process. ating pressure; and
Threat Standard 1 (2) Each potentially hazardous leak
has been located and eliminated.
External corrosion ..................................... 192.925 2
Internal corrosion in pipelines that trans- 192.927 (b) The test medium must be liquid,
port dry gas. air, natural gas, or inert gas that is
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Stress corrosion cracking ......................... 192.929 (1) Compatible with the material of
1 For lines not subject to subpart O of this part, the terms which the pipeline is constructed;
covered segment and covered pipeline segment in
192.925, 192.927, and 192.929 refer to the pipeline seg- (2) Relatively free of sedimentary
ment on which direct assessment is performed. materials; and
449
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192.505 49 CFR Ch. I (10111 Edition)
(3) Except for natural gas, nonflam- (c) Except as provided in paragraph
mable. (e) of this section, the strength test
(c) Except as provided in 192.505(a), must be conducted by maintaining the
if air, natural gas, or inert gas is used pressure at or above the test pressure
as the test medium, the following max- for at least 8 hours.
imum hoop stress limitations apply: (d) If a component other than pipe is
the only item being replaced or added
Maximum hoop stress allowed as per- to a pipeline, a strength test after in-
centage of SMYS
Class location stallation is not required, if the manu-
Natural gas Air or inert gas facturer of the component certifies
1 ......................... 80 80 that
2 ......................... 30 75 (1) The component was tested to at
3 ......................... 30 50 least the pressure required for the pipe-
4 ......................... 30 40 line to which it is being added;
(2) The component was manufactured
(d) Each joint used to tie in a test under a quality control system that en-
segment of pipeline is excepted from sures that each item manufactured is
the specific test requirements of this at least equal in strength to a proto-
subpart, but each non-welded joint type and that the prototype was tested
must be leak tested at not less than its to at least the pressure required for the
operating pressure. pipeline to which it is being added; or
[35 FR 13257, Aug. 19, 1970, as amended by (3) The component carries a pressure
Amdt. 19258, 53 FR 1635, Jan. 21, 1988; Amdt. rating established through applicable
19260, 53 FR 36029, Sept. 16, 1988; Amdt. 192 ASME/ANSI, MSS specifications, or by
60A, 54 FR 5485, Feb. 3, 1989] unit strength calculations as described
in 192.143.
192.505 Strength test requirements (e) For fabricated units and short
for steel pipeline to operate at a sections of pipe, for which a post in-
hoop stress of 30 percent or more of stallation test is impractical, a pre-
SMYS.
installation strength test must be con-
(a) Except for service lines, each seg- ducted by maintaining the pressure at
ment of a steel pipeline that is to oper- or above the test pressure for at least
ate at a hoop stress of 30 percent or 4 hours.
more of SMYS must be strength tested
[35 FR 13257, Aug. 19, 1970, as amended by
in accordance with this section to sub-
Amdt. 19285, 63 FR 37504, July 13, 1998;
stantiate the proposed maximum al- Amdt. 19294, 69 FR 32895, June 14, 2004;
lowable operating pressure. In addi- Amdt. 19594, 69 FR 54592, Sept. 9, 2004]
tion, in a Class 1 or Class 2 location, if
there is a building intended for human 192.507 Test requirements for pipe-
occupancy within 300 feet (91 meters) of lines to operate at a hoop stress less
a pipeline, a hydrostatic test must be than 30 percent of SMYS and at or
conducted to a test pressure of at least above 100 p.s.i. (689 kPa) gage.
125 percent of maximum operating Except for service lines and plastic
pressure on that segment of the pipe- pipelines, each segment of a pipeline
line within 300 feet (91 meters) of such that is to be operated at a hoop stress
a building, but in no event may the less than 30 percent of SMYS and at or
test section be less than 600 feet (183 above 100 p.s.i. (689 kPa) gage must be
meters) unless the length of the newly tested in accordance with the fol-
installed or relocated pipe is less than lowing:
600 feet (183 meters). However, if the (a) The pipeline operator must use a
buildings are evacuated while the hoop test procedure that will ensure dis-
stress exceeds 50 percent of SMYS, air covery of all potentially hazardous
or inert gas may be used as the test leaks in the segment being tested.
medium. (b) If, during the test, the segment is
(b) In a Class 1 or Class 2 location, to be stressed to 20 percent or more of
wreier-aviles on DSK3TPTVN1PROD with CFR
each compressor station regulator sta- SMYS and natural gas, inert gas, or air
tion, and measuring station, must be is the test medium
tested to at least Class 3 location test (1) A leak test must be made at a
requirements. pressure between 100 p.s.i. (689 kPa)
450
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Pipeline and Hazardous Materials Safety Admin., DOT 192.515
gage and the pressure required to that each segment of a steel service
produce a hoop stress of 20 percent of line stressed to 20 percent or more of
SMYS; or SMYS must be tested in accordance
(2) The line must be walked to check with 192.507 of this subpart.
for leaks while the hoop stress is held
at approximately 20 percent of SMYS. [35 FR 13257, Aug. 19, 1970, as amended by
Amdt. 19274, 61 FR 18517, Apr. 26, 1996; Amdt
(c) The pressure must be maintained
19285, 63 FR 37504, July 13, 1998]
at or above the test pressure for at
least 1 hour. 192.513 Test requirements for plastic
[35 FR 13257, Aug. 19, 1970, as amended by pipelines.
Amdt. 19258, 53 FR 1635, Jan. 21, 1988; Amdt.
(a) Each segment of a plastic pipeline
19285, 63 FR 37504, July 13, 1998]
must be tested in accordance with this
192.509 Test requirements for pipe- section.
lines to operate below 100 p.s.i. (689 (b) The test procedure must insure
kPa) gage. discovery of all potentially hazardous
Except for service lines and plastic leaks in the segment being tested.
pipelines, each segment of a pipeline (c) The test pressure must be at least
that is to be operated below 100 p.s.i. 150 percent of the maximum operating
(689 kPa) gage must be leak tested in pressure or 50 p.s.i. (345 kPa) gage,
accordance with the following: whichever is greater. However, the
(a) The test procedure used must en- maximum test pressure may not be
sure discovery of all potentially haz- more than three times the pressure de-
ardous leaks in the segment being test- termined under 192.121, at a tempera-
ed. ture not less than the pipe temperature
(b) Each main that is to be operated during the test.
at less than 1 p.s.i. (6.9 kPa) gage must (d) During the test, the temperature
be tested to at least 10 p.s.i. (69 kPa) of thermoplastic material may not be
gage and each main to be operated at more than 100 F (38 C), or the tem-
or above 1 p.s.i. (6.9 kPa) gage must be perature at which the materials long-
tested to at least 90 p.s.i. (621 kPa) term hydrostatic strength has been de-
gage. termined under the listed specification,
[35 FR 13257, Aug. 19, 1970, as amended by whichever is greater.
Amdt. 19258, 53 FR 1635, Jan. 21, 1988; Amdt.
19285, 63 FR 37504, July 13, 1998] [35 FR 13257, Aug. 19, 1970, as amended by
Amdt. 19277, 61 FR 27793, June 3, 1996; 61 FR
192.511 Test requirements for service 45905, Aug. 30, 1996; Amdt. 19285, 63 FR 37504,
lines. July 13, 1998]
(a) Each segment of a service line 192.515 Environmental protection
(other than plastic) must be leak test- and safety requirements.
ed in accordance with this section be-
fore being placed in service. If feasible, (a) In conducting tests under this
the service line connection to the main subpart, each operator shall insure
must be included in the test; if not fea- that every reasonable precaution is
sible, it must be given a leakage test at taken to protect its employees and the
the operating pressure when placed in general public during the testing.
service. Whenever the hoop stress of the seg-
(b) Each segment of a service line ment of the pipeline being tested will
(other than plastic) intended to be op- exceed 50 percent of SMYS, the oper-
erated at a pressure of at least 1 p.s.i. ator shall take all practicable steps to
(6.9 kPa) gage but not more than 40 keep persons not working on the test-
p.s.i. (276 kPa) gage must be given a ing operation outside of the testing
leak test at a pressure of not less than area until the pressure is reduced to or
50 p.s.i. (345 kPa) gage. below the proposed maximum allow-
(c) Each segment of a service line able operating pressure.
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(other than plastic) intended to be op- (b) The operator shall insure that the
erated at pressures of more than 40 test medium is disposed of in a manner
p.s.i. (276 kPa) gage must be tested to that will minimize damage to the envi-
at least 90 p.s.i. (621 kPa) gage, except ronment.
451
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192.517 49 CFR Ch. I (10111 Edition)
and it does not become potentially haz- (c) After complying with paragraph
ardous. (b) of this section, an operator may in-
(b) Records. Each operator who crease the maximum allowable oper-
uprates a segment of pipeline shall re- ating pressure of a segment of pipeline
452
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Pipeline and Hazardous Materials Safety Admin., DOT 192.557
constructed before September 12, 1970, SMYS and that is above the previously
to the highest pressure that is per- established maximum allowable oper-
mitted under 192.619, using as test ating pressure; or
pressure the highest pressure to which (2) A plastic, cast iron, or ductile
the segment of pipeline was previously iron pipeline segment to an operating
subjected (either in a strength test or pressure that is above the previously
in actual operation). established maximum allowable oper-
(d) After complying with paragraph ating pressure.
(b) of this section, an operator that (b) Before increasing operating pres-
does not qualify under paragraph (c) of sure above the previously established
this section may increase the pre- maximum allowable operating pres-
viously established maximum allow- sure, the operator shall:
able operating pressure if at least one (1) Review the design, operating, and
of the following requirements is met: maintenance history of the segment of
(1) The segment of pipeline is suc- pipeline;
cessfully tested in accordance with the
(2) Make a leakage survey (if it has
requirements of this part for a new line
been more than 1 year since the last
of the same material in the same loca-
survey) and repair any leaks that are
tion.
found, except that a leak determined
(2) An increased maximum allowable
not to be potentially hazardous need
operating pressure may be established
not be repaired, if it is monitored dur-
for a segment of pipeline in a Class 1
ing the pressure increase and it does
location if the line has not previously
not become potentially hazardous;
been tested, and if:
(i) It is impractical to test it in ac- (3) Make any repairs, replacements,
cordance with the requirements of this or alterations in the segment of pipe-
part; line that are necessary for safe oper-
(ii) The new maximum operating ation at the increased pressure;
pressure does not exceed 80 percent of (4) Reinforce or anchor offsets, bends
that allowed for a new line of the same and dead ends in pipe joined by com-
design in the same location; and pression couplings or bell and spigot
(iii) The operator determines that joints to prevent failure of the pipe
the new maximum allowable operating joint, if the offset, bend, or dead end is
pressure is consistent with the condi- exposed in an excavation;
tion of the segment of pipeline and the (5) Isolate the segment of pipeline in
design requirements of this part. which the pressure is to be increased
(e) Where a segment of pipeline is from any adjacent segment that will
uprated in accordance with paragraph continue to be operated at a lower
(c) or (d)(2) of this section, the increase pressure; and
in pressure must be made in incre- (6) If the pressure in mains or service
ments that are equal to: lines, or both, is to be higher than the
(1) 10 percent of the pressure before pressure delivered to the customer, in-
the uprating; or stall a service regulator on each serv-
(2) 25 percent of the total pressure in- ice line and test each regulator to de-
crease, termine that it is functioning. Pressure
whichever produces the fewer number may be increased as necessary to test
of increments. each regulator, after a regulator has
been installed on each pipeline subject
192.557 Uprating: Steel pipelines to a to the increased pressure.
pressure that will produce a hoop (c) After complying with paragraph
stress less than 30 percent of SMYS: (b) of this section, the increase in max-
plastic, cast iron, and ductile iron imum allowable operating pressure
pipelines. must be made in increments that are
(a) Unless the requirements of this equal to 10 p.s.i. (69 kPa) gage or 25 per-
section have been met, no person may cent of the total pressure increase,
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192.601 49 CFR Ch. I (10111 Edition)
approximately equal incremental in- (2) Unless the actual maximum cover
creases. depth is known, the operator shall
(d) If records for cast iron or ductile measure the actual cover in at least
iron pipeline facilities are not com- three places where the cover is most
plete enough to determine stresses pro- likely to be greatest and shall use the
duced by internal pressure, trench greatest cover measured.
loading, rolling loads, beam stresses, (3) Unless the actual nominal wall
and other bending loads, in evaluating thickness is known, the operator shall
the level of safety of the pipeline when
determine the wall thickness by cut-
operating at the proposed increased
pressure, the following procedures ting and measuring coupons from at
must be followed: least three separate pipe lengths. The
(1) In estimating the stresses, if the coupons must be cut from pipe lengths
original laying conditions cannot be in areas where the cover depth is most
ascertained, the operator shall assume likely to be the greatest. The average
that cast iron pipe was supported on of all measurements taken must be in-
blocks with tamped backfill and that creased by the allowance indicated in
ductile iron pipe was laid without the following table:
blocks with tamped backfill.
Allowance inches (millimeters)
(4) For cast iron pipe, unless the pipe (c) The Administrator or the State
manufacturing process is known, the Agency that has submitted a current
operator shall assume that the pipe is certification under the pipeline safety
pit cast pipe with a bursting tensile laws, (49 U.S.C. 60101 et seq.) with re-
strength of 11,000 p.s.i. (76 MPa) gage spect to the pipeline facility governed
and a modulus of rupture of 31,000 p.s.i. by an operators plans and procedures
(214 MPa) gage. may, after notice and opportunity for
[35 FR 13257, Aug. 19, 1970, as amended by hearing as provided in 49 CFR 190.237 or
Amdt. 19237, 46 FR 10160, Feb. 2, 1981; Amdt. the relevant State procedures, require
19262, 54 FR 5628, Feb. 6, 1989; Amdt. 19585, the operator to amend its plans and
63 FR 37504, July 13, 1998] procedures as necessary to provide a
reasonable level of safety.
Subpart LOperations [35 FR 13257, Aug. 19, 1970, as amended by
Amdt. 19266, 56 FR 31090, July 9, 1991; Amdt.
192.601 Scope. 19271, 59 FR 6584, Feb. 11, 1994; Amdt. 19275,
This subpart prescribes minimum re- 61 FR 18517, Apr. 26, 1996]
quirements for the operation of pipe-
line facilities. 192.605 Procedural manual for oper-
ations, maintenance, and emer-
192.603 General provisions. gencies.
(a) No person may operate a segment (a) General. Each operator shall pre-
of pipeline unless it is operated in ac- pare and follow for each pipeline, a
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454
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Pipeline and Hazardous Materials Safety Admin., DOT 192.605
must also include procedures for han- including a breathing apparatus and, a
dling abnormal operations. This man- rescue harness and line.
ual must be reviewed and updated by (10) Systematic and routine testing
the operator at intervals not exceeding and inspection of pipe-type or bottle-
15 months, but at least once each cal- type holders including
endar year. This manual must be pre- (i) Provision for detecting external
pared before operations of a pipeline corrosion before the strength of the
system commence. Appropriate parts container has been impaired;
of the manual must be kept at loca- (ii) Periodic sampling and testing of
tions where operations and mainte- gas in storage to determine the dew
nance activities are conducted. point of vapors contained in the stored
(b) Maintenance and normal oper- gas which, if condensed, might cause
ations. The manual required by para- internal corrosion or interfere with the
graph (a) of this section must include safe operation of the storage plant; and
procedures for the following, if applica- (iii) Periodic inspection and testing
ble, to provide safety during mainte- of pressure limiting equipment to de-
nance and operations. termine that it is in safe operating
(1) Operating, maintaining, and re- condition and has adequate capacity.
pairing the pipeline in accordance with (11) Responding promptly to a report
each of the requirements of this sub- of a gas odor inside or near a building,
part and subpart M of this part. unless the operators emergency proce-
(2) Controlling corrosion in accord- dures under 192.615(a)(3) specifically
ance with the operations and mainte- apply to these reports.
nance requirements of subpart I of this (12) Implementing the applicable con-
part. trol room management procedures re-
quired by 192.631.
(3) Making construction records,
(c) Abnormal operation. For trans-
maps, and operating history available
mission lines, the manual required by
to appropriate operating personnel.
paragraph (a) of this section must in-
(4) Gathering of data needed for re- clude procedures for the following to
porting incidents under Part 191 of this provide safety when operating design
chapter in a timely and effective man- limits have been exceeded:
ner. (1) Responding to, investigating, and
(5) Starting up and shutting down correcting the cause of:
any part of the pipeline in a manner (i) Unintended closure of valves or
designed to assure operation within the shutdowns;
MAOP limits prescribed by this part, (ii) Increase or decrease in pressure
plus the build-up allowed for operation or flow rate outside normal operating
of pressure-limiting and control de- limits;
vices. (iii) Loss of communications;
(6) Maintaining compressor stations, (iv) Operation of any safety device;
including provisions for isolating units and
or sections of pipe and for purging be- (v) Any other foreseeable malfunc-
fore returning to service. tion of a component, deviation from
(7) Starting, operating and shutting normal operation, or personnel error,
down gas compressor units. which may result in a hazard to per-
(8) Periodically reviewing the work sons or property.
done by operator personnel to deter- (2) Checking variations from normal
mine the effectiveness, and adequacy of operation after abnormal operation has
the procedures used in normal oper- ended at sufficient critical locations in
ation and maintenance and modifying the system to determine continued in-
the procedures when deficiencies are tegrity and safe operation.
found. (3) Notifying responsible operator
(9) Taking adequate precautions in personnel when notice of an abnormal
excavated trenches to protect per- operation is received.
wreier-aviles on DSK3TPTVN1PROD with CFR
sonnel from the hazards of unsafe accu- (4) Periodically reviewing the re-
mulations of vapor or gas, and making sponse of operator personnel to deter-
available when needed at the exca- mine the effectiveness of the proce-
vation, emergency rescue equipment, dures controlling abnormal operation
455
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192.607 49 CFR Ch. I (10111 Edition)
and taking corrective action where de- ating hoop stress, taking pressure gra-
ficiencies are found. dient into account, for the segment of
(5) The requirements of this para- pipeline involved; and
graph (c) do not apply to natural gas (f) The actual area affected by the
distribution operators that are oper- population density increase, and phys-
ating transmission lines in connection ical barriers or other factors which
with their distribution system. may limit further expansion of the
(d) Safety-related condition reports. more densely populated area.
The manual required by paragraph (a)
of this section must include instruc- 192.611 Change in class location:
tions enabling personnel who perform Confirmation or revision of max-
operation and maintenance activities imum allowable operating pressure.
to recognize conditions that poten-
(a) If the hoop stress corresponding
tially may be safety-related conditions
to the established maximum allowable
that are subject to the reporting re-
quirements of 191.23 of this sub- operating pressure of a segment of
chapter. pipeline is not commensurate with the
(e) Surveillance, emergency response, present class location, and the segment
and accident investigation. The proce- is in satisfactory physical condition,
dures required by 192.613(a), 192.615, the maximum allowable operating
and 192.617 must be included in the pressure of that segment of pipeline
manual required by paragraph (a) of must be confirmed or revised according
this section. to one of the following requirements:
(1) If the segment involved has been
[Amdt. 19271, 59 FR 6584, Feb. 11, 1994, as
amended by Amdt. 19271A, 60 FR 14381, Mar. previously tested in place for a period
17, 1995; Amdt. 19293, 68 FR 53901, Sept. 15, of not less than 8 hours:
2003; Amdt. 192112, 74 FR 63327, Dec. 3, 2009] (i) The maximum allowable operating
pressure is 0.8 times the test pressure
192.607 [Reserved] in Class 2 locations, 0.667 times the test
192.609 Change in class location: Re- pressure in Class 3 locations, or 0.555
quired study. times the test pressure in Class 4 loca-
tions. The corresponding hoop stress
Whenever an increase in population
may not exceed 72 percent of the SMYS
density indicates a change in class lo-
of the pipe in Class 2 locations, 60 per-
cation for a segment of an existing
steel pipeline operating at hoop stress cent of SMYS in Class 3 locations, or 50
that is more than 40 percent of SMYS, percent of SMYS in Class 4 locations.
or indicates that the hoop stress cor- (ii) The alternative maximum allow-
responding to the established max- able operating pressure is 0.8 times the
imum allowable operating pressure for test pressure in Class 2 locations and
a segment of existing pipeline is not 0.667 times the test pressure in Class 3
commensurate with the present class locations. For pipelines operating at
location, the operator shall imme- alternative maximum allowable pres-
diately make a study to determine: sure per 192.620, the corresponding
(a) The present class location for the hoop stress may not exceed 80 percent
segment involved. of the SMYS of the pipe in Class 2 loca-
(b) The design, construction, and tions and 67 percent of SMYS in Class
testing procedures followed in the 3 locations.
original construction, and a compari- (2) The maximum allowable oper-
son of these procedures with those re- ating pressure of the segment involved
quired for the present class location by must be reduced so that the cor-
the applicable provisions of this part. responding hoop stress is not more
(c) The physical condition of the seg- than that allowed by this part for new
ment to the extent it can be segments of pipelines in the existing
ascertained from available records;
class location.
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Pipeline and Hazardous Materials Safety Admin., DOT 192.612
part, and its maximum allowable oper- 192.612 Underwater inspection and
ating pressure must then be estab- reburial of pipelines in the Gulf of
lished according to the following cri- Mexico and its inlets.
teria: (a) Each operator shall prepare and
(i) The maximum allowable operating follow a procedure to identify its pipe-
pressure after the requalification test lines in the Gulf of Mexico and its in-
is 0.8 times the test pressure for Class lets in waters less than 15 feet (4.6 me-
2 locations, 0.667 times the test pres- ters) deep as measured from mean low
sure for Class 3 locations, and 0.555 water that are at risk of being an ex-
times the test pressure for Class 4 loca- posed underwater pipeline or a hazard
tions. to navigation. The procedures must be
(ii) The corresponding hoop stress in effect August 10, 2005.
may not exceed 72 percent of the SMYS (b) Each operator shall conduct ap-
of the pipe in Class 2 locations, 60 per- propriate periodic underwater inspec-
cent of SMYS in Class 3 locations, or 50 tions of its pipelines in the Gulf of
percent of SMYS in Class 4 locations. Mexico and its inlets in waters less
(iii) For pipeline operating at an al- than 15 feet (4.6 meters) deep as meas-
ternative maximum allowable oper- ured from mean low water based on the
ating pressure per 192.620, the alter- identified risk.
native maximum allowable operating (c) If an operator discovers that its
pressure after the requalification test pipeline is an exposed underwater pipe-
is 0.8 times the test pressure for Class line or poses a hazard to navigation,
2 locations and 0.667 times the test the operator shall
pressure for Class 3 locations. The cor- (1) Promptly, but not later than 24
responding hoop stress may not exceed hours after discovery, notify the Na-
80 percent of the SMYS of the pipe in tional Response Center, telephone: 1
Class 2 locations and 67 percent of 8004248802, of the location and, if
SMYS in Class 3 locations. available, the geographic coordinates
(b) The maximum allowable oper- of that pipeline.
ating pressure confirmed or revised in (2) Promptly, but not later than 7
accordance with this section, may not days after discovery, mark the location
exceed the maximum allowable oper- of the pipeline in accordance with 33
ating pressure established before the CFR part 64 at the ends of the pipeline
confirmation or revision. segment and at intervals of not over
(c) Confirmation or revision of the 500 yards (457 meters) long, except that
maximum allowable operating pressure a pipeline segment less than 200 yards
of a segment of pipeline in accordance (183 meters) long need only be marked
with this section does not preclude the at the center; and
application of 192.553 and 192.555. (3) Within 6 months after discovery,
(d) Confirmation or revision of the or not later than November 1 of the fol-
maximum allowable operating pressure lowing year if the 6 month period is
that is required as a result of a study later than November 1 of the year of
under 192.609 must be completed with- discovery, bury the pipeline so that the
in 24 months of the change in class lo- top of the pipe is 36 inches (914 milli-
cation. Pressure reduction under para- meters) below the underwater natural
graph (a) (1) or (2) of this section with- bottom (as determined by recognized
in the 24-month period does not pre- and generally accepted practices) for
clude establishing a maximum allow- normal excavation or 18 inches (457
able operating pressure under para- millimeters) for rock excavation.
graph (a)(3) of this section at a later (i) An operator may employ engi-
date. neered alternatives to burial that meet
[Amdt. 19263A, 54 FR 24174, June 6, 1989 as or exceed the level of protection pro-
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457
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192.613 49 CFR Ch. I (10111 Edition)
notify OPS; specify whether the re- line system must be covered by a quali-
quired permit is State or Federal; and, fied one-call system where there is one
justify the delay. in place. For the purpose of this sec-
[Amdt. 19298, 69 FR 48406, Aug. 10, 2004]
tion, a one-call system is considered a
qualified one-call system if it meets
192.613 Continuing surveillance. the requirements of section (b)(1) or
(b)(2) of this section.
(a) Each operator shall have a proce-
dure for continuing surveillance of its (1) The state has adopted a one-call
facilities to determine and take appro- damage prevention program under
priate action concerning changes in 198.37 of this chapter; or
class location, failures, leakage his- (2) The one-call system:
tory, corrosion, substantial changes in (i) Is operated in accordance with
cathodic protection requirements, and 198.39 of this chapter;
other unusual operating and mainte- (ii) Provides a pipeline operator an
nance conditions. opportunity similar to a voluntary par-
(b) If a segment of pipeline is deter- ticipant to have a part in management
mined to be in unsatisfactory condition responsibilities; and
but no immediate hazard exists, the op- (iii) Assesses a participating pipeline
erator shall initiate a program to re- operator a fee that is proportionate to
condition or phase out the segment in- the costs of the one-call systems cov-
volved, or, if the segment cannot be re- erage of the operators pipeline.
conditioned or phased out, reduce the (c) The damage prevention program
maximum allowable operating pressure required by paragraph (a) of this sec-
in accordance with 192.619 (a) and (b). tion must, at a minimum:
(1) Include the identity, on a current
192.614 Damage prevention program.
basis, of persons who normally engage
(a) Except as provided in paragraphs in excavation activities in the area in
(d) and (e) of this section, each oper- which the pipeline is located.
ator of a buried pipeline must carry (2) Provides for notification of the
out, in accordance with this section, a public in the vicinity of the pipeline
written program to prevent damage to and actual notification of the persons
that pipeline from excavation activi- identified in paragraph (c)(1) of this
ties. For the purposes of this section, section of the following as often as
the term excavation activities in- needed to make them aware of the
cludes excavation, blasting, boring, damage prevention program:
tunneling, backfilling, the removal of (i) The programs existence and pur-
aboveground structures by either ex- pose; and
plosive or mechanical means, and other
(ii) How to learn the location of un-
earthmoving operations.
derground pipelines before excavation
(b) An operator may comply with any
of the requirements of paragraph (c) of activities are begun.
this section through participation in a (3) Provide a means of receiving and
public service program, such as a one- recording notification of planned exca-
call system, but such participation vation activities.
does not relieve the operator of respon- (4) If the operator has buried pipe-
sibility for compliance with this sec- lines in the area of excavation activity,
tion. However, an operator must per- provide for actual notification of per-
form the duties of paragraph (c)(3) of sons who give notice of their intent to
this section through participation in a excavate of the type of temporary
one-call system, if that one-call system marking to be provided and how to
is a qualified one-call system. In areas identify the markings.
that are covered by more than one (5) Provide for temporary marking of
qualified one-call system, an operator buried pipelines in the area of exca-
need only join one of the qualified one- vation activity before, as far as prac-
call systems if there is a central tele- tical, the activity begins.
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phone number for excavators to call for (6) Provide as follows for inspection
excavation activities, or if the one-call of pipelines that an operator has rea-
systems in those areas communicate son to believe could be damaged by ex-
with one another. An operators pipe- cavation activities:
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Pipeline and Hazardous Materials Safety Admin., DOT 192.615
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192.616 49 CFR Ch. I (10111 Edition)
460
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Pipeline and Hazardous Materials Safety Admin., DOT 192.619
192.619 Maximum allowable oper- (i) For plastic pipe in all locations,
ating pressure: Steel or plastic pipe- the test pressure is divided by a factor
lines. of 1.5.
(a) No person may operate a segment (ii) For steel pipe operated at 100
of steel or plastic pipeline at a pressure p.s.i. (689 kPa) gage or more, the test
that exceeds a maximum allowable op- pressure is divided by a factor deter-
erating pressure determined under mined in accordance with the following
paragraph (c) or (d) of this section, or table:
the lowest of the following:
Factors 1, segment
(1) The design pressure of the weak-
est element in the segment, deter- Class location Installed Installed Converted
before
mined in accordance with subparts C (Nov. 12, after (Nov. under
11, 1970) 192.14
and D of this part. However, for steel 1970)
pipe in pipelines being converted under 1 ............................... 1.1 1.1 1.25
192.14 or uprated under subpart K of 2 ............................... 1.25 1.25 1.25
this part, if any variable necessary to 3 ............................... 1.4 1.5 1.5
determine the design pressure under 4 ............................... 1.4 1.5 1.5
the design formula ( 192.105) is un- 1 For offshore segments installed, uprated or converted after
known, one of the following pressures July 31, 1977, that are not located on an offshore platform,
the factor is 1.25. For segments installed, uprated or con-
is to be used as design pressure: verted after July 31, 1977, that are located on an offshore
(i) Eighty percent of the first test platform or on a platform in inland navigable waters, including
a pipe riser, the factor is 1.5.
pressure that produces yield under sec-
tion N5 of Appendix N of ASME B31.8 (3) The highest actual operating pres-
(incorporated by reference, see 192.7), sure to which the segment was sub-
reduced by the appropriate factor in jected during the 5 years preceding the
paragraph (a)(2)(ii) of this section; or applicable date in the second column.
(ii) If the pipe is 1234 inches (324 mm) This pressure restriction applies unless
or less in outside diameter and is not the segment was tested according to
tested to yield under this paragraph, the requirements in paragraph (a)(2) of
200 p.s.i. (1379 kPa). this section after the applicable date in
(2) The pressure obtained by dividing the third column or the segment was
the pressure to which the segment was uprated according to the requirements
tested after construction as follows: in subpart K of this part:
Pipeline segment Pressure date Test date
Onshore gathering line that first be- March 15, 2006, or date line becomes 5 years preceding applicable date in sec-
came subject to this part (other than subject to this part, whichever is later. ond column.
192.612) after April 13, 2006.
Onshore transmission line that was a
gathering line not subject to this part
before March 15, 2006.
Offshore gathering lines ........................... July 1, 1976 ............................................. July 1, 1971.
All other pipelines ..................................... July 1, 1970 ............................................. July 1, 1965.
pressure from being exceeded, in ac- (d) The operator of a pipeline seg-
cordance with 192.195.
ment of steel pipeline meeting the con-
(c) The requirements on pressure re- ditions prescribed in 192.620(b) may
strictions in this section do not apply
461
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192.620 49 CFR Ch. I (10111 Edition)
[35 FR 13257, Aug. 19, 1970] 1 For Class 2 alternative maximum allowable operating
pressure segments installed prior to December 22, 2008 the
EDITORIAL NOTE: For FEDERAL REGISTER ci- alternative test factor is 1.25.
tations affecting 192.619, see the List of CFR
Sections Affected, which appears in the (b) When may an operator use the alter-
Finding Aids section of the printed volume native maximum allowable operating pres-
and at www.fdsys.gov. sure calculated under paragraph (a) of
this section? An operator may use an al-
192.620 Alternative maximum allow- ternative maximum allowable oper-
able operating pressure for certain ating pressure calculated under para-
steel pipelines. graph (a) of this section if the fol-
(a) How does an operator calculate the lowing conditions are met:
alternative maximum allowable operating (1) The pipeline segment is in a Class
pressure? An operator calculates the al- 1, 2, or 3 location;
ternative maximum allowable oper- (2) The pipeline segment is con-
ating pressure by using different fac- structed of steel pipe meeting the addi-
tors in the same formulas used for cal- tional design requirements in 192.112;
culating maximum allowable operating (3) A supervisory control and data ac-
pressure under 192.619(a) as follows: quisition system provides remote mon-
(1) In determining the alternative de- itoring and control of the pipeline seg-
sign pressure under 192.105, use a de- ment. The control provided must in-
sign factor determined in accordance clude monitoring of pressures and
with 192.111(b), (c), or (d) or, if none of flows, monitoring compressor start-ups
these paragraphs apply, in accordance
and shut-downs, and remote closure of
with the following table:
valves per paragraph (d)(3) of this sec-
Alternative de- tion;
Class location sign factor (F) (4) The pipeline segment meets the
1 ..................................................................... 0.80 additional construction requirements
2 ..................................................................... 0.67 described in 192.328;
3 ..................................................................... 0.56 (5) The pipeline segment does not
contain any mechanical couplings used
(i) For facilities installed prior to De- in place of girth welds;
cember 22, 2008, for which 192.111(b), (6) If a pipeline segment has been pre-
(c), or (d) applies, use the following de- viously operated, the segment has not
sign factors as alternatives for the fac- experienced any failure during normal
tors specified in those paragraphs: operations indicative of a systemic
192.111(b)0.67 or less; 192.111(c) and fault in material as determined by a
(d)0.56 or less.
root cause analysis, including met-
(ii) [Reserved] allurgical examination of the failed
(2) The alternative maximum allow- pipe. The results of this root cause
able operating pressure is the lower of analysis must be reported to each
the following: PHMSA pipeline safety regional office
(i) The design pressure of the weakest where the pipeline is in service at least
element in the pipeline segment, deter- 60 days prior to operation at the alter-
mined under subparts C and D of this
native MAOP. An operator must also
part.
notify a State pipeline safety authority
(ii) The pressure obtained by dividing when the pipeline is located in a State
the pressure to which the pipeline seg-
where PHMSA has an interstate agent
ment was tested after construction by
agreement, or an intrastate pipeline is
a factor determined in the following
regulated by that State; and
table:
(7) At least 95 percent of girth welds
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Pipeline and Hazardous Materials Safety Admin., DOT 192.620
(c) What is an operator electing to use (ii) For a pipeline segment in exist-
the alternative maximum allowable oper- ence prior to December 22, 2008, certify,
ating pressure required to do? If an oper- under paragraph (c)(2) of this section,
ator elects to use the alternative max- that the strength test performed under
imum allowable operating pressure cal- 192.505 was conducted at test pressure
culated under paragraph (a) of this sec- calculated under paragraph (a) of this
tion for a pipeline segment, the oper- section, or conduct a new strength test
ator must do each of the following: in accordance with paragraph (c)(4)(i)
(1) Notify each PHMSA pipeline safe- of this section.
ty regional office where the pipeline is
(5) Comply with the additional oper-
in service of its election with respect
ation and maintenance requirements
to a segment at least 180 days before
described in paragraph (d) of this sec-
operating at the alternative maximum
tion.
allowable operating pressure. An oper-
ator must also notify a State pipeline (6) If the performance of a construc-
safety authority when the pipeline is tion task associated with imple-
located in a State where PHMSA has menting alternative MAOP that occurs
an interstate agent agreement, or an after December 22, 2008, can affect the
intrastate pipeline is regulated by that integrity of the pipeline segment, treat
State. that task as a covered task, notwith-
(2) Certify, by signature of a senior standing the definition in 192.801(b)
executive officer of the company, as and implement the requirements of
follows: subpart N as appropriate.
(i) The pipeline segment meets the (7) Maintain, for the useful life of the
conditions described in paragraph (b) of pipeline, records demonstrating com-
this section; and pliance with paragraphs (b), (c)(6), and
(ii) The operating and maintenance (d) of this section.
procedures include the additional oper- (8) A Class 1 and Class 2 pipeline loca-
ating and maintenance requirements of tion can be upgraded one class due to
paragraph (d) of this section; and class changes per 192.611(a)(3)(i). All
(iii) The review and any needed pro- class location changes from Class 1 to
gram upgrade of the damage preven- Class 2 and from Class 2 to Class 3 must
tion program required by paragraph have all anomalies evaluated and reme-
(d)(4)(v) of this section has been com- diated per: The original pipeline class
pleted.
grade 192.620(d)(11) anomaly repair
(3) Send a copy of the certification
requirements; and all anomalies with a
required by paragraph (c)(2) of this sec-
wall loss equal to or greater than 40
tion to each PHMSA pipeline safety re-
percent must be excavated and remedi-
gional office where the pipeline is in
service 30 days prior to operating at ated. Pipelines in Class 4 may not oper-
the alternative MAOP. An operator ate at an alternative MAOP.
must also send a copy to a State pipe- (d) What additional operation and
line safety authority when the pipeline maintenance requirements apply to oper-
is located in a State where PHMSA has ation at the alternative maximum allow-
an interstate agent agreement, or an able operating pressure? In addition to
intrastate pipeline is regulated by that compliance with other applicable safe-
State. ty standards in this part, if an operator
(4) For each pipeline segment, do one establishes a maximum allowable oper-
of the following: ating pressure for a pipeline segment
(i) Perform a strength test as de- under paragraph (a) of this section, an
scribed in 192.505 at a test pressure operator must comply with the addi-
calculated under paragraph (a) of this tional operation and maintenance re-
section or quirements as follows:
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192.620 49 CFR Ch. I (10111 Edition)
(1) Identifying and evaluating Develop a threat matrix consistent with 192.917 to do the following:
threats. (i) Identify and compare the increased risk of operating the pipeline at the increased stress
level under this section with conventional operation; and
(ii) Describe and implement procedures used to mitigate the risk.
(2) Notifying the public ............. (i) Recalculate the potential impact circle as defined in 192.903 to reflect use of the alter-
native maximum operating pressure calculated under paragraph (a) of this section and pipe-
line operating conditions; and
(ii) In implementing the public education program required under 192.616, perform the fol-
lowing:
(A) Include persons occupying property within 220 yards of the centerline and within the po-
tential impact circle within the targeted audience; and
(B) Include information about the integrity management activities performed under this section
within the message provided to the audience.
(3) Responding to an emer- (i) Ensure that the identification of high consequence areas reflects the larger potential impact
gency in an area defined as circle recalculated under paragraph (d)(2)(i) of this section.
a high consequence area in
192.903.
(ii) If personnel response time to mainline valves on either side of the high consequence area
exceeds one hour (under normal driving conditions and speed limits) from the time the event
is identified in the control room, provide remote valve control through a supervisory control
and data acquisition (SCADA) system, other leak detection system, or an alternative method
of control.
(iii) Remote valve control must include the ability to close and monitor the valve position (open
or closed), and monitor pressure upstream and downstream.
(iv) A line break valve control system using differential pressure, rate of pressure drop or other
widely-accepted method is an acceptable alternative to remote valve control.
(4) Protecting the right-of-way .. (i) Patrol the right-of-way at intervals not exceeding 45 days, but at least 12 times each cal-
endar year, to inspect for excavation activities, ground movement, wash outs, leakage, or
other activities or conditions affecting the safety operation of the pipeline.
(ii) Develop and implement a plan to monitor for and mitigate occurrences of unstable soil and
ground movement.
(iii) If observed conditions indicate the possible loss of cover, perform a depth of cover study
and replace cover as necessary to restore the depth of cover or apply alternative means to
provide protection equivalent to the originally-required depth of cover.
(iv) Use line-of-sight line markers satisfying the requirements of 192.707(d) except in agricul-
tural areas, large water crossings or swamp, steep terrain, or where prohibited by Federal
Energy Regulatory Commission orders, permits, or local law.
(v) Review the damage prevention program under 192.614(a) in light of national consensus
practices, to ensure the program provides adequate protection of the right-of-way. Identify
the standards or practices considered in the review, and meet or exceed those standards or
practices by incorporating appropriate changes into the program.
(vi) Develop and implement a right-of-way management plan to protect the pipeline segment
from damage due to excavation activities.
(5) Controlling internal corro- (i) Develop and implement a program to monitor for and mitigate the presence of, deleterious
sion. gas stream constituents.
(ii) At points where gas with potentially deleterious contaminants enters the pipeline, use filter
separators or separators and gas quality monitoring equipment.
(iii) Use gas quality monitoring equipment that includes a moisture analyzer, chromatograph,
and periodic hydrogen sulfide sampling.
(iv) Use cleaning pigs and sample accumulated liquids. Use inhibitors when corrosive gas or
liquids are present.
(v) Address deleterious gas stream constituents as follows:
(A) Limit carbon dioxide to 3 percent by volume;
(B) Allow no free water and otherwise limit water to seven pounds per million cubic feet of
gas; and
(C) Limit hydrogen sulfide to 1.0 grain per hundred cubic feet (16 ppm) of gas, where the hy-
drogen sulfide is greater than 0.5 grain per hundred cubic feet (8 ppm) of gas, implement a
pigging and inhibitor injection program to address deleterious gas stream constituents, in-
cluding follow-up sampling and quality testing of liquids at receipt points.
(vi) Review the program at least quarterly based on the gas stream experience and implement
adjustments to monitor for, and mitigate the presence of, deleterious gas stream constitu-
ents.
(6) Controlling interference that (i) Prior to operating an existing pipeline segment at an alternate maximum allowable oper-
can impact external corrosion. ating pressure calculated under this section, or within six months after placing a new pipe-
line segment in service at an alternate maximum allowable operating pressure calculated
wreier-aviles on DSK3TPTVN1PROD with CFR
under this section, address any interference currents on the pipeline segment.
(ii) To address interference currents, perform the following:
(A) Conduct an interference survey to detect the presence and level of any electrical current
that could impact external corrosion where interference is suspected;
(B) Analyze the results of the survey; and
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Pipeline and Hazardous Materials Safety Admin., DOT 192.620
(C) Take any remedial action needed within 6 months after completing the survey to protect
the pipeline segment from deleterious current.
(7) Confirming external corro- (i) Within six months after placing the cathodic protection of a new pipeline segment in oper-
sion control through indirect ation, or within six months after certifying a segment under 192.620(c)(1) of an existing
assessment. pipeline segment under this section, assess the adequacy of the cathodic protection through
an indirect method such as close-interval survey, and the integrity of the coating using direct
current voltage gradient (DCVG) or alternating current voltage gradient (ACVG).
(ii) Remediate any construction damaged coating with a voltage drop classified as moderate or
severe (IR drop greater than 35% for DCVG or 50 dBv for ACVG) under section 4 of
NACE RP05022002 (incorporated by reference, see 192.7).
(iii) Within six months after completing the baseline internal inspection required under para-
graph (d)(9) of this section, integrate the results of the indirect assessment required under
paragraph (d)(7)(i) of this section with the results of the baseline internal inspection and take
any needed remedial actions.
(iv) For all pipeline segments in high consequence areas, perform periodic assessments as
follows:
(A) Conduct periodic close interval surveys with current interrupted to confirm voltage drops in
association with periodic assessments under subpart O of this part.
(B) Locate pipe-to-soil test stations at half-mile intervals within each high consequence area
ensuring at least one station is within each high consequence area, if practicable.
(C) Integrate the results with those of the baseline and periodic assessments for integrity done
under paragraphs (d)(9) and (d)(10) of this section.
(8) Controlling external corro- (i) If an annual test station reading indicates cathodic protection below the level of protection
sion through cathodic protec- required in subpart I of this part, complete remedial action within six months of the failed
tion. reading or notify each PHMSA pipeline safety regional office where the pipeline is in service
demonstrating that the integrity of the pipeline is not compromised if the repair takes longer
than 6 months. An operator must also notify a State pipeline safety authority when the pipe-
line is located in a State where PHMSA has an interstate agent agreement, or an intrastate
pipeline is regulated by that State; and
(ii) After remedial action to address a failed reading, confirm restoration of adequate corrosion
control by a close interval survey on either side of the affected test station to the next test
station unless the reason for the failed reading is determined to be a rectifier connection or
power input problem that can be remediated and otherwise verified.
(iii) If the pipeline segment has been in operation, the cathodic protection system on the pipe-
line segment must have been operational within 12 months of the completion of construc-
tion.
(9) Conducting a baseline as- (i) Except as provided in paragraph (d)(9)(iii) of this section, for a new pipeline segment oper-
sessment of integrity. ating at the new alternative maximum allowable operating pressure, perform a baseline in-
ternal inspection of the entire pipeline segment as follows:
(A) Assess using a geometry tool after the initial hydrostatic test and backfill and within six
months after placing the new pipeline segment in service; and
(B) Assess using a high resolution magnetic flux tool within three years after placing the new
pipeline segment in service at the alternative maximum allowable operating pressure.
(ii) Except as provided in paragraph (d)(9)(iii) of this section, for an existing pipeline segment,
perform a baseline internal assessment using a geometry tool and a high resolution mag-
netic flux tool before, but within two years prior to, raising pressure to the alternative max-
imum allowable operating pressure as allowed under this section.
(iii) If headers, mainline valve by-passes, compressor station piping, meter station piping, or
other short portion of a pipeline segment operating at alternative maximum allowable oper-
ating pressure cannot accommodate a geometry tool and a high resolution magnetic flux
tool, use direct assessment (per 192.925, 192.927 and/or 192.929) or pressure testing
(per subpart J of this part) to assess that portion.
(10) Conducting periodic as- (i) Determine a frequency for subsequent periodic integrity assessments as if all the alternative
sessments of integrity. maximum allowable operating pressure pipeline segments were covered by subpart O of
this part and
(ii) Conduct periodic internal inspections using a high resolution magnetic flux tool on the fre-
quency determined under paragraph (d)(10)(i) of this section, or
(iii) Use direct assessment (per 192.925, 192.927 and/or 192.929) or pressure testing
(per subpart J of this part) for periodic assessment of a portion of a segment to the extent
permitted for a baseline assessment under paragraph (d)(9)(iii) of this section.
(11) Making repairs .................. (i) Perform the following when evaluating an anomaly:
(A) Use the most conservative calculation for determining remaining strength or an alternative
validated calculation based on pipe diameter, wall thickness, grade, operating pressure, op-
erating stress level, and operating temperature: and
(B) Take into account the tolerances of the tools used for the inspection.
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192.621 49 CFR Ch. I (10111 Edition)
(C) The alternative maximum allowable operating pressure was based on a design factor of
0.67 under paragraph (a) of this section and the failure pressure is less than 1.25 times the
alternative maximum allowable operating pressure.
(D) The alternative maximum allowable operating pressure was based on a design factor of
0.56 under paragraph (a) of this section and the failure pressure is less than or equal to 1.4
times the alternative maximum allowable operating pressure.
(iii) If paragraph (d)(11)(ii) of this section does not require immediate repair, repair a defect
within one year if any of the following apply:
(A) The defect meets the criteria for repair within one year in 192.933(d).
(B) The alternative maximum allowable operating pressure was based on a design factor of
0.80 under paragraph (a) of this section and the failure pressure is less than 1.25 times the
alternative maximum allowable operating pressure.
(C) The alternative maximum allowable operating pressure was based on a design factor of
0.67 under paragraph (a) of this section and the failure pressure is less than 1.50 times the
alternative maximum allowable operating pressure.
(D) The alternative maximum allowable operating pressure was based on a design factor of
0.56 under paragraph (a) of this section and the failure pressure is less than or equal to
1.80 times the alternative maximum allowable operating pressure.
(iv) Evaluate any defect not required to be repaired under paragraph (d)(11)(ii) or (iii) of this
section to determine its growth rate, set the maximum interval for repair or re-inspection,
and repair or re-inspect within that interval.
(e) Is there any change in overpressure p.s.i. (414 kPa) gage, unless the service
protection associated with operating at lines in the segment are equipped with
the alternative maximum allowable oper- service regulators or other pressure
ating pressure? Notwithstanding the re- limiting devices in series that meet the
quired capacity of pressure relieving requirements of 192.197(c).
and limiting stations otherwise re- (3) 25 p.s.i. (172 kPa) gage in segments
quired by 192.201, if an operator estab- of cast iron pipe in which there are
lishes a maximum allowable operating unreinforced bell and spigot joints.
pressure for a pipeline segment in ac- (4) The pressure limits to which a
cordance with paragraph (a) of this sec- joint could be subjected without the
tion, an operator must: possibility of its parting.
(1) Provide overpressure protection (5) The pressure determined by the
that limits mainline pressure to a max-
operator to be the maximum safe pres-
imum of 104 percent of the maximum
sure after considering the history of
allowable operating pressure; and
the segment, particularly known corro-
(2) Develop and follow a procedure for
sion and the actual operating pres-
establishing and maintaining accurate
sures.
set points for the supervisory control
and data acquisition system. (b) No person may operate a segment
of pipeline to which paragraph (a)(5) of
[73 FR 62177, Oct. 17, 2008, as amended by this section applies, unless over-
Amdt. 192111, 74 FR 62505, Nov. 30, 2009] pressure protective devices are in-
stalled on the segment in a manner
192.621 Maximum allowable oper-
ating pressure: High-pressure dis- that will prevent the maximum allow-
tribution systems. able operating pressure from being ex-
ceeded, in accordance with 192.195.
(a) No person may operate a segment
of a high pressure distribution system [35 FR 13257, Aug. 19, 1970, as amended by
at a pressure that exceeds the lowest of Amdt 19285, 63 FR 37504, July 13, 1998]
the following pressures, as applicable:
(1) The design pressure of the weak- 192.623 Maximum and minimum al-
est element in the segment, deter- lowable operating pressure; Low-
pressure distribution systems.
mined in accordance with subparts C
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Pipeline and Hazardous Materials Safety Admin., DOT 192.629
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192.631 49 CFR Ch. I (10111 Edition)
192.631 Control room management. even if the controller is not the first to
(a) General. detect the condition, including the con-
(1) This section applies to each oper- trollers responsibility to take specific
ator of a pipeline facility with a con- actions and to communicate with oth-
troller working in a control room who ers;
monitors and controls all or part of a (3) A controllers role during an
pipeline facility through a SCADA sys- emergency, even if the controller is not
tem. Each operator must have and fol- the first to detect the emergency, in-
low written control room management cluding the controllers responsibility
procedures that implement the require- to take specific actions and to commu-
ments of this section, except that for nicate with others; and
each control room where an operators (4) A method of recording controller
activities are limited to either or both shift-changes and any hand-over of re-
of: sponsibility between controllers.
(i) Distribution with less than 250,000 (c) Provide adequate information. Each
services, or operator must provide its controllers
(ii) Transmission without a com- with the information, tools, processes
pressor station, the operator must have and procedures necessary for the con-
and follow written procedures that im- trollers to carry out the roles and re-
plement only paragraphs (d) (regarding sponsibilities the operator has defined
fatigue), (i) (regarding compliance vali- by performing each of the following:
dation), and (j) (regarding compliance (1) Implement sections 1, 4, 8, 9, 11.1,
and deviations) of this section. and 11.3 of API RP 1165 (incorporated
(2) The procedures required by this by reference, see 192.7) whenever a
section must be integrated, as appro- SCADA system is added, expanded or
priate, with operating and emergency replaced, unless the operator dem-
procedures required by 192.605 and
onstrates that certain provisions of
192.615. An operator must develop the
sections 1, 4, 8, 9, 11.1, and 11.3 of API
procedures no later than August 1, 2011,
RP 1165 are not practical for the
and must implement the procedures ac-
SCADA system used;
cording to the following schedule. The
procedures required by paragraphs (b), (2) Conduct a point-to-point
(c)(5), (d)(2) and (d)(3), (f) and (g) of this verification between SCADA displays
section must be implemented no later and related field equipment when field
than October 1, 2011. The procedures re- equipment is added or moved and when
quired by paragraphs (c)(1) through (4), other changes that affect pipeline safe-
(d)(1), (d)(4), and (e) must be imple- ty are made to field equipment or
mented no later than August 1, 2012. SCADA displays;
The training procedures required by (3) Test and verify an internal com-
paragraph (h) must be implemented no munication plan to provide adequate
later than August 1, 2012, except that means for manual operation of the
any training required by another para- pipeline safely, at least once each cal-
graph of this section must be imple- endar year, but at intervals not to ex-
mented no later than the deadline for ceed 15 months;
that paragraph. (4) Test any backup SCADA systems
(b) Roles and responsibilities. Each op- at least once each calendar year, but at
erator must define the roles and re- intervals not to exceed 15 months; and
sponsibilities of a controller during (5) Establish and implement proce-
normal, abnormal, and emergency op- dures for when a different controller
erating conditions. To provide for a assumes responsibility, including the
controllers prompt and appropriate re- content of information to be ex-
sponse to operating conditions, an op- changed.
erator must define each of the fol- (d) Fatigue mitigation. Each operator
lowing: must implement the following methods
(1) A controllers authority and re- to reduce the risk associated with con-
wreier-aviles on DSK3TPTVN1PROD with CFR
sponsibility to make decisions and troller fatigue that could inhibit a con-
take actions during normal operations; trollers ability to carry out the roles
(2) A controllers role when an abnor- and responsibilities the operator has
mal operating condition is detected, defined:
468
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Pipeline and Hazardous Materials Safety Admin., DOT 192.631
(1) Establish shift lengths and sched- affect control room operations are co-
ule rotations that provide controllers ordinated with the control room per-
off-duty time sufficient to achieve sonnel by performing each of the fol-
eight hours of continuous sleep; lowing:
(2) Educate controllers and super- (1) Establish communications be-
visors in fatigue mitigation strategies tween control room representatives,
and how off-duty activities contribute operators management, and associated
to fatigue; field personnel when planning and im-
(3) Train controllers and supervisors plementing physical changes to pipe-
to recognize the effects of fatigue; and line equipment or configuration;
(4) Establish a maximum limit on (2) Require its field personnel to con-
controller hours-of-service, which may tact the control room when emergency
provide for an emergency deviation conditions exist and when making field
from the maximum limit if necessary changes that affect control room oper-
for the safe operation of a pipeline fa- ations; and
cility. (3) Seek control room or control
(e) Alarm management. Each operator room management participation in
using a SCADA system must have a planning prior to implementation of
written alarm management plan to significant pipeline hydraulic or con-
provide for effective controller re- figuration changes.
sponse to alarms. An operators plan (g) Operating experience. Each oper-
must include provisions to: ator must assure that lessons learned
(1) Review SCADA safety-related from its operating experience are in-
alarm operations using a process that corporated, as appropriate, into its
ensures alarms are accurate and sup- control room management procedures
port safe pipeline operations; by performing each of the following:
(2) Identify at least once each cal- (1) Review incidents that must be re-
endar month points affecting safety ported pursuant to 49 CFR part 191 to
that have been taken off scan in the determine if control room actions con-
SCADA host, have had alarms inhib- tributed to the event and, if so, cor-
ited, generated false alarms, or that rect, where necessary, deficiencies re-
have had forced or manual values for lated to:
periods of time exceeding that required (i) Controller fatigue;
for associated maintenance or oper- (ii) Field equipment;
ating activities; (iii) The operation of any relief de-
(3) Verify the correct safety-related vice;
alarm set-point values and alarm de- (iv) Procedures;
scriptions at least once each calendar (v) SCADA system configuration; and
year, but at intervals not to exceed 15 (vi) SCADA system performance.
months; (2) Include lessons learned from the
(4) Review the alarm management operators experience in the training
plan required by this paragraph at program required by this section.
least once each calendar year, but at (h) Training. Each operator must es-
intervals not exceeding 15 months, to tablish a controller training program
determine the effectiveness of the plan; and review the training program con-
(5) Monitor the content and volume tent to identify potential improve-
of general activity being directed to ments at least once each calendar year,
and required of each controller at least but at intervals not to exceed 15
once each calendar year, but at inter- months. An operators program must
vals not to exceed 15 months, that will provide for training each controller to
assure controllers have sufficient time carry out the roles and responsibilities
to analyze and react to incoming defined by the operator. In addition,
alarms; and the training program must include the
(6) Address deficiencies identified following elements:
through the implementation of para- (1) Responding to abnormal operating
wreier-aviles on DSK3TPTVN1PROD with CFR
graphs (e)(1) through (e)(5) of this sec- conditions likely to occur simulta-
tion. neously or in sequence;
(f) Change management. Each operator (2) Use of a computerized simulator
must assure that changes that could or non-computerized (tabletop) method
469
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192.701 49 CFR Ch. I (10111 Edition)
470
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Pipeline and Hazardous Materials Safety Admin., DOT 192.713
line marker must be placed and main- (a) The date, location, and descrip-
tained as close as practical over each tion of each repair made to pipe (in-
buried main and transmission line: cluding pipe-to-pipe connections) must
(1) At each crossing of a public road be retained for as long as the pipe re-
and railroad; and mains in service.
(2) Wherever necessary to identify (b) The date, location, and descrip-
the location of the transmission line or tion of each repair made to parts of the
main to reduce the possibility of dam- pipeline system other than pipe must
age or interference. be retained for at least 5 years. How-
(b) Exceptions for buried pipelines. Line ever, repairs generated by patrols, sur-
markers are not required for the fol- veys, inspections, or tests required by
lowing pipelines: subparts L and M of this part must be
(1) Mains and transmission lines lo- retained in accordance with paragraph
cated offshore, or at crossings of or (c) of this section.
under waterways and other bodies of (c) A record of each patrol, survey,
water. inspection, and test required by sub-
(2) Mains in Class 3 or Class 4 loca- parts L and M of this part must be re-
tions where a damage prevention pro- tained for at least 5 years or until the
gram is in effect under 192.614. next patrol, survey, inspection, or test
is completed, whichever is longer.
(3) Transmission lines in Class 3 or 4
locations until March 20, 1996. [Amdt. 19278, 61 FR 28786, June 6, 1996]
(4) Transmission lines in Class 3 or 4
locations where placement of a line 192.711 Transmission lines: General
marker is impractical. requirements for repair procedures.
(c) Pipelines aboveground. Line mark- (a) Temporary repairs. Each operator
ers must be placed and maintained must take immediate temporary meas-
along each section of a main and trans- ures to protect the public whenever:
mission line that is located above- (1) A leak, imperfection, or damage
ground in an area accessible to the that impairs its serviceability is found
public. in a segment of steel transmission line
(d) Marker warning. The following operating at or above 40 percent of the
must be written legibly on a back- SMYS; and
ground of sharply contrasting color on (2) It is not feasible to make a perma-
each line marker: nent repair at the time of discovery.
(1) The word Warning, Caution, (b) Permanent repairs. An operator
or Danger followed by the words must make permanent repairs on its
Gas (or name of gas transported) pipeline system according to the fol-
Pipeline all of which, except for lowing:
markers in heavily developed urban (1) Non integrity management re-
areas, must be in letters at least 1 inch pairs: The operator must make perma-
(25 millimeters) high with 14 inch (6.4 nent repairs as soon as feasible.
millimeters) stroke. (2) Integrity management repairs:
(2) The name of the operator and the When an operator discovers a condition
telephone number (including area code) on a pipeline covered under Subpart O
where the operator can be reached at Gas Transmission Pipeline Integrity
all times. Management, the operator must reme-
diate the condition as prescribed by
[Amdt. 19220, 40 FR 13505, Mar. 27, 1975; 192.933(d).
Amdt. 19227, 41 FR 39752, Sept. 16, 1976, as (c) Welded patch. Except as provided
amended by Amdt. 19220A, 41 FR 56808, Dec.
30, 1976; Amdt. 19244, 48 FR 25208, June 6,
in 192.717(b)(3), no operator may use a
1983; Amdt. 19273, 60 FR 14650, Mar. 20, 1995; welded patch as a means of repair.
Amdt. 19285, 63 FR 37504, July 13, 1998] [Amdt. 192114, 75 FR 48604, Aug. 11, 2010]
471
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192.715 49 CFR Ch. I (10111 Edition)
472
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Pipeline and Hazardous Materials Safety Admin., DOT 192.727
(2) Outside business districts, at in- ner as a new service line, before recon-
tervals not exceeding 712 months, but necting. However, if provisions are
at least twice each calendar year. made to maintain continuous service,
[35 FR 13257, Aug. 19, 1970, as amended by
such as by installation of a bypass, any
Amdt. 19243, 47 FR 46851, Oct. 21, 1982; Amdt. part of the original service line used to
19278, 61 FR 28786, June 6, 1996] maintain continuous service need not
be tested.
192.723 Distribution systems: Leak-
age surveys. 192.727 Abandonment or deactiva-
(a) Each operator of a distribution tion of facilities.
system shall conduct periodic leakage (a) Each operator shall conduct aban-
surveys in accordance with this sec- donment or deactivation of pipelines in
tion. accordance with the requirements of
(b) The type and scope of the leakage this section.
control program must be determined (b) Each pipeline abandoned in place
by the nature of the operations and the must be disconnected from all sources
local conditions, but it must meet the and supplies of gas; purged of gas; in
following minimum requirements: the case of offshore pipelines, filled
(1) A leakage survey with leak detec- with water or inert materials; and
tor equipment must be conducted in sealed at the ends. However, the pipe-
business districts, including tests of line need not be purged when the vol-
the atmosphere in gas, electric, tele- ume of gas is so small that there is no
phone, sewer, and water system man- potential hazard.
holes, at cracks in pavement and side- (c) Except for service lines, each in-
walks, and at other locations providing active pipeline that is not being main-
an opportunity for finding gas leaks, at tained under this part must be discon-
intervals not exceeding 15 months, but nected from all sources and supplies of
at least once each calendar year. gas; purged of gas; in the case of off-
(2) A leakage survey with leak detec- shore pipelines, filled with water or
tor equipment must be conducted out- inert materials; and sealed at the ends.
side business districts as frequently as However, the pipeline need not be
necessary, but at least once every 5 purged when the volume of gas is so
calendar years at intervals not exceed- small that there is no potential hazard.
ing 63 months. However, for cathodi- (d) Whenever service to a customer is
cally unprotected distribution lines discontinued, one of the following must
subject to 192.465(e) on which elec- be complied with:
trical surveys for corrosion are imprac- (1) The valve that is closed to prevent
tical, a leakage survey must be con- the flow of gas to the customer must be
ducted at least once every 3 calendar provided with a locking device or other
years at intervals not exceeding 39 means designed to prevent the opening
months. of the valve by persons other than
[35 FR 13257, Aug. 19, 1970, as amended by those authorized by the operator.
Amdt. 19243, 47 FR 46851, Oct. 21, 1982; Amdt. (2) A mechanical device or fitting
19270, 58 FR 54528, 54529, Oct. 22, 1993; Amdt. that will prevent the flow of gas must
19271, 59 FR 6585, Feb. 11, 1994; Amdt. 19294, be installed in the service line or in the
69 FR 32895, June 14, 2004; Amdt. 19294, 69 FR
54592, Sept. 9, 2004]
meter assembly.
(3) The customers piping must be
192.725 Test requirements for rein- physically disconnected from the gas
stating service lines. supply and the open pipe ends sealed.
(a) Except as provided in paragraph (e) If air is used for purging, the oper-
(b) of this section, each disconnected ator shall insure that a combustible
service line must be tested in the same mixture is not present after purging.
manner as a new service line, before (f) Each abandoned vault must be
being reinstated. filled with a suitable compacted mate-
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474
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Pipeline and Hazardous Materials Safety Admin., DOT 192.743
each gas detection and alarm system 192.741 Pressure limiting and regu-
required by this section must lating stations: Telemetering or re-
(1) Continuously monitor the com- cording gauges.
pressor building for a concentration of (a) Each distribution system supplied
gas in air of not more than 25 percent
by more than one district pressure reg-
of the lower explosive limit; and
(2) If that concentration of gas is de- ulating station must be equipped with
tected, warn persons about to enter the telemetering or recording pressure
building and persons inside the build- gauges to indicate the gas pressure in
ing of the danger. the district.
(c) Each gas detection and alarm sys- (b) On distribution systems supplied
tem required by this section must be by a single district pressure regulating
maintained to function properly. The station, the operator shall determine
maintenance must include performance the necessity of installing telemetering
tests. or recording gauges in the district,
[58 FR 48464, Sept. 16, 1993, as amended by taking into consideration the number
Amdt. 19285, 63 FR 37504, July 13, 1998] of customers supplied, the operating
pressures, the capacity of the installa-
192.739 Pressure limiting and regu- tion, and other operating conditions.
lating stations: Inspection and test- (c) If there are indications of abnor-
ing.
mally high or low pressure, the regu-
(a) Each pressure limiting station, lator and the auxiliary equipment
relief device (except rupture discs), and must be inspected and the necessary
pressure regulating station and its measures employed to correct any un-
equipment must be subjected at inter-
satisfactory operating conditions.
vals not exceeding 15 months, but at
least once each calendar year, to in- 192.743 Pressure limiting and regu-
spections and tests to determine that lating stations: Capacity of relief
it is devices.
(1) In good mechanical condition;
(2) Adequate from the standpoint of (a) Pressure relief devices at pressure
capacity and reliability of operation limiting stations and pressure regu-
for the service in which it is employed; lating stations must have sufficient ca-
(3) Except as provided in paragraph pacity to protect the facilities to which
(b) of this section, set to control or re- they are connected. Except as provided
lieve at the correct pressure consistent in 192.739(b), the capacity must be
with the pressure limits of 192.201(a); consistent with the pressure limits of
and 192.201(a). This capacity must be de-
(4) Properly installed and protected termined at intervals not exceeding 15
from dirt, liquids, or other conditions months, but at least once each cal-
that might prevent proper operation. endar year, by testing the devices in
(b) For steel pipelines whose MAOP is place or by review and calculations.
determined under 192.619(c), if the (b) If review and calculations are
MAOP is 60 psi (414 kPa) gage or more, used to determine if a device has suffi-
the control or relief pressure limit is as cient capacity, the calculated capacity
follows:
must be compared with the rated or ex-
If the MAOP produces a hoop Then the pressure limit is:
perimentally determined relieving ca-
stress that is:
pacity of the device for the conditions
Greater than 72 percent of MAOP plus 4 percent. under which it operates. After the ini-
SMYS. tial calculations, subsequent calcula-
Unknown as a percentage of A pressure that will prevent
SMYS. unsafe operation of the tions need not be made if the annual
pipeline considering its op- review documents that parameters
erating and maintenance have not changed to cause the rated or
history and MAOP.
experimentally determined relieving
wreier-aviles on DSK3TPTVN1PROD with CFR
capacity to be insufficient.
[35 FR 13257, Aug. 19, 1970, as amended by
(c) If a relief device is of insufficient
Amdt. 19243, 47 FR 46851, Oct. 21, 1982; Amdt.
19293, 68 FR 53901, Sept. 15, 2003; Amdt. 192 capacity, a new or additional device
96, 69 FR 27863, May 17, 2004]
475
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192.745 49 CFR Ch. I (10111 Edition)
must be installed to provide the capac- (d) Each vault cover must be in-
ity required by paragraph (a) of this spected to assure that it does not
section. present a hazard to public safety.
[Amdt. 19293, 68 FR 53901, Sept. 15, 2003, as [35 FR 13257, Aug. 19, 1970, as amended by
amended by Amdt. 19296, 69 FR 27863, May Amdt. 19243, 47 FR 46851, Oct. 21, 1982; Amdt.
17, 2004] 19285, 63 FR 37504, July 13, 1998]
476
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Pipeline and Hazardous Materials Safety Admin., DOT 192.805
477
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192.807 49 CFR Ch. I (10111 Edition)
that ensures the safe operation of pipe- be used as the sole method of evalua-
line facilities; and tion.
(i) After December 16, 2004, notify the
[Amdt. 19286, 64 FR 46865, Aug. 27, 1999, as
Administrator or a state agency par- amended by Amdt. 19290, 66 FR 43524, Aug.
ticipating under 49 U.S.C. Chapter 601 20, 2001; Amdt. 192100, 70 FR 10335, Mar. 3,
if the operator significantly modifies 2005]
the program after the Administrator or
state agency has verified that it com- Subpart OGas Transmission
plies with this section.
Pipeline Integrity Management
[Amdt. 19286, 64 FR 46865, Aug. 27, 1999, as
amended by Amdt. 192100, 70 FR 10335, Mar. SOURCE: 68 FR 69817, Dec. 15, 2003, unless
3, 2005]
otherwise noted.
192.807 Recordkeeping. 192.901 What do the regulations in
Each operator shall maintain records this subpart cover?
that demonstrate compliance with this This subpart prescribes minimum re-
subpart. quirements for an integrity manage-
(a) Qualification records shall in- ment program on any gas transmission
clude: pipeline covered under this part. For
(1) Identification of qualified indi- gas transmission pipelines constructed
vidual(s); of plastic, only the requirements in
(2) Identification of the covered tasks 192.917, 192.921, 192.935 and 192.937
the individual is qualified to perform; apply.
(3) Date(s) of current qualification;
and 192.903 What definitions apply to this
(4) Qualification method(s). subpart?
(b) Records supporting an individ- The following definitions apply to
uals current qualification shall be this subpart:
maintained while the individual is per- Assessment is the use of testing tech-
forming the covered task. Records of niques as allowed in this subpart to as-
prior qualification and records of indi- certain the condition of a covered pipe-
viduals no longer performing covered line segment.
tasks shall be retained for a period of Confirmatory direct assessment is an in-
five years. tegrity assessment method using more
focused application of the principles
192.809 General. and techniques of direct assessment to
(a) Operators must have a written identify internal and external corro-
qualification program by April 27, 2001. sion in a covered transmission pipeline
The program must be available for re- segment.
view by the Administrator or by a Covered segment or covered pipeline seg-
state agency participating under 49 ment means a segment of gas trans-
U.S.C. Chapter 601 if the program is mission pipeline located in a high con-
under the authority of that state agen- sequence area. The terms gas and
cy. transmission line are defined in 192.3.
(b) Operators must complete the Direct assessment is an integrity as-
qualification of individuals performing sessment method that utilizes a proc-
covered tasks by October 28, 2002. ess to evaluate certain threats (i.e., ex-
(c) Work performance history review ternal corrosion, internal corrosion
may be used as a sole evaluation meth- and stress corrosion cracking) to a cov-
od for individuals who were performing ered pipeline segments integrity. The
a covered task prior to October 26, 1999. process includes the gathering and in-
(d) After October 28, 2002, work per- tegration of risk factor data, indirect
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478
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Pipeline and Hazardous Materials Safety Admin., DOT 192.903
High consequence area means an area feet) [or 200 meters]/potential impact
established by one of the methods de- radius in feet [or meters] 2).
scribed in paragraphs (1) or (2) as fol- Identified site means each of the fol-
lows: lowing areas:
(1) An area defined as (a) An outside area or open structure
(i) A Class 3 location under 192.5; or that is occupied by twenty (20) or more
(ii) A Class 4 location under 192.5; or persons on at least 50 days in any
(iii) Any area in a Class 1 or Class 2 twelve (12)-month period. (The days
location where the potential impact ra- need not be consecutive.) Examples in-
dius is greater than 660 feet (200 me- clude but are not limited to, beaches,
ters), and the area within a potential playgrounds, recreational facilities,
impact circle contains 20 or more camping grounds, outdoor theaters,
buildings intended for human occu- stadiums, recreational areas near a
pancy; or body of water, or areas outside a rural
(iv) Any area in a Class 1 or Class 2 building such as a religious facility; or
location where the potential impact (b) A building that is occupied by
circle contains an identified site. twenty (20) or more persons on at least
(2) The area within a potential im- five (5) days a week for ten (10) weeks
pact circle containing in any twelve (12)-month period. (The
(i) 20 or more buildings intended for days and weeks need not be consecu-
human occupancy, unless the exception tive.) Examples include, but are not
in paragraph (4) applies; or limited to, religious facilities, office
(ii) An identified site. buildings, community centers, general
(3) Where a potential impact circle is stores, 4-H facilities, or roller skating
calculated under either method (1) or rinks; or
(2) to establish a high consequence (c) A facility occupied by persons
area, the length of the high con- who are confined, are of impaired mo-
sequence area extends axially along bility, or would be difficult to evac-
the length of the pipeline from the out- uate. Examples include but are not
ermost edge of the first potential im- limited to hospitals, prisons, schools,
pact circle that contains either an day-care facilities, retirement facili-
identified site or 20 or more buildings ties or assisted-living facilities.
intended for human occupancy to the Potential impact circle is a circle of ra-
outermost edge of the last contiguous dius equal to the potential impact ra-
potential impact circle that contains dius (PIR).
Potential impact radius (PIR) means
either an identified site or 20 or more
the radius of a circle within which the
buildings intended for human occu-
potential failure of a pipeline could
pancy. (See figure E.I.A. in appendix
have significant impact on people or
E.)
property. PIR is determined by the for-
(4) If in identifying a high con-
mula r = 0.69* (square root of (p*d 2)),
sequence area under paragraph (1)(iii)
where r is the radius of a circular area
of this definition or paragraph (2)(i) of
in feet surrounding the point of failure,
this definition, the radius of the poten-
p is the maximum allowable oper-
tial impact circle is greater than 660 ating pressure (MAOP) in the pipeline
feet (200 meters), the operator may segment in pounds per square inch and
identify a high consequence area based d is the nominal diameter of the pipe-
on a prorated number of buildings in- line in inches.
tended for human occupancy with a
distance of 660 feet (200 meters) from NOTE: 0.69 is the factor for natural gas.
the centerline of the pipeline until De- This number will vary for other gases de-
pending upon their heat of combustion. An
cember 17, 2006. If an operator chooses
operator transporting gas other than natural
this approach, the operator must pro- gas must use section 3.2 of ASME/ANSI
rate the number of buildings intended B31.8S2001 (Supplement to ASME B31.8; in-
for human occupancy based on the corporated by reference, see 192.7) to cal-
ratio of an area with a radius of 660 culate the impact radius formula.
wreier-aviles on DSK3TPTVN1PROD with CFR
feet (200 meters) to the area of the po- Remediation is a repair or mitigation
tential impact circle (i.e., the prorated activity an operator takes on a covered
number of buildings intended for segment to limit or reduce the prob-
human occupancy is equal to 20 (660 ability of an undesired event occurring
479
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192.905 49 CFR Ch. I (10111 Edition)
or the expected consequences from the (c) Newly identified areas. When an op-
event. erator has information that the area
[68 FR 69817, Dec. 15, 2003, as amended by
around a pipeline segment not pre-
Amdt. 19295, 69 FR 18231, Apr. 6, 2004; Amdt. viously identified as a high con-
19295, 69 FR 29904, May 26, 2004; Amdt. 192 sequence area could satisfy any of the
103, 72 FR 4657, Feb. 1, 2007] definitions in 192.903, the operator
must complete the evaluation using
192.905 How does an operator iden- method (1) or (2). If the segment is de-
tify a high consequence area? termined to meet the definition as a
(a) General. To determine which seg- high consequence area, it must be in-
ments of an operators transmission corporated into the operators baseline
pipeline system are covered by this assessment plan as a high consequence
subpart, an operator must identify the area within one year from the date the
high consequence areas. An operator area is identified.
must use method (1) or (2) from the def-
inition in 192.903 to identify a high 192.907 What must an operator do to
consequence area. An operator may implement this subpart?
apply one method to its entire pipeline (a) General. No later than December
system, or an operator may apply one 17, 2004, an operator of a covered pipe-
method to individual portions of the line segment must develop and follow a
pipeline system. An operator must de- written integrity management pro-
scribe in its integrity management pro- gram that contains all the elements de-
gram which method it is applying to scribed in 192.911 and that addresses
each portion of the operators pipeline the risks on each covered transmission
system. The description must include pipeline segment. The initial integrity
the potential impact radius when uti- management program must consist, at
lized to establish a high consequence a minimum, of a framework that de-
area. (See appendix E.I. for guidance on scribes the process for implementing
identifying high consequence areas.) each program element, how relevant
(b)(1) Identified sites. An operator decisions will be made and by whom, a
must identify an identified site, for time line for completing the work to
purposes of this subpart, from informa- implement the program element, and
tion the operator has obtained from
how information gained from experi-
routine operation and maintenance ac-
ence will be continuously incorporated
tivities and from public officials with
into the program. The framework will
safety or emergency response or plan-
evolve into a more detailed and com-
ning responsibilities who indicate to
prehensive program. An operator must
the operator that they know of loca-
make continual improvements to the
tions that meet the identified site cri-
program.
teria. These public officials could in-
clude officials on a local emergency (b) Implementation Standards. In car-
planning commission or relevant Na- rying out this subpart, an operator
tive American tribal officials. must follow the requirements of this
(2) If a public official with safety or subpart and of ASME/ANSI B31.8S (in-
emergency response or planning re- corporated by reference, see 192.7) and
sponsibilities informs an operator that its appendices, where specified. An op-
it does not have the information to erator may follow an equivalent stand-
identify an identified site, the operator ard or practice only when the operator
must use one of the following sources, demonstrates the alternative standard
as appropriate, to identify these sites. or practice provides an equivalent level
(i) Visible marking (e.g., a sign); or of safety to the public and property. In
(ii) The site is licensed or registered the event of a conflict between this
by a Federal, State, or local govern- subpart and ASME/ANSI B31.8S, the re-
ment agency; or quirements in this subpart control.
(iii) The site is on a list (including a
wreier-aviles on DSK3TPTVN1PROD with CFR
list on an internet web site) or map 192.909 How can an operator change
maintained by or available from a Fed- its integrity management program?
eral, State, or local government agency (a) General. An operator must docu-
and available to the general public. ment any change to its program and
480
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Pipeline and Hazardous Materials Safety Admin., DOT 192.911
the reasons for the change before im- (e) Provisions meeting the require-
plementing the change. ments of 192.933 for remediating con-
(b) Notification. An operator must no- ditions found during an integrity as-
tify OPS, in accordance with 192.949, sessment.
of any change to the program that may (f) A process for continual evaluation
substantially affect the programs im- and assessment meeting the require-
plementation or may significantly ments of 192.937.
modify the program or schedule for (g) If applicable, a plan for confirm-
carrying out the program elements. An
atory direct assessment meeting the
operator must also notify a State or
requirements of 192.931.
local pipeline safety authority when ei-
ther a covered segment is located in a (h) Provisions meeting the require-
State where OPS has an interstate ments of 192.935 for adding preventive
agent agreement, or an intrastate cov- and mitigative measures to protect the
ered segment is regulated by that high consequence area.
State. An operator must provide the (i) A performance plan as outlined in
notification within 30 days after adopt- ASME/ANSI B31.8S, section 9 that in-
ing this type of change into its pro- cludes performance measures meeting
gram. the requirements of 192.945.
[68 FR 69817, Dec. 15, 2003, as amended by (j) Record keeping provisions meet-
Amdt. 19295, 69 FR 18231, Apr. 6, 2004] ing the requirements of 192.947.
(k) A management of change process
192.911 What are the elements of an as outlined in ASME/ANSI B31.8S, sec-
integrity management program? tion 11.
An operators initial integrity man- (l) A quality assurance process as
agement program begins with a frame- outlined in ASME/ANSI B31.8S, section
work (see 192.907) and evolves into a 12.
more detailed and comprehensive in- (m) A communication plan that in-
tegrity management program, as infor- cludes the elements of ASME/ANSI
mation is gained and incorporated into B31.8S, section 10, and that includes
the program. An operator must make procedures for addressing safety con-
continual improvements to its pro- cerns raised by
gram. The initial program framework
(1) OPS; and
and subsequent program must, at min-
(2) A State or local pipeline safety
imum, contain the following elements.
(When indicated, refer to ASME/ANSI authority when a covered segment is
B31.8S (incorporated by reference, see located in a State where OPS has an
192.7) for more detailed information interstate agent agreement.
on the listed element.) (n) Procedures for providing (when
(a) An identification of all high con- requested), by electronic or other
sequence areas, in accordance with means, a copy of the operators risk
192.905. analysis or integrity management pro-
(b) A baseline assessment plan meet- gram to
ing the requirements of 192.919 and (1) OPS; and
192.921. (2) A State or local pipeline safety
(c) An identification of threats to authority when a covered segment is
each covered pipeline segment, which located in a State where OPS has an
must include data integration and a interstate agent agreement.
risk assessment. An operator must use (o) Procedures for ensuring that each
the threat identification and risk as- integrity assessment is being con-
sessment to prioritize covered seg- ducted in a manner that minimizes en-
ments for assessment ( 192.917) and to vironmental and safety risks.
evaluate the merits of additional pre-
(p) A process for identification and
ventive and mitigative measures
assessment of newly-identified high
( 192.935) for each covered segment.
wreier-aviles on DSK3TPTVN1PROD with CFR