ISS. GOVERNMENT INFORMATION GPO

Pt. 177 49 CFR Ch. I (10—1—10 Edition)

WARNING—MAY CONTAIN EXPLO engine using liquid fuel that has a flash SIVE MIXTURES WITH AIR—KEEP point less than 38 °C (100 5F), the fuel IGNITION SOURCES AWAY WHEN tank is empty, and the engine is run OPENING until it stalls for lack of fuel; (2) The motor vehicle or mechanical (6) A motor vehicle or mechanical equipment has an internal combustion equipments ignition key may in not be engine using liquid fuel that has a flash the ignition while the vehicle or me point of 38 °C (100 °F) or higher, the fuel chanical equipment is stowed aboard a tank contains 418 L (110 gallons) of fuel vessel. or less, and there are no fuel leaks in (b) All equipment used for handling any portion of the fuel system; vehicles or mechanical equipment (3) The motor vehicle or mechanical must be designed so that the fuel tank equipment is stowed in a hold or com and fuel system of the vehicle or me partment designated by the adminis chanical equipment are protected from tration of the country in which the stress that might cause rupture or vessel is registered other damage incident to handling. to be specially suit (c) Two hand-held, portable, dry ed for vehicles. See 46 CFR 70.10-1 and chemical fire extinguishers of at least 90.10—38 for U.S. vessels; 4.5 kg (10 pounds) capacity each must (4) The motor vehicle or mechanical equipment be separately located in an accessible is electrically powered by location in each hold or compartment wet electric storage batteries; or in which any motor vehicle or mechan (5) The motor vehicle or mechanical ical equipment is stowed. equipment is equipped with liquefied (d) “NO SMOKING” signs must be petroleum gas or other compressed gas conspicuously posted at each access fuel tanks, the tanks are completely opening to the hold or compartment. emptied of liquid and the positive pres (e) Each portable electrical light, in sure in the tank does not exceed 2 bar cluding a flashlight, used in the stow (29 psig), the line from the fuel tank to age area must be an approved, explo the regulator and the regulator itself is sion-proof type. All electrical connec drained of all trace of (liquid) gas, and tions for any portable light must be the fuel shut-off valve is closed. made to outlets outside the space in (j) Except as provided in §173.220(d) of which any vehicle or mechanical equip this subchapter, the provisions of this ment is stowed. subchapter do not apply to items of (f) Each hold or compartment must equipment such as fire extinguishers, be ventilated and fitted with an over compressed gas accumulators, airbag head water sprinkler system or fixed inflators and the like which are in fire extinguishing system. stalled in the motor vehicle or mechan (g) Each hold or compartment must ical equipment if they are necessary be equipped with a smoke or fire detec for the operation of the vehicle or tion system capable of alerting per equipment, or for the safety of its oper sonnel on the bridge. ator or passengers. (h) All electrical equipment in the [Amdt. 176—43, 62 FR 24742, May 6, 1997, as hold or compartment other than fixed amended at 65 FR 58630, Sept. 29, 2000; 66 FR explosion-proof lighting must be dis 45384, 45385, Aug. 28, 2001; 70 FR 56099, Sept. connected from its power source at a 23, 20051 location outside the hold or compart ment during the handling and trans PART 177—CARRIAGE BY PUBLIC portation of any vehicle or mechanical HIGHWAY equipment. Where the disconnecting means is a switch or circuit breaker, it Subpart A—General Information and must be locked in the open position Regulations until all vehicles have been removed. (i) Exceptions. A motor vehicle or me Sec. chanical equipment is excepted from 177.800 Purpose and scope of this part and responsibility for compliance and train the requirements of this subchapter if ing. the following requirements are met: 177.801 Unacceptable hazardous materials (1) The motor vehicle or mechanical shipments. equipment has an internal combustion 177.802 Inspection.

796 Pipeline and Hazardous Materials Safety Admin., DOT § 177.810 177.804 Compliance with Federal Motor Car and shall ensure its hazmat employees rier Safety Regulations. receive training in relation thereto. 177.810 Vehicular tunnels. (c) Responsibility for training. A car 177.816 Driver training. may 177.817 Shipping . rier not transport a hazardous ma 177.823 Movement of motor vehicles in terial by motor vehicle unless each of emergency situations. its hazmat employees involved in that transportation is trained as required Subpart B—Loading and Unloading by this part and subpart H of part 172 of this subchapter. 177.834 General requirements. (d) No unnecessary delay in movement 177.835 Class 1 materials. 177.837 Class 3 materials. of shipments. All shipments of haz 177.838 Class 4 (flammable solid) materials, ardous materials must be transported Class 5 (oxidizing) materials, and Divi without unnecessary delay, from and sion 4.2 (pyroforic liquid) materials. including the time of commencement 177.839 Class 8 (corrosive) materials. of the loading of the hazardous mate 177.840 Class 2 (gases) materials. rial until its final unloading at destina 177.841 Division 6.1 and Division 2.3 mate tion. rials. 177.842 Class 7 (radioactive) material. [Amdt. 177—79, 57 FR 20954, May 15, 1992, as 177.843 Contamination of vehicles. amended by Amdt.177—86, 61 FR 18933, Apr. 29. 19961 Subpart C—Segregation and Separation Chart of Hazardous Materials § 177.801 Unacceptable hazardous ma terials shipments. 177.848 Segregation of hazardous materials. No person may accept for transpor Subpart D—Vehicles and Shipments in tation or transport by motor vehicle a Transit; Accidents forbidden material or hazardous mate rial that is not prepared in accordance 177.854 Disabled vehicles and broken or with the requirements of this sub leaking packages; repairs. chapter. Subpart E—Regulations Applying to Haz lAmdt. 177—87. 61 FR 27175, May 30. 1996] ardous Material on Motor Vehicles Carrying Passengers for Hire § 177.802 Inspection. Records, equipment, packagings and 177.870 Regulations for passenger carrying vehicles. under the control of a motor carrier, insofar as they affect AUTHORITY: 49 U.S.C. 5101-5127; 49 CFR 1.53. safety in transportation of hazardous materials by motor vehicle, must be Subpart A—General Information made available for examination and in and Regulations spection by a duly authorized rep resentative of the Department. § 177.800 Purpose and scope of this part and responsibility for compli lAmdt. 177—71. 54 FR 25015. June 12. 19891 ance and training. § 177.804 Compliance with Federal (a) Purpose and scope. This part pre Motor Carrier Safety Regulations. scribes requirements, in addition to Motor carriers and other persons sub those contained in parts 171, 172, 173, ject to this part must comply with 49 178 and 180 of this subchapter, that are CFR part 383 and 49 CFR parts 390 applicable to the acceptance and trans through 397 (excluding §397.3 and 397.9) portation of hazardous materials by to the extent those regulations apply. private, common, or contract carriers by motor vehicle. 168 FR 23842, May 5, 2003] (b) Responsibility for compliance. Un less this subchapter specifically pro § 177.810 Vehicular tunnels. vides that another person shall perform Except as regards Class 7 (radio a particular duty, each carrier, includ active) materials, nothing contained in ing a connecting carrier, shall perform parts 170—189 of this subchapter shall be the duties specified and comply with so construed as to nullify or supersede all applicable requirements in this part regulations established and published 797 § 177.816 49 CFR Ch. I (10—1—10 Edition) under authority of State statute or subchapter and have the appropriate municipal ordinance regarding the State-issued commercial driver’s li kind, character, or quantity of any cense required by 49 CFR part 383. Spe hazardous material permitted by such cialized training shall include the fol regulations to be transported through lowing: any urban vehicular tunnel used for (1) Operation of emergency control mass transportation. features of the cargo tank or portable [Amdt. 177—52, 46 FR 5316, Jan. 19, 1981, as tank; amended by Amdt. 177-78, 55 FR 52710, Dec. (2) Special vehicle handling charac 21, 1990; 62 FR 51561, Oct. 1, 1997] teristics, including: high center of gravity, fluid-load subject to surge, ef § 177.816 Driver training. fects of fluid-load surge on braking, (a) In addition to the training re characteristic differences in stability quirements of §177.800, no carrier may among baffled, unbaffled, and multi transport, or cause to be transported, a compartmented tanks; and effects of hazardous material unless each hazmat partial loads on vehicle stability; employee who will operate a motor ve (3) Loading and unloading proce hicle has been trained in the applicable dures; requirements of 49 CFR parts 390 (4) The properties and hazards of the through 397 and the procedures nec material transported; and essary for the safe operation of that (5) Retest and inspection require motor vehicle. Driver training shall in ments for cargo tanks. clude the following subjects: (c) The training required by para (I) Pre-trip safety inspection; graphs (a) and (b) of this section may (2) Use of vehicle controls and equip be satisfied by compliance with the ment, including operation of emer current requirements for a Commercial gency equipment; Driver’s License (CDL) with a tank ve (3) Operation of vehicle, including hicle or hazardous materials endorse turning, backing, braking, parking, ment. handling, and vehicle characteristics (d) Training required by paragraph including those that affect vehicle sta (b) of this section must conform to the bility, such as effects of braking and requirements of § 172.704 of this sub curves, effects of speed on vehicle con chapter with respect to frequency and trol, dangers associated with maneu recordkeeping. vering through curves, dangers associ ated with weather or road conditions [Amdt. 177—79, 57 FR 20954, May 15, 1992, as that a driver may experience (e.g., bliz amended by Amdt. 177-79, 58 FR 5852, Jan. 22, zards, mountainous terrain, high 1993] winds), and high center of gravity; § 177.817 Shipping papers. (4) Procedures for maneuvering tun nels, bridges, and railroad crossings; (a) General requirements. A person (5) Requirements pertaining to at may not accept a hazardous material tendance of vehicles, parking, smok for transportation or transport a haz ing, routing, and incident reporting; ardous material by highway unless and that person has received a shipping (6) Loading and unloading of mate prepared in accordance with part rials, including— 172 of this subchapter or the material (i) Compatibility and segregation of is excepted from shipping paper re cargo in a mixed load; quirements under this subchapter. A (ii) Package handling methods; and subsequent carrier may not transport a (iii) Load securement. hazardous material unless it is accom (b) Specialized requirements for cargo panied by a shipping paper prepared in tanks and portable tanks. In addition to accordance with part 172 of this sub the training requirement of paragraph chapter, except for §172.204, which is (a) of this section, each person who op not required. erates a cargo tank or a vehicle with a (b) Shipper certification. An initial portable tank with a capacity of 1,000 carrier may not accept a hazardous gallons or more must receive training material offered for transportation un applicable to the requirements of this less the shipping paper describing the 798 Pipeline and Hazardous Materials Safety Admin., DOT § 177.823 material includes a shipper’s certifi copy or an electronic image thereof, cation which meets the requirements that is accessible at or through its in §172.204 of this subchapter. Except principal place of business and must for a hazardous waste, the certification make the shipping paper available, is not required for shipments to be upon request, to an authorized official transported entirely by private car of a Federal, State, or local govern riage and for bulk shipments to be ment agency at reasonable times and transported in a cargo tank supplied by locations. For a hazardous waste, the the carrier. shipping paper copy must be retained (c) Requirements when interlining with for three years after the material is ac carriers by rail. A motor carrier shall cepted by the initial carrier. For all mark on the shipping paper required by other hazardous materials, the ship this section, if it offers or delivers a ping paper copy must be retained for freight or transport vehicle one year after the material is accepted to a rail carrier for further transpor by the carrier. Each shipping paper tation: copy must include the date of accept (1) A description of the freight con ance by the carrier, A motor carrier (as tainer or transport vehicle; and defined in §390.5 of subchapter B of (2) The kind of placard affixed to the chapter III of subtitle B) using a ship freight container or transport vehicle. ping paper without change for multiple (d) This subpart does not apply to a shipments of one or more hazardous material that is excepted from ship materials having the same shipping ping paper requirements as specified in name and identification number may § 172.200 of this subchapter. retain a single copy of the shipping (e) Shipping paper accessibility—acci paper, instead of a copy for each ship dent or inspection. A driver of a motor ment made, if the carrier also retains a vehicle containing hazardous material, record of each shipment made that in and each carrier using such a vehicle, cludes shipping name, identification shall ensure that the shipping paper re number, quantity transported, and quired by this section is readily avail date of shipment. able to, and recognizable by, authori jAmdt. 177—35, 41 FR 16130, Apr. 15, 1976, as ties in the event of accident or inspec amended by Amdt. 177-35A, 41 FR 40691, Sept. tion. Specifically, the driver and the 20, 1976; Amdt. 177—48, 45 FR 47670, Nov. 10, carrier shall: 1980; Amdt. 177—65, 50 FR 11055, Mar. 19, 1985; (1) Clearly distinguish the shipping Amdt. 177—72, 53 FR 17160, May 13, 1988: 67 FR 46128, July 12, 67 paper, if it is carried with other ship 2002; FR 66574, Nov. 1, 2002; 68 FR 19277, Apr. 18, 2003; 68 FR 57633, Oct. 6, ping papers or other papers of any 2003: 70 FR 73165, Dec. 9, 20051 kind, by either distinctively tabbing it or by having it appear first; and § 177.823 Movement of motor vehicles (2) Store the shipping paper as fol in emergency situations. lows: (a) A carrier may not move a trans (i) When the driver is at the vehicle’s port vehicle containing a hazardous controls, the shipping paper shall be: material unless the vehicle is marked (A) Within his immediate reach while and placarded in accordance with part he is restrained by the lap belt; and (B) 172 or as authorized in § 17l.12a of this either readily visible to a person enter subchapter, or unless, in an emergency: ing the driver’s compartment or in a (1) The vehicle is escorted by a rep holder which is mounted to the inside resentative of a state or local govern of the door on the driver’s side of the ment; vehicle. (2) The carrier has permission from (ii) When the driver is not at the ve the Department; or hicle’s controls, the shipping paper (3) Movement of the transport vehicle shall be: (A) In a holder which is is necessary to protect life or property. mounted to the inside of the door on (b) Disposition of contents of cargo tank the driver’s side of the vehicle; or (B) when unsafe to continue. In the event of on the driver’s seat in the vehicle. a leak in a cargo tank of such a char (f) Retention of shipping papers. Each acter as to make further transpor person receiving a shipping paper re tation unsafe, the leaking vehicle quired by this section must retain a should be removed from the traveled 799 § 177.834 49 CFR Ch. 1(10—1—10 Edition) portion of the highway and every avail liquid), Class 4 (flammable solid), Class able means employed for the safe dis 5 (oxidizing), or Division 2.1 (flammable posal of the leaking material by pre gas) materials is forbidden. venting, so far as practicable, its (d) Keep fire away, loading and unload spread over a wide area, such as by ing. Extreme care shall be taken in the digging trenches to drain to a hole or loading or unloading of any Class I (ex depression in the ground, diverting the plosive), Class 3 (flammable liquid), liquid away from streams or sewers if Class 4 (flammable solid), Class 5 (oxi possible, or catching the liquid in con dizing), or Division 2.1 (flammable gas) tainers if practicable. Smoking, and materials into or from any motor vehi any other source of ignition, in the vi cle to keep fire away and to prevent cinity of a leaking cargo tank is not persons in the vicinity from smoking, permitted. lighting matches, or carrying any (c) Movement of leaking cargo tanks. A flame or lighted cigar, pipe, or ciga leaking cargo tank may be transported rette. only the minimum distance necessary (e) Handbrake set while loading and to reach a place where the contents of unloading. No hazardous material shall the tank or compartment may be dis be loaded into or on, or unloaded from, posed of safely. Every available means any motor vehicle unless the hand- must be utilized to prevent the leakage brake be securely set and all other rea or spillage of the liquid upon the high sonable precautions be taken to pre way. vent motion of the motor vehicle dur [Amdt. 177-35, 41 FR 16130, Apr. 15, 1976, as ing such loading or unloading process. amended by Amdt. 177-67, 50 FR 41521, Oct. (I) Use of tools, loading and unloading. 11, 1985; Amdt. 177-86, 61 FR 18933, Apr. 29, No tools which are likely to damage 1996] the effectiveness of the of any package or other container, or likely Subpart B—Loading and adversely to affect such package or Unloading container, shall be used for the loading or unloading of any Class 1 (explosive) NOTE: For prohibited loading and storage material or other dangerous article. of hazardous materials, see § 177.848. (g) [Reserved] (h) Precautions concerning containers § 177.834 General requirements. in transit; fueling road units. Reasonable (a) Packages secured in a motor vehicle. care should be taken to prevent undue Any package containing any hazardous rise in temperature of containers and material, not permanently attached to their contents during transit. There a motor vehicle, must be secured must be no tampering with such con against shifting, including relative mo tainer or the contents thereof nor any tion between packages, within the ve discharge of the contents of any con hicle on which it is being transported, tainer between point of origin and under conditions normally incident to point of billed destination. Discharge transportation. Packages having valves of contents of any container, other or other fittings must be loaded in a than a cargo tank or TM portable tank, manner to minimize the likelihood of must not be made prior to removal damage during transportation. from the motor vehicle. Nothing con (b) Each package containing a haz tained in this paragraph shall be so ardous material bearing package ori construed as to prohibit the fueling of entation markings prescribed in machinery or vehicles used in road con §172.312 of this subchapter must be struction or maintenance. loaded on a transport vehicle or within (i) Attendance requirements— (1) Load a freight container in accordance with ing. A cargo tank must be attended by such markings and must remain in the a qualified person at all times when it correct position indicated by the mark is being loaded. The person who is re ings during transportation. sponsible for loading the cargo tank is (c) No smoking while loading or unload also responsible for ensuring that it is ing. Smoking on or about any motor so attended. vehicle while loading or unloading any (2) Unloading. A motor carrier who Class 1 (explosive), Class 3 (flammable transports hazardous materials by a

800 Pipeline and Hazardous Materials Safety Admin., DOT § 177.834 cargo tank must ensure that the cargo (2) When transporting certain flam tank is attended by a qualified person mable material—(i) Use of combustion at all times during unloading. How cargo heaters. A motor vehicle equipped ever, the carrier’s obligation to ensure with a combustion cargo heater may be attendance during unloading ceases used to transport Class 3 (flammable when: liquid) or Division 2.1 (flammable gas) (i) The carrier’s obligation for trans materials only if each of the following porting the materials is fulfilled; requirements are met: (ii) The cargo tank has been placed (A) It is a catalytic heater. upon the consignee’s premises; and (B) The heater’s surface temperature (iii) The motive power has been re cannot exceed 54 °C (130 °F)—either on moved from the cargo tank and re a thermostatically controlled heater or moved from the premises. on a heater without thermostatic con (3) Except for unloading operations trol when the outside or ambient tem subject to § 177.837(d), 177.840(p), and perature is 16 °C (61 °F) or less. 177.840(q), a qualified person ‘attends” (C) The heater is not ignited in a the loading or unloading of a cargo loaded vehicle. tank if, throughout the process, he is (D) There is no flame, either on the alert and is within 7.62 m (25 feet) of catalyst or anywhere in the heater. the cargo tank. The qualified person (F) The manufacturer has certified attending the unloading of a cargo that the heater meets the requirements tank must have an unobstructed view under paragraph (1) (2) (i) of this section of the cargo tank and delivery hose to by permanently marking the heater the maximum extent practicable dur “MEETS DOT REQUIREMENTS ing the unloading operation. FOR CA TAL YTIC HEA TERS USED WITH (4) A person is “qualified” if he has FLAMMABLE LIQUID AND GAS.” been made aware of the nature of the (F) The hazardous material which is to be load heater is also marked “DO ed or unloaded, he has been instructed NOT LOAD INTO OR USE IN CARGO on the procedures to be followed in COMPARTMENTS CONTAINING FLAM emergencies, he is authorized to move MABLE LIQUID OR GAS IF FLAME IS the cargo tank, and he has the means VISIBLE ON CA TAL YST OR IN HEAT to do so. ER.” (j) Except for a cargo tank con (G) Heater requirements under forming to § 173.29(b)(2) of this sub §393.77 of this title are complied with. chapter, a person may not drive a (ii) Effective date for combustion heater cargo tank motor vehicle containing a requirements. The requirements under hazardous material regardless of quan paragraph (1) (2) (1) of this section gov tity unless: ern as follows: (I) All manhole closures are closed (A) Use of a heater manufactured and secured; and after November 14, 1975, is governed by (2) All valves and other closures in every requirement under (1) (2) (i) of this liquid discharge systems are closed and section; free of leaks, (B) Use of a heater manufactured be (k) [Reservedi fore November 15, 1975, is governed (1) Use of cargo heaters when trans only by the requirements under (l)(2)(i) porting certain hazardous material, (A), (C), (D), (F) and (G) of this section Transportation includes loading, car until October 1, 1976; and rying, and unloading. (C) Use of any heater after September (I) When transporting Class I (explo 30, 1976, is governed by every require sive) materials. A motor vehicle ment under paragraph (l)(2)(i) of this equipped with a cargo heater of any section. type may transport Class 1 (explosive) (iii) Restrictions on automatic cargo materials only if the cargo heater is space-heating temperature control devices. rendered inoperable by: (i) Draining or Restrictions on these devices have two removing the cargo heater fuel tank; dimensions: Restrictions upon use and and (ii) disconnecting the heater’s restrictions which apply when the de power source. vice must not be used. 801 § 177.834 49 CFR Ch. 1(10—1—10 Edition)

(A) Use restrictions. An automatic and for trailer-on-flat-car service is re cargo-space-heating temperature con quired. trol device may be used when trans (n) Specification 56, 57, TM 101, and porting Class 3 (flammable liquid) or IM 102 portable tanks, when loaded, Division 2.1 (flammable gas) materials may not be stacked on each other nor only if each of the following require placed under other freight during ments is met: transportation by motor vehicle. (1) Electrical apparatus in the cargo (o) Unloading of IM and UN portable compartment is nonsparking or explo tanks. No person may unload an TM or sion proof. UN portable tank while it remains on a (2) There is no combustion apparatus transport vehicle with the motive in the cargo compartment. power unit attached except under the ( There is no connection for return following conditions: of air from the cargo compartment to (1) The unloading operation must be the combustion apparatus. attended by a qualified person in ac (4) The heating system will not heat cordance with the requirements in any part of the cargo to more than 54 paragraph (i) of this section. The per °C (129 °F). son performing unloading functions (. Heater requirements under §393.77 must be trained in handling emer of this title are complied with. gencies that may occur during the un loading operation. (B) Protection against use. Class 3 operator (flammable liquid) or Division 2.1 (2) Prior to unloading, the of the vehicle on which the portable (flammable gas) materials may be ascertain transported by a vehicle, which is tank is transported must equipped with an automatic cargo- that the conditions of this paragraph are space-heating temperature control de (o) met. vice that does not meet each require (3) An TM or UN portable tank outlet ment of paragraph (l)(2)(iii)(A) of this equipped with a bottom as au section, only if the device is first ren thorized in Column (7) of the §172.101 Table of this subchapter assignment dered inoperable, as follows: by of a T Code in the appropriate proper (1) Each cargo heater fuel tank, if shipping name entry, and that contains other than LPG, must be emptied or a liquid hazardous material of Class 3, removed. PG I or IT, or PG III with a flash point (2) Each LPG fuel tank for automatic of less than 100 °F (38 °C); Division 5.1, temperature control equipment must PG I or II; or Division 6.1, PG I or II, have its discharge valve closed and its must conform to the outlet require fuel feed line disconnected. ments in §178.275(d)(3) of this sub (m) Tanks constructed and main chapter; or, until October 1, 2004, be un tained in compliance with Spec. l06A loaded only at a facility conforming to or 110A (179.300, 179.301 of this sub the following— chapter) that are authorized for the (1) The applicable fire suppression re shipment of hazardous materials by quirements in 29 CFR 1910.106(e), (f), highway in part 173 of this subchapter (g), (h), and (1); must be carried in accordance with the (ii) The emergency shutdown require following requirements: ments in 29 CFR 1910.119(f), 1910.120(q) (1) Tanks must be securely chocked and 1910.38(a); or clamped on vehicles to prevent any (iii) The emergency response plan shifting. ning requirements in 29 CFR part 1910 (2) Equipment suitable for handling a and 40 CFR part 68; tank must be provided at any point (iv) An emergency discharge control where a tank is to be loaded upon or re procedure applicable to unloading oper moved from a vehicle. ations, including instructions on han (3) No more than two cargo carrying dling emergencies that may occur dur vehicles may be in the same combina ing the unloading operation; and tion of vehicles. (v) Public access to the unloading (4) Compliance with §l74.200 and area must be controlled in a manner 174.204 of this subchapter for combina ensuring no public access during un tion rail freight, highway shipments loading.

802 Pipeline and Hazardous Materials Safety Admin., DOT § 177.835 (4) Alternatively, conformance to (2) Any full trailer in the combina equivalent or more stringent non-fed tion has a wheel base of less than 184 eral requirements is authorized in inches; place of paragraphs (o) (3) (i) through (3) Any vehicle in the combination is (o) (3) (iv) of this section. a cargo tank which is required to be marked or placarded under §177.823; or [29 FR 18795, Dec. 29, 1964. 32 Redesignated at (4) The other vehicle in the combina FR 5606, Apr. 5, 1967] tion contains any: EDITORIAL NOTE: For FEDERAL REGISTER ci (i) Substances, explosive, n.o.s., Divi tations affecting § 177.834, see the List of CFR sion 1.1A (explosive) material (Initi Sections Affected which appears in the Find ating explosive), ing Aids section of the printed volume and (ii) Packages of Class 7 (radioactive) on GPO Access. materials bearing “Yellow III” , (iii) Division 2.3, Hazard § 177.835 Class 1 materials. Zone A or Hazard Zone B materials or Division (See also § 177.834 (a) to (j).) 6.1, PG I, Hazard Zone A materials, or (a) Engine stopped. No Class 1 (explo (iv) Hazardous materials in a port sive) materials shall be loaded into or able tank or a DOT specification 106A on or be unloaded from any motor vehi or llOA tank. cle with the engine running. (d) [Reservedj (b) Care in loading, unloading, or other (e) No sharp projections inside body of handling of Class 1 (explosive) materials. vehicles. No motor vehicle transporting No bale hooks or other metal tools any kind of Class 1 (explosive) material shall be used for the loading, unload shall have on the interior of the body ing, or other handling of Class 1 (explo in which the Class 1 (explosive) mate sive) materials, nor shall any package rials are contained, any inwardly pro or other container of Class 1 (explosive) jecting bolts, screws, nails, or other in materials, except or , be wardly projecting parts likely to rolled. No packages of Class 1 (explo produce damage to any package or con sive) materials shall be thrown or tainer of Class 1 (explosive) materials dropped during process of loading or during the loading or unloading process unloading or handling of Class 1 (explo or in transit. sive) materials. Special care shall be (f) Class 1 (explosive) materials vehicles, exercised to the end that packages or floors tight and lined. Motor vehicles other containers containing Class 1 (ex transporting Division 1.1, 1.2, or 1.3 (ex plosive) materials shall not catch fire plosive) materials shall have tight from sparks or hot gases from the ex floors; shall have that portion of the haust tailpipe. interior in contact with the load lined with either non-metallic material or (1) Whenever tarpaulins are used for non-ferrous metals, except that the lin covering Class 1 (explosive) materials, ing is not required for truck load ship they shall be secured by means of rope, ments loaded by the Departments of wire, or other equally efficient tie the Army, Navy or Air Force of the downs. Class 1 (explosive) materials United States Government provided placards or markings required by the Class 1 (explosive) materials are of 177.823 shall be secured, in the appro § such nature that they are not liable to priate locations, directly to the equip leakage of dust, powder, or vapor which ment transporting the Class 1 (explo might become the cause of an explo sive) materials. If the vehicle is pro sion. The interior of the cargo space vided with placard boards, the placards must be in good condition so that there must be applied to these boards. will not be any likelihood of containers (2) [Reservedl being damaged by exposed bolts, nuts, (c) Class 1 (explosive) materials on vehi broken side panels or floor boards, or cles in combination. Division 1.1 or 1.2 any similar projections. (explosive) materials may not be load (g) No detonator assembly or booster ed into or carried on any vehicle or a with detonator may be transported on combination of vehicles if: the same motor vehicle with any Divi (I) More than two cargo carrying ve sion 1.1, 1.2 or 1.3 material (except hicles are in the combination; other detonator assemblies, boosters 803 § 177.837 49 CFR Ch. I (10—1—10 Edition) with detonators or detonators), deto in either event care must be taken to nating cord Division 1.4 material or Di protect the load from moisture and vision 1.5 material. No detonator may sparks, except that subject to other be transported on the same motor vehi provisions of these regulations, Class 1 cle with any Division 1.1, 1.2 or 1.3 ma (explosive) materials other than black terial (except other detonators, deto powder may be transported on flat-bed nator assemblies or boosters with deto vehicles if the explosive portion of the nators), detonating cord Division 1.4 load on each vehicle is packed in fire material or Division 1.5 material un and water resistant containers or cov less— ered with a fire and water resistant (I) It is packed in a specification MC tarpaulin. 201 ( 178.318 of this subchapter) con (i) Class 1 (explosive) materials to be tainer; or protected against damage by other lading. (2) The package conforms with re No motor vehicle transporting any quirements prescribed in § 173.62 of this Class 1 (explosive) material may trans subchapter, and its use is restricted to port as a part of its load any metal or instances when— other articles or materials likely to (i) There is no Division 1.1, 1.2, 1.3 or damage such Class 1 (explosive) mate 1.5 material loaded on the motor vehi rial or any package in which it is con cle; and tained, unless the different parts of (ii) A separation of 61 cm (24 inches) such load be so segregated or secured is maintained between each package of in place in or on the motor vehicle and detonators and each package of deto separated by bulkheads or other suit nating cord; or able means as to prevent such damage. (3) It is packed and loaded in accord (j) Transfer of Class 1 (explosive) mate ance with a method approved by the rials en route. No Division 1.1, 1.2, or 1.3 Department. One method approved by (explosive) material shall be trans the Department requires that— ferred from one container to another, (1) The detonators are in packagings or from one motor vehicle to another as prescribed in § 173.63 of this sub vehicle, or from another vehicle to a chapter which in turn are loaded into motor vehicle, on any public highway, suitable containers or separate com street, or road, except in of emer partments; and gency. In such cases red electric lan (ii) That both the detonators and the terns, red emergency reflectors or red container or compartment meet the re flags shall be set out in the manner quirements of the Institute of Makers prescribed for disabled or stopped of Explosives’ Safety Library Publica motor vehicles. (See Motor Carrier tion No. 22 (IBR, see § 171.7 of this sub Safety Regulations, part 392 of this chapter). title.) In any event, all practicable (h) Lading within body or covered tail means, in addition to these herein- gate closed. Except as provided in para before prescribed, shall be taken to graph (g) of this section, dealing with protect and warn other users of the the transportation of liquid nitroglyc highway against the hazard involved in erin, desensitized liquid nitroglycerin any such transfer or against the hazard or diethylene glycol dinitrate, all of occasioned by the emergency making that portion of the lading of any motor such transfer necessary. vehicle which consists of Class 1 (explo [29 FR 18795, Dec. 29, 1964. Redesignated at 32 sive) materials shall be contained en FR 5606, Apr. 5, 1967] tirely within the body of the motor ve EDITORIAL NOTE: For FEDERAL REGISTER ci hicle or within the horizontal outline tations affecting § 177.835, see the List of CFR thereof, without overhang or projec Sections Affected which appears in the Find tion of any part of the load and if such ing Aids section of the printed volume and motor vehicle has a tailboard or tail on GPO Access. gate, it shall be closed and secured in place during such transportation. § 177.837 Class 3 materials. Every motor vehicle transporting Class (See also § 177.834 (a) to (j).) 1 (explosive) materials must either (a) Engine stopped. Unless the engine have a closed body or have the body of a cargo tank motor vehicle is to be thereof covered with a tarpaulin, and used for the operation of a pump, Class

804 Pipeline and Hazardous Materials Safety Admin., DOT § 177.838 3 material may not be loaded into, or so that there is no release of vapor at on, or unloaded from any cargo tank a point where a spark could occur, motor vehicle while the engine is run bonding or grounding is not required. ning. The diesel engine of a cargo tank Contact of the closed connection must motor vehicle may be left running dur be made before flow starts and must ing the loading and unloading of a not be broken until after the flow is Class 3 material if the ambient atmos completed. pheric temperature is at or below —12 (3) Bonding or grounding is not re °C (10 °F). quired when a cargo tank is unloaded (b) Bonding and grounding containers through a nonvapor-tight connection other than cargo tanks prior to and dur into a stationary tank provided the ing transfer of lading. For containers metallic filling connection is main which are not in metallic contact with tained in contact with the filling hole. each other, either metallic bonds or (d) Unloading combustible liquids. For ground conductors shall be provided for a cargo tank unloading a material the neutralization of possible static meeting the definition for combustible charges prior to and during transfers of liquid in §173.150(1) of this subchapter, Class 3 (flammable liquid) materials the qualified person attending the un between such containers. Such bonding loading operation must remain within shall be made by first connecting an 45.72 meters (150 feet) of the cargo tank electric conductor to the container to and 7.62 meters (25 feet) of the delivery be filled and subsequently connecting hose and must observe both the cargo the conductor to the container from tank and the receiving container at which the liquid is to come, and not in least once every five minutes during any other order. To provide against ig unloading operations that take more nition of vapors by discharge of static than five minutes to complete. electricity, the latter connection shall 129 FR 18795, Dec. 29. 19641 be made at a point well removed from the opening from which the Class 3 EDITORIAL NOTE: For FEDERAL REGIsTER ci (flammable liquid) material is to be tations affecting § 177.837, see the List of CFR discharged. Sections Affected which appears in the Find ing Aids section of the printed volume and Cc) Bonding and grounding cargo tanks on GPO Access. before and during transfer of lading. (1) When a cargo tank is loaded through § 177,S38 Class 4 (flammable solid) ma an open filling hole, one end of a bond terials, Class 5 (oxidizing) mate wire shall be connected to the sta rials, and Division 4.2 (pyroforic liq tionary system piping or integrally uid) materials. connected steel framing, and the other (See also § 177.834 (a) to (j).) end to the shell of the cargo tank to (a) Lading within body or covered; tail provide a continuous electrical connec gate closed; pick-up and delivery. All of tion. (If bonding is to the framing, it is that portion of the lading of any motor essential that piping and framing be vehicle transporting Class 4 (flam electrically interconnected.) This con mable solid) or Class 5 (oxidizing) ma nection must be made before any fill terials shall be contained entirely ing hole is opened, and must remain in within the body of the motor vehicle place until after the last filling hole and shall be covered by such body, by has been closed. Additional bond wires tarpaulins, or other suitable means, are not needed around All-Metal flexi and if such motor vehicle has a tail ble or swivel joints, but are required board or tailgate, it shall be closed and for nonmetallic flexible connections in secured in place during such transpor the stationary system piping. When a tation: Provided, however, That the pro cargo tank is unloaded by a suction- visions of this paragraph need not piping system through an open filling apply to “pick-up and delivery” motor hole of the cargo tank, electrical con vehicles when such motor vehicles are tinuity shall be maintained from cargo used in no other transportation than in tank to receiving tank. and about cities, towns, or villages. (2) When a cargo tank is loaded or Shipment in water-tight bulk con unloaded through a vapor-tight (not tainers need not be covered by a tar open hole) top or bottom connection, paulin or other means.

805 § 177.839 49 CFR Ch. 1(10—1—10 Edition)

(b) Articles to be kept dry. Special care (g) A motor vehicle may only contain shall be taken in the loading of any 45.4 kg (100 pounds) or less net mass of motor vehicle with Class 4 (flammable material described as “Smokeless pow solid) or Class 5 (oxidizing) materials der for small arms, Division 4.1”. which are likely to become hazardous (h) Division 4.2 (pyrophoric liquid) ma to transport when wet, to keep them terials in cylinders. Cylinders containing from being wetted during the loading Division 4.2 (pyrophoric liquid) mate process and to keep them dry during rials, unless packed in a strong or transit. Special care shall also be case and secured therein to protect taken in the loading of any motor vehi valves, must be loaded with all valves cle with Class 4 (flammable solid) or and safety relief devices in the vapor Class 5 (oxidizing) materials, which are space. All cylinders must be secured so likely to become more hazardous to that no shifting occurs in transit. transport by wetting, to keep them [29 FR 18795, Dec. 29, 1964. Redesignated at 32 from being wetted during the loading FR 5606. Apr. 5. 1967] process and to keep them dry during transit. Examples of such dangerous EDITORIAL NOTE: For FEDERAL REGISTER ci materials are charcoal screenings, tations affecting § 177.838, see the List of CFR Sections Affected which appears in the Find ground, crushed, or pulverized char ing Aids section of the printed volume and coal, and lump charcoal. on GPO Access. (c) Lading ventilation, precautions against spontaneous combustion. When § 177.839 Class 8 (corrosive) materials. ever a motor carrier has knowledge (See also §177.834(a) through (j).) concerning the hazards of spontaneous (a) Nitric acid. No packaging of nitric combustion or heating of any article to acid of 50 percent or greater concentra be loaded on a motor vehicle, such arti tion may be loaded above any pack cle shall be so loaded as to afford suffi aging containing any other kind of ma cient ventilation of the load to provide terial. reasonable assurance against fire from (b) Storage batteries. All storage bat this cause; and in such a case the teries containing any electrolyte must motor vehicle shall be unloaded as soon be so loaded, if loaded with other lad as practicable after reaching its des ing, that all such batteries will be pro tination. Charcoal screenings, or tected against other lading falling onto ground, crushed, granulated, or pulver or against them, and adequate means ized charcoal, in , shall be so load must be provided in all cases for the ed that the bags are laid horizontally protection and insulation of battery in the motor vehicle, and so piled that terminals against short circuits. there will be spaces for effective air circulation, which spaces shall not be [Amdt. 177—87, 61 FR 27175, May 30, 1996] less than 10 cm (3.9 inches) wide; and air spaces shall be maintained between § 177.840 Class 2 (gases) materials. rows of bags. Bags shall not be piled (See also § 177.834 (a) to (j).) closer than 15 cm (5.9 inches) from the (a) Floors or platforms essentially flat. top of any motor vehicle with a closed Cylinders containing Class 2 (gases) body. materials shall not be loaded onto any (d)—(e) [Reserved] part of the floor or platform of any (I) Nitrates, except ammonium ni motor vehicle which is not essentially trate having organic , must be flat; cylinders containing Class 2 loaded in closed or open type motor ve (gases) materials may be loaded onto hicles, which must be swept clean and any motor vehicle not having a floor or be free of any projections capable of in platform only if such motor vehicle be juring bags when so packaged. When equipped with suitable racks having shipped in open type motor vehicles, adequate means for securing such cyl the lading must be suitably covered. inders in place therein. Nothing con Ammonium nitrate having organic tained in this section shall be so con coating must not be loaded in all-metal strued as to prohibit the loading of vehicles, other than those made of alu such cylinders on any motor vehicle minum or aluminum alloys of the having a floor or platform and racks as closed type. hereinbefore described.

806 Pipeline and Hazardous Materials Safety Admin., DOT § 177.840

(1) Cylinders. Cylinders containing No Division 2.1 (flammable gas) mate Class 2 gases must be securely re rial shall be loaded into or on or un strained in an upright or horizontal po loaded from any cargo tank motor ve sition, loaded in racks, or packed in hicles with the engine running unless or to prevent the cylinders the engine is used for the operation of from being shifted, overturned or eject the transfer pump of the vehicle. Un ed from the motor vehicle under nor less the delivery hose is equipped with mal transportation conditions. How a shut-off valve at its discharge end, ever, after December 31, 2003, a pres the engine of the motor vehicle shall sure relief device, when installed, must be stopped at the finish of such loading be in communication with the vapor or unloading operation while the filling space of a cylinder containing a Divi or discharge connections are discon sion 2.1 (flammable gas) material. nected. (2) Cylinders for hydrogen, cryogenic (e) Chlorine cargo tank motor vehi liquid. A Specification DOT-4L cylinder cles shall be shipped only when containing hydrogen, cryogenic liquid equipped: may only be transported on a motor (I) With a gas mask of a type ap vehicle as follows: proved by the National Institute of Oc (i) The vehicle must have an open cupational Safety and Health (NIOSH) body equipped with a suitable rack or Pittsburgh Research Center, U.S. De support having a means to hold the partment of Health and Human Serv cylinder upright when subjected to an ices for chlorine service; and acceleration of 2 any “g” in horizontal (2) With an emergency kit for con direction; trolling leaks in fittings on the dome (ii) The combined total of the hydro cover plate. gen venting rates, as marked, on the (f) A cargo tank motor vehicle cylinders transported on one motor ve used for transportation of chlorine may not hicle may not exceed 60 SCF per hour; be moved, coupled or uncoupled, when (iii) The vehicle may not enter a tun any loading unloading nel; and or connections are attached to the vehicle, nor may (iv) Highway transportation is lim it be left without the power unit attached ited to private and contract carriage unless the vehicle is chocked or equiva and to direct movement from point of lent means provided origin to destination. are to prevent mo tion. For additional requirements, (b) Portable tank containers con see §173.315(o) of this subchapter. taining Class 2 (gases) materials shall Each be loaded on motor vehicles only as fol (g) liquid discharge valve on a lows: cargo tank motor vehicle, other than (1) Onto a flat floor or platform of a an engine fuel line valve, must be motor vehicle. closed during transportation except (2) Onto a suitable frame of a motor during loading and unloading. vehicle. (h) The driver of a motor vehicle (3) In either such case, such con transporting a Division 2.1 (flammable tainers shall be safely and securely gas) material that is a cryogenic liquid blocked or held down to prevent shift in a package exceeding 450 L (119 gal ing relative to each other or to the sup lons) of water capacity shall avoid un porting structure when in transit, par necessary delays during transpor ticularly during sudden starts and tation. If unforeseen conditions cause stops and changes of direction of the an excessive pressure rise, the driver vehicle. shall manually vent the tank at a re (4) Requirements of paragraphs (1) mote and safe location. For each ship and (2) of this paragraph (b) shall not ment, the driver shall make a written be construed as prohibiting stacking of record of the cargo tank pressure and containers provided the provisions of ambient (outside) temperature: paragraph (3) of this paragraph (b) are (1) At the start of each trip, fully complied with. (2) Immediately before and after any (c) [Reserved] manual venting, (d) Engine to be stopped in cargo tank (3) At least once every five hours, and motor vehicles, except for transfer pump. (4) At the destination point. 807 § 177.840 49 CFR Ch. 1(10—1—10 Edition)

(i) No person may transport a Divi (m) Cargo tank motor vehicle safety sion 2.1 (flammable gas) material that check. Before unloading from a cargo is a cryogenic liquid in a cargo tank tank motor vehicle containing a lique motor vehicle unless the pressure of fied compressed gas, the qualified per the lading is equal to or less than that son performing the function must used to determine the marked rated check those components of the dis holding time (MRHT) and the one-way charge system, including delivery hose travel time (OWTT), marked on the assemblies and piping, that are readily cargo tank in conformance with observed during the normal course of § 173.318(g) of this subchapter, is equal unloading to assure that they are of to or greater than the elapsed time be sound quality, without obvious defects tween the start and termination of detectable through visual observation travel. This prohibition does not apply and audio awareness, and that connec if, prior to expiration of the OWTT, the tions are secure. This check must be cargo tank is brought to full equilibra made after the pressure in the dis tion as specified in paragraph U) of this charge system has reached at least section. equilibrium with the pressure in the U) Full equilibration of a cargo tank cargo tank. Operators need not use in transporting a Division 2.1 (flammable struments or take extraordinary ac gas) material that is a cryogenic liquid tions to check components not readily may only be done at a facility that visible. No operator may unload lique loads or unloads a Division 2.1 (flam fied compressed gases from a cargo mable gas) material that is a cryogenic tank motor vehicle with a delivery liquid and must be performed and hose assembly found to have any condi verified as follows: tion identified in §l80.416(g)(l) of this (1) The temperature and pressure of subchapter or with piping systems the liquid must be reduced by a manu found to have any condition identified ally controlled release of vapor; and in 180.416(g) (2) of this subchapter. (2) The pressure in the cargo tank § (n) Emergency shut must be measured at least ten minutes down. If there is after the manual release is terminated. an unintentional release of product to (k) A carrier of carbon monoxide, the environment during unloading of a cryogenic liquid must provide each liquefied compressed gas, the qualified driver with a self-contained air breath person unloading the cargo tank motor ing apparatus that is approved by the vehicle must promptly shut the inter National Institute of Occupational nal self-closing stop valve or other pri Safety and Health; for example, Mine mary means of closure and shut down Safety Appliance Co., Model 401, cata all motive and auxiliary power equip log number 461704. ment. (1) Operating procedure. Each operator (o) Daily test of off-truck remote shut of a cargo tank motor vehicle that is off activation device. For a cargo tank subject to the emergency discharge motor vehicle equipped with an off- control requirements in § 173.315(n) of truck remote means to close the inter this subchapter must carry on or with nal self-closing stop valve and shut off in the cargo tank motor vehicle writ all motive and auxiliary power equip ten emergency discharge control proce ment, an operator must successfully dures for all delivery operations. The test the activation device within 18 procedures must describe the cargo hours prior to the first delivery of each tank motor vehicle’s emergency dis day. For a wireless transmitter/re charge control features and, for a pas ceiver, the person conducting the test sive shut-down capability, the param must be at least 45.72 m (150 feet) from eters within which they are designed to the cargo tank and may have the cargo function. The procedures must describe tank in his line of sight. the process to be followed if a facility- (p) Unloading procedures for liquefied provided hose is used for unloading petroleum gas and anhydrous ammonia in when the cargo tank motor vehicle has metered delivery service. An operator a specially equipped delivery hose as must use the following procedures for sembly to meet the requirements of unloading liquefied petroleum gas or § 173.315(n) (2) of this subchapter. anhydrous ammonia from a cargo tank 808 Pipeline and Hazardous Materials Safety Admin., DOT § 177.840 motor vehicle in metered delivery serv (1) The qualified person attending the ice: unloading operation must remain with (1) For a cargo tank with a capacity in 7.62 m (25 feet) of the cargo tank of 13,247.5 L (3,500 water gallons) or when the internal self-closing stop less, excluding delivery hose and pip valve is open. ing, the qualified person attending the (2) The qualified person attending the unloading operation must remain with unloading operation must have an un in 45.72 meters (150 feet) of the cargo obstructed view of the cargo tank and tank and 7.62 meters (25 feet) of the de delivery hose to the maximum extent livery hose and must observe both the practicable, except during short peri cargo tank and the receiving container ods when it is necessary to activate at least once every five minutes when controls or monitor the receiving con the internal self-closing stop valve is tainer. open during unloading operations that (r) Unloading using facility-provided take more than five minutes to com hoses. A cargo tank motor vehicle plete. equipped with a specially designed de (2) For a cargo tank with a capacity livery hose assembly to meet the re greater than 13,247.5 L (3,500 water gal quirements of § 173.315(n) (2) of this sub lons), excluding delivery hose and pip chapter may be unloaded using a deliv ing, the qualified person attending the ery hose assembly provided by the re unloading operation must remain with ceiving facility under the following in 45.72 m (150 feet) of the cargo tank conditions: and 762 m (25 feet) of the delivery hose (I) The qualified person monitoring when the internal self-closing stop unloading must visually examine the valve is open. facility hose assembly for obvious de (i) Except as provided in paragraph fects prior to its use in the unloading (p)(2)(ii) of this section, the qualified operation. person attending the unloading oper (2) The qualified person monitoring ation must have an unobstructed view unloading must remain within arm’s of the cargo tank and delivery hose to reach of the mechanical means of clo the maximum extent practicable, ex sure for the internal self-closing stop cept during short periods when it is valve when the internal self-closing necessary to activate controls or mon stop valve is open except for short peri itor the receiving container. ods when it is necessary to activate (ii) For deliveries where the qualified controls or monitor the receiving con person attending the unloading oper tainer. For chlorine cargo tank motor ation cannot maintain an unobstructed vehicles, the qualified person must re view of the cargo tank, when the inter main within arm’s reach of a means to nal self-closing stop valve is open, the stop the flow of product except for qualified person must observe both the short periods when it is necessary to cargo tank and the receiving container activate controls or monitor the re at least once every five minutes during ceiving container. unloading operations that take more (3) If the facility hose is equipped than five minutes to complete. In addi with a passive means to shut off the tion, by the compliance dates specified flow of product that conforms to and is in §173.3l5(n)(5) and 180.405(m)(3) of maintained to the performance stand this subchapter, the cargo tank motor ard in §l73.3l5(n)(2) of this subchapter, vehicle must have an emergency dis the qualified person may attend the charge control capability that meets unloading operation in accordance with the requirements of § 173.3l5(n)(2) or the attendance requirements pre § 173.315(n) (4) of this subchapter. scribed for the material being unloaded (q) Unloading procedures for liquefied in § 177.834 of this section. petroleum gas and anhydrous ammonia in (s) Off-truck remote shut-off activation other than metered delivery service. An device. For a cargo tank motor vehicle operator must use the following proce with an off-truck remote control shut dures for unloading liquefied petroleum off capability as required by gas or anhydrous ammonia from a §l73.3l5(n)(3) or (n)(4) of this sub cargo tank motor vehicle in other than chapter, the qualified person attending metered delivery service: the unloading operation must be in 809 § 177.841 49 CFR Ch. 1(10—1—10 Edition) possession of the activation device at proof, dust-proof covers well secured in all times during the unloading process. place on all openings, to accomplish This requirement does not apply if the such loading with the minimum spread activation device is part of a system of such compounds into the atmosphere that will shut off the unloading oper by all means that are practicable; and ation without human intervention in no such loading or unloading shall be the event of a leak or separation in the done near or adjacent to any place hose. where there are or are likely to be, dur (t) Unloading without appropriate ing the loading or unloading process emergency discharge control equipment. assemblages of persons other than Until a cargo tank motor vehicle is those engaged in the loading or unload equipped with emergency discharge ing process, or upon any public high control equipment in conformance with way or in any public place. Before any §l73.3l5(n)(2) and l80.405(m)(l) of this motor vehicle may be used for trans subchapter, the qualified person at porting any other articles, all detect tending the unloading operation must able traces of arsenical materials must remain within arm’s reach of a means be removed therefrom by flushing with to close the internal self-closing stop water, or by other appropriate method, valve when the internal self-closing and the marking removed. stop valve is open except during short (b) [Reserved] periods when the qualified person must (c) Division 2.3 (poisonous gas) or Divi activate controls or monitor the re sion 6.1 (poisonous) materials. The trans ceiving container. For chlorine cargo portation of a Division 2.3 (poisonous tank motor vehicles unloaded after De gas) or Division 6.1 (poisonous) mate cember 31, 1999, the qualified person rial is not permitted if there is any must remain within arm’s reach of a interconnection between packagings. means to stop the flow of product ex (d) [Reserved] cept for short periods when it is nec (e) A motor carrier may not trans essary to activate controls or monitor port a package: the receiving container. (1) Except as provided in paragraph (u) Unloading of chlorine cargo tank (e)(3) of this section, bearing or re motor vehicles. After July 1, 2001, un quired to bear a POISON or POISON loading of chlorine from a cargo tank INHALATION HAZARD or motor vehicle must be performed in placard in the same motor vehicle with compliance with Section 3 of the Chlo material that is marked as or known to rine Institute Pamphlet 57, ‘Emer be foodstuffs, feed or edible material gency Shut-off Systems for Bulk intended for consumption by humans Transfer of Chlorine” (IBR, see § 171.7 or animals unless the poisonous mate of this subchapter). rial is packaged in accordance with (Approved by the Office of Management and this subchapter and is: Budget under control number 2l37—0542) (i) Overpacked in a metal as [29 FR 18795, Dec. 29, 1964. Redesignated at 32 specified in §173.25(c) of this sub FR 5606, Apr. 5, 1967] chapter; or (ii) Loaded into a closed de EDITORIAL NOTE: For FEDERAL REGISTER ci and tations affecting § 177.840, see the List of CFR vice the foodstuffs, feed, or other Sections Affected which appears in the Find edible material are loaded into another ing Aids section of the printed volume and closed unit load device; on GPO Access. (2) Bearing or required to bear a POI SON, POISON GAS or POISON INHA § 177.841 Division 6.1 and Division 2.3 LATION HAZARD label in the driver’s materials. compartment (including a sleeper (See also §177.834 (a) to (j).) berth) of a motor vehicle; or (a) Arsenical compounds in bulk. Care (3) Bearing a POISON label dis shall be exercised in the loading and playing the text “PG III,” or bearing a unloading of “arsenical dust”, “arsenic “PG III” mark adjacent to the POISON trioxide”, and “sodium arsenate”, al label, with materials marked as, or lowable to be loaded into sift-proof, known to be, foodstuffs, feed or any steel hopper-type or dump-type motor- other edible material intended for con vehicle bodies equipped with water- sumption by humans or animals, unless 810 Pipeline and Hazardous Materials Safety Admin., DOT § 177.842

the package containing the Division (b) Packages of Class 7 (radioactive) 6.1, Packing Group III material is sepa material bearing “RADIOACTIVE rated in a manner that, in the event of YELLOW-Il” or “RADIOACTIVE YEL leakage from packages under condi LOW-Ill” labels may not be placed in a tions normally incident to transpor transport vehicle, storage location or tation, commingling of hazardous ma in any other place closer than the dis terials with foodstuffs, feed or any tances shown in the following table to other edible material would not occur. any area which may be continuously occupied by any passenger, employee, [29 FR 18795, Dec. 29, 1984[ or animal, nor closer than the dis EDITORIAL NOTE: For FEDERAL REGISTER ci tances shown in the table to any pack tations affecting §177.841, see the List of CFR age containing undeveloped film (if so Sections Affected which appears in the Find marked), and must conform to the fol ing Aids section of the printed volume and lowing conditions: on GPO Access. (1) If more than one of these pack ages is present, the distance § 177.842 Class 7 (radioactive) mate must be rial. computed from the following table on the basis of the total transport index (a) The number of packages of Class 7 number determined by adding together (radioactive) materials in any trans the transport index number on the la port vehicle or in any single group in bels on the individual packages and any storage location must be limited overpacks in the vehicle or storeroom. so that the total transport index num (2) Where more than one group of ber does not exceed 50. The total trans packages is present in any single stor port index of a group of packages and age location, a single group may not overpacks is determined by adding to have a total transport index greater gether the transport index number on than 50. Each group of packages must the labels on the individual packages be handled and stowed not closer than and overpacks in the group. This provi 6 m (20 feet) (measured edge to edge) to sion does not apply to exclusive use any other group. The following table is shipments described in §l73.44l(b), to be used in accordance with the pro 173.457, and 173.427 of this subchapter. visions of paragraph (b) of this section:

Minimum separation distance in meters (feet) to nearest undeveloped film Minimum dis in various times of transit lance in meters (feet) to area of persons, or mm- Total transport index Slum distance 2—4 hours 4—8 hours 8—12 hours °t’r2 partition of cargo compartments

None 0.0 (0) 0.0 (0) 0.0 (0) 0.0 (0) 0.0 (0) 0.0 (0) 0.1 to 1.0 0.3 (1) 0.6 (2) 0.9 (3) 1.2 (4) 1.5 (5) 0.3 (1) 1.1 to 5.0 0.9 (3) 1.2 (4) 1.8 (6) 2.4 (8) 3.4(11) 0.6 (2) 5.1 to 10.0 1.2 (4) 1.8 (6) 2.7 (9) 3.4(11) 4.6 (15) 0.9 (3) 10.1 to 20.0 1.5 (5) 2.4 (8) 3.7 (12) 4.9 (16) 6.7 (22) 1.2 (4) 20.1 to 30.0 2.1 (7) 3.0 (10) 4.6 (15) 6.1 (20) 8.8 (29) 1.5 (5) 30.1 to 40.0 2.4 (8) 3.4(11) 5.2 (17) 6.7 (22) 10.1 (33) 1.8 (6) 40.1 to 50.0 2.7 (9) 3.7 (12) 5.8 (19) 7.3 (24) 11.0 (36) 2.1 (7) NOTE: The distance in this table must be measured from the nearest point on the nearest packages of Class 7 (radioactive) material.

(c) Shipments of low specific activity tion during conditions normally inci materials and surface contaminated dent to transportation. objects, as defined in § 173.403 of this (e) Persons should not remain unnec subchapter, must be loaded so as to essarily in a vehicle containing Class 7 avoid spillage and scattering of loose (radioactive) materials. materials. Loading restrictions are set (I) The number of packages of fissile forth in § 173.427 of this subchapter. Class 7 (radioactive) material in any (d) Packages must be so blocked and non-exclusive use transport vehicle braced that they cannot change posi must be limited so that the sum of the 811 § 177.843 49 CFR Ch. 1(10—1—10 Edition) criticality safety indices (CSIs) does words “For Radioactive Materials Use not exceed 50. In loading and storage Only” in lettering at least 7.6 cm (3 areas, fissile material packages must inches) high in a conspicuous place, on be grouped so that the sum of CSIs in both sides of the exterior of the vehi any one group is not greater than 50; cle. These vehicles must be kept closed there may be more than one group of at all times other than loading and un fissile material packages in a loading loading. or storage area, so long as each group (c) In case of fire, accident, breakage, is at least 6 m (20 feet) away from all or unusual delay involving shipments other such groups. All pertinent re of Class 7 (radioactive) material, see quirements of §5173.457 and 173.459 §5171.15, 171.16 and 177.854 of this sub apply. chapter. (g) For shipments transported under (d) Each transport vehicle used to exclusive use conditions the radiation transport Division 6.2 materials must dose rate may not exceed 0.02 mSv per be disinfected prior to reuse if a Divi hour (2 mrem per hour) in any position sion 6.2 material is released from its normally occupied in the motor vehi packaging during transportation. Dis cle. For shipments transported as ex infection may be by any means effec clusive use under the provisions of tive for neutralizing the material re § 173.441(b) of this subchapter for pack leased. ages with external radiation levels in excess of 2 mSv (200 mrem per hour) at [Amdt. 177—3, 33 FR 14933, Oct. 4, 1968, as the package surface, the motor vehicle amended by Amdt. 177-35. 41 FR 16131, Apr. 15, 1976; Amdt. 177—57, 48 FR 10247, Mar. 10, must meet the requirements of a closed 1983; Amdt. 177—78, 55 FR 52712, Dec. 21, 1990; transport vehicle (see § 173.403 of this Amdt. 177—85, 60 FR 50335, Sept. 28, 1995; 63 subchapter). The sum of criticality FR 52850, Oct. 1, 1998; 65 FR 58631, Sept. 29, safety indices (CSI5) for packages con 2000; 67 FR 53142, Aug. 14, 2002; 75 FR 53597, taining fissile material may not exceed Sept. 1, 2010] 100 in an exclusive use vehicle. [Amdt. 177—85, 60 FR 50334, Sept. 28, 1995, as Subpart C—Segregation and Sep amended at 63 FR 52850, Oct. 1, 1998; 66 FR aration Chart of Hazardous 45385, Aug. 28. 2001; 69 FR 3696. Jan. 26, 2004] Materials § 177.843 Contamination of vehicles. § 177.848 Segregation of hazardous ma (a) Each motor vehicle used for terials. transporting Class 7 (radioactive) ma (a) This section applies to materials terials under exclusive use conditions which meet one or more of the hazard in accordance with §173.427(b)(4) or (c) classes defined in this subchapter and or § 173.443(c) of this subchapter must are; be surveyed with radiation detection (1) In packages that must be labeled instruments after each use. A vehicle or placarded in accordance with part may not be returned to service until 172 of this subchapter; the radiation dose rate at every acces (2) In a compartment within a multi sible surface is 0.005 mSv per hour (0.5 compartmented cargo tank subject to mrem per hour) or less and the remov the restrictions in § 173.33 of this sub able (non-fixed) radioactive surface chapter; or contamination is not greater than the (3) In a portable tank loaded in a level prescribed in § 173.443(a) of this transport vehicle or freight container. subchapter. (b) When a transport vehicle is to be (b) This section does not apply to any transported by vessel, other than a vehicle used solely for transporting ferry vessel, hazardous materials on or Class 7 (radioactive) material if a sur within that vehicle must be stowed and vey of the interior surface shows that segregated in accordance with the radiation dose rate does not exceed § 176.83(b) of this subchapter. 0.1 mSv per hour (10 mrem per hour) at (c) In addition to the provisions of the interior surface or 0.02 mSv per paragraph (d) of this section and except hour (2 mrem per hour) at 1 meter (3.3 as provided in §173.12(e) of this sub feet) from any interior surface. These chapter, cyanides, cyanide mixtures or vehicles must be stenciled with the solutions may not be stored, loaded 812 Pipeline and Hazardous Materials Safety Admin., DOT § 177.848 and transported with acids; Division 4.2 material, Class 8 liquids, and Division materials may not be stored, loaded 4.1, 4.2, 4.3, 5.1 or 5.2 material. and transported with Class 8 liquids; (d) Except as otherwise provided in and Division 6.1 Packing Group I, Haz this subchapter, hazardous materials ard Zone A material may not be stored, must be stored, loaded or transported loaded and transported with Class 3 in accordance with the following table and other provisions of this section:

813 SEGREGATION TABLE FOR HAZARDOUS MATERIALS (0

8 liquids Class ordivision Notes 1.3 1.4 1.5 1.6 2.1 2.2 3 4.1 4.2 4.3 5.1 5.2 7 only x Explosives 1.1 and A x x x x x x x x x x x x 1.2 x x Explosives 1.3 x x x x x x x x Explosives 1.4 A 0 0 0 0 0 0 0 Very insensitive explo- 1.5 x x x x x x x x x x x x x sives. Extremely insensitive 1.6 explosives. Flammable gsees 2.1 x x 0 x x 0 0 0 Non-toxic, non-flam- 2.2 x x x x mable gases. x x Poixonoux gas Zone A 2.3 x x x x x x x x x x 0 x Poisonous gsa Zone B 2.3 x 0 0 O 0 0 0 0 0 x Flammable liquids 3 x x 0 x 0 x Flammable solids 4.1 x x x 0 x 0 0 Spontaneously combus- 4.2 x x x x x tible materials. x 0 x x 0 x x Dangerous when wet 4.3 x x 0 0 materials. x x x Oxidizers 5.1 A 0 x 0 Organic peroxides 5.2 x x x x 0 Poisonous liquids PG I 6.1 x x x x x x x x x x0 Zone A. 0 x x Radioactive materials .., 7 x x 0 0 x Corrosive liquids 8 x 0 0 O X 0 0 0 0 C) C)

C m 0. 0 Pipeline and Hazardous Materials Safety Admin., DOT § 177.848

(e) instructions for using the segrega 1 (explosive) materials is governed by tion table for hazardous materials are the compatibility table in paragraph (f) as follows: of this section. (1) The absence of any hazard class or (5) The note “A” in the second col division or a blank space in the table umn of the table means that, notwith indicates that no restrictions apply. standing the requirements of the letter (2) The letter “X” in the table indi ‘X”, ammonium nitrate (UN 1942) and cates that these materials may not be ammonium nitrate loaded, transported, or stored together fertilizer may be in the same transport vehicle or stor loaded or stored with Division 1.1 (ex age facility during the course of trans plosive) or Division 1.5 materials. portation. (6) When the §172.101 table or §172.402 (3) The letter ‘0” in the table indi of this subchapter requires a package cates that these materials may not be to bear a subsidiary hazard label, seg loaded, transported, or stored together regation appropriate to the subsidiary in the same transport vehicle or stor hazard must be applied when that seg age facility during the course of trans regation is more restrictive than that portation unless separated in a manner required by the primary hazard. How that, in the event of leakage from ever, hazardous materials of the same packages under conditions normally in class may be stowed together without cident to transportation, commingling regard to segregation required for any of hazardous materials would not secondary hazard if the materials are occur. Notwithstanding the methods of not capable of reacting dangerously separation employed, Class 8 (corro with each other and causing combus sive) liquids may not be loaded above tion or dangerous evolution of heat, or adjacent to Class 4 (flammable) or evolution of flammable, Class 5 (oxidizing) materials; except poisonous, or asphyxiant that shippers may load truckload ship gases, or formation of cor ments of such materials together when rosive or unstable materials. it is known that the mixture of con (f) Class 1 (explosive) materials shall tents would not cause a fire or a dan not be loaded, transported, or stored gerous evolution of heat or gas. together, except as provided in this (4) The “*“ in the table indicates section, and in accordance with the fol that segregation among different Class lowing table:

COMPATIBILITY TABLE FOR CLASS 1 (ExPLOSIvE) MATERIALS

Compatibility group A B C D E F G H J K L N S

A X X XX X X X X X X XX B X X X XX X XX X XX 4/5 C X X 2 2 X 6 X X X X 3 4/5 D X X 2 2 X 6 X XX X 3 4/5 E X X 2 2 X 6 XX X X 3 4/5 F XX X X X X XX X X X 4/5 0 X X 6 6 6 X X XX X X 4/5 H X X XX XX X X X XX 4/5 J X XX X XX XX X X X 4/5 K X X X X X XX X X X X 4/5 L X X X X X X X X XX 1 X X N X X 3 3 3 X X X X X X 4/5 S X 4/5 4/5 4/5 4/5 4/5 4/5 4/5 4/5 4/5 X 4/5

(g) Instructions for using the compat (3) The numbers in the table mean ibility table for Class 1 (explosive) ma the following: terials are as follows: (i) “1” means an explosive from com (1) A blank space in the table indi patibility group L shall only be carried cates that no restrictions apply. on the same transport vehicle with an (2) The letter “X” in the table indi identical explosive. cates that explosives of different com (H) “2” means any combination of ex patibility groups may not be carried on plosives from compatibility groups C, the same transport vehicle.

815 § 177.854 49 CFR Ch. I (10—1—10 Edition)

D, or E is assigned to compatibility stopped upon the traveled portion of group E. any highway or shoulder thereof, spe (iii) “3” means any combination of cial care shall be taken to guard the explosives from compatibility groups vehicle and its load or to take such C, D, or E with those in compatibility steps as may be necessary to provide group N is assigned to compatibility against hazard. Special effort shall be group D. made to remove the motor vehicle to a (iv)”4” means see § 177.835(g) when place where the hazards of the mate transporting detonators. rials being transported may be pro (v) “5” means Division l.4S fireworks vided against. See §392.22, 392.24, and may not be loaded on the same trans 392.25 of this title for warning devices port vehicle with Division 1.1 or 1.2 (ex required to be displayed on the high plosive) materials. way. (vi) “6” means explosive articles in (b) Disposition of containers found bro compatibility group G, other than fire ken or leaking in transit. When leaks works and those requiring special han occur in packages or containers during dling, may be loaded, transported and the course of transportation, subse stored with other explosive articles of quent to initial loading, disposition of compatibility groups C, D and E, pro such package or container shall be vided that explosive substances (such made by the safest practical means af as those not contained in articles) are forded under paragraphs (c), (d), and (e) not carried in the same vehicle. of this section. (h) Except as provided in paragraph (c) Repairing or overpacking packages. (1) of this section, explosives of the (1) Packages may be repaired when safe same compatibility group but of dif and practicable, such repairing to be in ferent divisions may be transported to accordance with the best and safest gether provided that the whole ship practice known and available. ment is transported as though its en (2) Packages of hazardous materials tire contents were of the lower numer that are damaged or found leaking dur ical division (i.e., Division 1.1 being ing transportation, and hazardous ma lower than Division 1.2). For example, terials that have spilled or leaked dur a mixed shipment of Division 1.2 (ex ing transportation, may be forwarded plosive) materials and Division 1.4 (ex to destination or returned to the ship plosive) materials, both of compat per in a salvage drum in accordance ibility group D, must be transported as with the requirements of § 173.3(c) of Division 1.2 (explosive) materials. this subchapter. (i) When Division 1.5 materials, com (d) Transportation of repaired pack patibility group D, are transported in ages. Any package repaired in accord the same freight container as Division ance with the requirements of para 1.2 (explosive) materials, compatibility graph (c)(l) of this section may be group D, the shipment must be trans transported to the nearest place at ported as Division 1.1 (explosive) mate rials, compatibility group D. which it may safely be disposed of only in compliance with the following re [Amdt. 177-78, 55 FR 52712, Dec. 21, 1990] quirements: EDITORIAL NOTE: For FEDERAL REGISTER ci (1) The package must be safe for tations affecting §177.848, see the List of CFR transportation. Sections Affected which appears in the Find (2) The repair of the package must be ing Aids section of the printed volume and adequate to prevent contamination of on GPO Access. or hazardous admixture with other lad ing transported on the same motor ve Subpart D—Vehicles and hicle therewith. Shipments in Transit; Accidents (3) If the carrier is not himself the shipper, the consignee’s name and ad § 177.854 Disabled vehicles and broken dress must be plainly marked on the or leaking packages; repairs. repaired package. (a) Care of lading, hazardous materials. (e) Disposition of unsafe broken pack Whenever for any cause other than nec ages. In the event any leaking package essary traffic stops any motor vehicle or container cannot be safely and ade transporting any hazardous material is quately repaired for transportation or

816 Pipeline and Hazardous Materials Safety Admin., DOT § 177.870

transported, it shall be stored pending motor vehicle if necessary in an emer proper disposition in the safest and gency; most expeditious manner possible. (iii) The motor vehicle is removed (f) Stopped vehicles; other dangerous from the enclosed area upon comple articles. Whenever any motor vehicle tion of repair or maintenance work; transporting Class 3 (flammable liq and uid), Class 4 (flammable solid), Class 5 (iv) For motor vehicles loaded with (oxidizing), Class 8 (corrosive), Class 2 Division 1.1, 1.2, or 1.3 (explosive), Class (gases), or Division 6.1 (poisonous) ma 3 (flammable liquid), or Division 2.1 terials, is stopped for any cause other (flammable gas) materials, all sources than necessary traffic stops upon the of spark, flame or glowing heat within traveled portion of any highway, or a the area of enclosure (including any shoulder next thereto, the following re heating system drawing air therefrom) quirements shall be complied with dur are extinguished. made inoperable or ing the period of such stop: rendered explosion-proof by a suitable (1) For motor vehicles other than method. Exception: Electrical equip cargo tank motor vehicles used for the ment on the vehicle, necessary to ac transportation of Class 3 (flammable complish the maintenance function, liquid) or Division 2.1 (flammable gas) may remain operational. materials and not transporting Divi (h) No repair with flame unless gas-free. sion 1.1, 1.2, or 1.3 (explosive) mate No repair of a cargo tank used for the rials, warning devices must be set out transportation of any Class 3 (flam in the manner prescribed in §392.22 of mable liquid) or Division 6.1 (poisonous this title. liquid) material, or any compartment (2) For cargo tanks used for the thereof, or of any container for fuel of transportation of Class 3 (flammable whatever nature, may be repaired by liquid) or Division 2.1 (flammable gas) any method employing a flame, arc, or materials, whether loaded or empty, other means of welding, unless the and vehicles transporting Division 1.1, tank or compartment shall first have 1.2, or 1.3 (explosive) materials, warn been made gas-free. ing devices must be set out in the man [29 FR 18795, Dec. 29, ner prescribed by §392.25 of this title. 1964. Redesignated at 32 FR 5606, Apr. 5. 1967] (g) Repair and maintenance of vehicles containing certain hazardous materials— EDITORIAL NOTE: For FEDERAL REGISTER ci (I) General. No person may use heat, tations affecting §177.854, see the List of CFR flame or spark producing devices to re Sections Affected which appears in the Find ing Aids section the pair or of printed volume and maintain the cargo or fuel con on GPO Access. tainment system of a motor vehicle re quired to be placarded, other than COMBUSTIBLE, in accordance with Subpart E—Regulations Applying subpart F of part 172 of this sub to Hazardous Material on chapter. As used in this section, ‘con Motor Vehicles Carrying Pas tainment system” includes all vehicle sengers for Hire components intended physically to contain cargo or fuel during loading or § 177.870 Regulations for passenger filling, transport, or unloading. carrying vehicles. (2) Repair and maintenance inside a (a) Vehicles transporting passengers building. No person may perform repair and property. In addition to the regula or maintenance on a motor vehicle sub tions in parts 170—189 of this subchapter ject to paragraph (g) (1) of this section the following requirements shall apply inside a building unless: to vehicles transporting passengers and (i) The motor vehicle’s cargo and fuel property. containment systems are closed (ex (b) No Class 1 (explosive) materials or cept as necessary to maintain or repair other’ hazardous materials on passenger the vehicle’s motor) and do not show carrying vehicles, exceptions. No haz any indication of leakage; ardous materials except small-arms (ii) A means is provided, and a person ammunition, emergency shipments of capable to operate the motor vehicle is drugs, chemicals and hospital supplies, available, to immediately remove the and the accompanying munitions of

817 Pt. 178 49 CFR Ch. I (10—1—10 Edition) war of the Departments of the Army. sion 2.3 (poisonous gas) material, or Navy, and Air Force of the United any paranitroaniline, in any amount, States Government, are authorized by in or on any bus while engaged in the parts 170—189 of this subchapter to be transportation of passengers: or any transported on motor vehicles carrying less dangerous Division 6.1 (poisonous) passengers for hire where other prac material, which is other than a liquid, ticable means of transportation is in any amount exceeding an aggregate available. of 45 kg (99 pounds) gross weight in or (c) Class 1 (explosive) materials in pas on any such bus. senger-carrying space forbidden. No Class (g) Class 7 (radioactive) materials. In 1 (explosive) material, except small- addition to the limitations prescribed arms ammunition, may be carried in in paragraphs (b) and (e) of this sec the passenger-carrying space of any tion, no person may transport any motor vehicle transporting passengers Class 7 (radioactive) material requiring for hire. labels under § 172.436, 172.438, and (d) Hazardous materials on passenger 172.440 of this subchapter in or on any carrying vehicles; quantity. Where no motor vehicle carrying passengers for other practicable means of transpor hire except where no other practicable tation is available the following arti means of transportation is available. cles in the quantities as shown may be Packages of Class 7 (radioactive) mate transported in motor vehicles carrying rials must be stored only in the trunk passengers for hire in a space other or baggage compartment of the vehi than that provided for passengers: Not cle, and must not be stored in any com to exceed 45 kg (99 pounds) gross partment occupied by persons. Pack weight of any or all of the kinds of ages of Class 7 (radioactive) materials Class I (explosive) materials permitted must be handled and placed in the vehi to be transported by passenger-car cle as prescribed in § 177.842. rying aircraft or rail car may be trans [29 FR 18795, Dec. 29. 1964. Redesignated ported a motor vehicle at 32 on transporting FR 5606, Apr. 5, 19671 passengers: Provided, however, That samples of Class 1 (explosive) materials EDITORIAL NOTE: For FEDERAL REGISTER ci for laboratory examination, not to ex tations affecting § 177.870 see the List of CFR Sections Affected appears samples, or total which in the Find ceed two a of no more ing Aids section of the printed volume and than 100 detonators, Division 1.4 (explo on GPO Access. sive) materials at one time in a single motor vehicle, may be transported in a PART 178—SPECIFICATIONS FOR motor vehicle transporting passengers. (e) Articles other than Class I (explo PACKAGINGS sive) materials on passenger-carrying ve hicles. The gross weight of any given Sec. 178.1 Purpose and scope. class of hazardous material other than 178.2 Applicability and responsibility. Class 1 (explosive) materials shall not 178.3 Marking of packagings. exceed 45 kg (99 pounds), and the aggre gate weight of all such other dangerous Subpart A [Reserved] articles shall not exceed 225 kg (496 pounds). This provision does not apply Subpart B—Specifications for Inside to nontoxic, nonflammable refrig Containers, and Linings erants, when such refrigerant is for 178.33 Specification 2P; inner nonrefillable servicing operations of a motor carrier metal receptacles. on whose motor vehicles the refrig 178.33—1 Compliance. erant is used. A cylinder secured 178.33—2 Type and size. against shifting while in transit and 178.33—3 Inspection. not exceeding 113 kg (250 pounds) gross 178.33—4 Duties of inspector weight may be transported. 178.33—5 Material. 178.33—6 (f) Division 6.1 (poisonous) or Division Manufacture. 178.33—7 Wall thickness. 2.3 (poisonous gas) materials on pas 178.33—8 Tests. senger-carrying vehicles. No motor car 178.33—9 Marking. rier may transport any extremely dan 178.33a Specification 2Q; inner nonrefillable gerous Division 6.1 (poisonous) or Divi metal receptacles. 818

U.S GOVERNMENT .lN1ORMATION GPO

L :rjG,NL

Pt. 178 49 CFR Ch. I (10—1—10 Edition)

war of the Departments of the Army, sion 2.3 (poisonous gas) material, or Navy, and Air Force of the United any paranitroaniline, in any amount, States Government, are authorized by in or on any bus while engaged in the parts 170—189 of this subchapter to be transportation of passengers; or any transported on motor vehicles carrying less dangerous Division 6.1 (poisonous) passengers for hire where other prac material, which is other than a liquid, ticable means of transportation is in any amount exceeding an aggregate available. of 45 kg (99 pounds) gross weight in or (c) Class 1 (explosive) materials in pas on any such bus. senger-carrying space forbidden. No Class (g) Class 7 (radioactive) materials. In 1 (explosive) material, except small- addition to the limitations prescribed arms ammunition, may be carried in in paragraphs (b) and (e) of this sec the passenger-carrying space of any tion, no person may transport any motor vehicle transporting passengers Class 7 (radioactive) material requiring for hire. labels under § 172.436, 172.438, and (d) Hazardous materials on passenger 172.440 of this subchapter in or on any carrying vehicles; quantity. Where no motor vehicle carrying passengers for other practicable means of transpor hire except where no other practicable tation is available the following arti means of transportation is available. cles in the quantities as shown may be Packages of Class 7 (radioactive) mate transported in motor vehicles carrying rials must be stored only in the trunk passengers for hire in a space other or baggage compartment of the vehi than that provided for passengers: Not cle, and must not be stored in any com to exceed 45 kg (99 pounds) gross partment occupied by persons. Pack weight of any or all of the kinds of ages of Class 7 (radioactive) materials Class 1 (explosive) materials permitted must be handled and placed in the vehi to be transported by passenger-car cle as prescribed in § 177.842. aircraft or rail car may be trans rying [29 FR 18795, Dec. 29, 1964. Redesignated at 32 ported on a motor vehicle transporting FR 5606, Apr. 5, 19671 passengers: Provided, however, That samples of Class 1 (explosive) materials EDITORIAL NOTE: For FEDERAL REGIsTER ci examination, not to ex tations affecting §177.870 see the List of CFR for laboratory Sections Affected which appears in the Find ceed two samples, or a total of no more ing Aids section of the printed volume and than 100 detonators, Division 1.4 (explo on GPO Access. sive) materials at one time in a single motor vehicle, may be transported in a PART 178—SPECIFICATIONS FOR motor vehicle transporting passengers. (e) Articles other than Class I (explo PACKAGINGS sive) materials on passenger-carrying ve The gross weight of any given Sec. hicles. 178.1 Purpose and scope. class of hazardous material other than 178.2 Applicability and responsibility. Class 1 (explosive) materials shall not 178.3 Marking of packagings. exceed 45 kg (99 pounds), and the aggre gate weight of all such other dangerous Subpart A [Reserved] articles shall not exceed 225 kg (496 pounds). This provision does not apply Subpart B—Specifications for Inside to nontoxic, nonflammable refrig Containers, and Linings erants, when such refrigerant is for 178.33 Specification 2P; inner nonrefillable servicing operations of a motor carrier metal receptacles. on whose motor vehicles the refrig 178.33-1 Compliance. erant is used. A cylinder secured 178.33-2 Type and size. against shifting while in transit and 178.33—3 Inspection. not exceeding 113 kg (250 pounds) gross 178.33-4 Duties of inspector. weight may be transported. 178.33—5 Material. or Division 178.33-6 Manufacture. (I) Division 6.1 (poisonous) 178.33—7 Wall thickness. 2.3 (poisonous gas) materials on pas 178.33—8 Tests. senger-carrying vehicles. No motor car 178.33—9 Marking. rier may transport any extremely dan 178.33a Specification 2Q; inner nonrefillable gerous Division 6.1 (poisonous) or Divi metal receptacles.

818 Pipeline and Hazardous Materials Safety Admin., DOT Pt. 178

178.33a-l Compliance. 178.68 Specification 4E welded aluminum 178.33a-2 Type and size. cylinders. 178.33a—3 Inspection. 178.69 Responsibilities and requirements for l78.33a—4 Duties of inspector. manufacturers of UN pressure recep 178.33a—5 Material. tacles. 178.33a—6 Manufacture. 178.70 Approval of UN pressure receptacles. 178.33a—7 Wall thickness. 178.71 Specifications for UN pressure recep 178.33a—8 Tests. tacles. 178.33a-.9 Marking. 178.74 Approval of MEGCs. I 78.33b Specification 2S; inner nonrefillable 178.75 Specifications for MEGCs. plastic receptacles APPENDIX A TO SUBPART C—ILLUSTRATIONS: 178.33b-.l Compliance. CYLINDER TENSILE SAMPLE l78.33b-2 Type and size. 178.33b—3 Inspection. Subparts D-G [Reserved] 178.33b—4 Duties of inspector. l78.33b—5 Material. Subpart H—Specifications for Portable l78.33b-6 Manufacture. Tanks 178.33b—7 Design qualification test. 178.33b—8 Production tests. 178.251—178.253—5 IReservedi I 78.33b—9 Marking. 178.255 Specification 60; steel portable tanks. Subpart C—Specifications for Cylinders 178.255—I General requirements. 178.255—2 Material. 178.35 General requirements for specifica 178.255—3 Expansion domes. tion cylinders. 178.255—4 Closures for manholes and domes. 178.36 Specification 3A and 3AX seamless 178.255—5 Bottom discharge outlets. steel cylinders. 178.255—6 Loading and unloading accessories. 178.37 Specification 3AA and 3AAX seamless 178.255—7 Protection of valves and acces steel cylinders. sories. 178.38 Specification 3B seamless steel cyl 178.255—8 Safety devices. inders. 178.255—9 Compartments. 178.39 Specification 3BN seamless nickel 178.255—10 Lining. cylinders. 178.255-11 Tank mountings. 178.42 Specification 3E seamless steel cyl 178.255-12 Pressure test. inders. 178.255—13 Repair of tanks. 178.44 Specification 3HT seamless steel cyl 178.255—14 Marking. inders for aircraft use. 178.255—15 Report. 178.45 Specification 3T seamless steel cyl 178.273 Approval of Specification UN port inders. able tanks. 178.46 Specification 3AL seamless alu 178.274 Specification for UN portable tanks. minum cylinders. 178.275 Specification for UN Portable Tanks 178.47 Specification welded 4D5 stainless intended for the transportation of liquid steel cylinders for aircraft use. and solid hazardous materials. 178.50 Specification 4B welded or brazed 178.276 Requirements for the design. con steel cylinders. struction, inspection and testing of port 178.51 Specification 4BA welded or brazed able tanks intended for the transpor steel cylinders. tation of non-refrigerated liquefied com 178.53 Specification 4D welded steel cyl pressed gases. inders for aircraft use. 178.277 Requirements for the design, con 178.55 Specification 4B240ET welded or struction, inspection and testing of purt brazed cylinders. able tanks intended for the transpor 178.56 Specification 4AA480 welded steel cyl tation of refrigerated liquefied gases. inders. 178.57 Specification 4L welded insulated cyl Subpart I [Reserved] inders. 178.58 Specification 4DA welded steel cyl Subpart J—Specifications for Containers for inders for aircraft use. Motor Vehicle Transportation 178.59 Specification 8 steel cylinders with porous fillings for acetylene. 178.318 Specification MC 201; container for 178.60 Specification 8AL steel cylinders detonators and percussion caps. with porous fillings for acetylene. 178.318—I Scope. 178.61 Specification 4BW welded steel cyl 178.318—2 Container. inders with electric-arc welded longitu 178.318—3 Marking. dinal seam. 178.320 General requirements applicable to 178.65 Specification 39 non-reusable (non-re all DOT specification cargo tank motor fillable) cylinders. vehicles.

819 Pt. 178 49 CFR Ch. 1(10—1—10 Edition)

178.337 Specification MC 331; cargo tank 178.345—15 Certification. motor vehicle primarily for transpor 178.346 Specification DOT 406; cargo tank tation of compressed gases as defined in motor vehicle. subpart C of part 173 of this subchapter. 178.346—1 General requirements. 178.337—1 General requirements. 178.346—2 Material and thickness of mate 178.337—2 Material. rial. 178.337—3 Structural integrity. 178.346—3 Pressure relief. 178.337-4 Joints. 178.346—4 Outlets. 178.337—5 Bulkheads, baffles and ring stiff 178.346—5 Pressure and leakage tests. eners. 178.347 Specification DOT 407; cargo tank 178.337—6 Closure for manhole. motor vehicle. 178.337—7 Overturn protection. 178.347—1 General requirements. 178.337-8 Openings, inlets and outlets. 178.347-2 Material and thickness of mate 178.337—9 Pressure relief devices, piping, rial. valves, hoses, and fittings. 178.347—3 Manhole assemblies. 178.337-10 Accident damage protection. 178.347—4 Pressure relief. 178.337—Il Emergency discharge control. 178.347—5 Pressure and leakage test. 178.337—12 [Reserved] 178.348 Specification DOT 412; cargo tank 178.337-13 Supporting and anchoring. motor vehicle. 178.337—14 Gauging devices. 178.348—1 General requirements. 178.337—15 Pumps and compressors. 178.348—2 Material and thickness of mate 178.337—16 Testing. rial. 178.337—17 Marking. 178.348-3 Pumps, piping, hoses and connec 178.337—18 Certification. tions. 178.338 Specification MC—338; insulated 178.348—4 Pressure relief. cargo tank motor vehicle. 178.348—5 Pressure and leakage test. 178.338—1 General requirements. 178.338—2 Material. Subpart K—Specifications for Packagings 178.338—3 Structural integrity. for Class 7 (Radioactive) Materials 178.338—4 Joints. 178.338—5 Stiffening rings. 178.350 Specification 7A; general packaging, 178.338—6 Manholes. Type A. 178.338—7 Openings. 178.356 Specification 2OPF phenolic-foam in 178.338—8 Pressure relief devices, piping, sulated, metal overpack. valves, and fittings. 178.356—1 General requirements. 178.338-9 Holding time. 178.356—2 Materials of construction and 178.338-10 Accident damage protection. other requirements. 178.338—11 Oischarge control devices. 178.356—3 Tests. 178.338—12 Shear section. 178.356—4 Required markings. 178.338—13 Supporting and anchoring. 178.356—5 Typical assembly detail. 178.338—14 Gauging devices. 178.358 Specification 21PF fire and shock re 178.338—15 Cleanliness. sistant, phenolic-foam insulated, metal 178.338—16 Inspection and testing. overpack. 178.338-17 Pumps and compressors. 178.358—1 General requirements. 178.338—18 Marking. 178.358—2 Materials of construction and 178.338—19 Certification. other requirements. 178.340—178.343 [Reserved] 178.358—3 Modification of Specification 178.345 General design and construction re 21PF-l overpacks. quirements applicable to Specification 178.358—4 Construction of Specification DOT 406 ( 178.346), DOT 407 ( 178.347), and 21PF-1B overpacks. DOT 412 ( 178.348) cargo tank motor vehi 178.358—5 Required markings. des. 178.358—6 Typical assembly detail. 178.345—1 General requirements. 178.360 Specification 2R; inside containment 178.345—2 Material and material thickness. vessel. 178.345—3 Structural integrity. 178.360-1 General requirements. 178.345—4 Joints. 178.360—2 Manufacture. 178.345—5 Manhole assemblies. 178.360—3 Dimensions. 178.345—6 Supports and anchoring. 178.360—4 Closure devices. 178.345—7 Circumferential reinforcements. 178.345—8 Accident damage protection. Subpart 1—Non-bulk Performance- 178.345—9 Pumps, piping, hoses and connec Oriented Packaging Standards tiOns. 178.345—10 Pressure relief. 178.500 Purpose, scope and definitions. 178.345—11 Tank outlets. 178.502 Identification codes for packagings. 178.345—12 Gauging devices. 178.503 Marking of packagings. 178.345—13 Pressure and leakage tests. 178.504 Standards for steel drums. 178.345—14 Marking. 178.505 Standards for aluminum drums.

820 Pipeline and Hazardous Materials Safety Admin., DOT § 178.1

178.506 Standards for metal drums other 178.811 Bottom lift test. than steel or aluminum. 178.812 Top lift test. 178.507 Standards for plywood drums. 178.813 Leakproofness test. 178.508 for fiber Standards drums. 178.814 Hydrostatic pressure test. 178.509 Standards for plastic drums and 178.815 Stacking test. jerricans. 178.5 10 Standards for wooden barrels. 178.816 Topple test. 178.511 Standards for aluminum and steel 178.817 Righting test. jerricans. 178.818 Tear test. 178.512 Standards for steel or aluminum 178.819 Vibration test. boxes. 178.513 Standards for boxes of natural wood. Subpart P—Large Packagings Standards 178.514 Standards for plywood boxes. 178.515 Standards for reconstituted wood 178.900 Purpose and scope. boxes. 178.905 Large Packaging identification 178.516 Standards for fiberboard boxes. codes. 178.5 17 Standards for plastic boxes. 178.910 Marking of Large Packagings. 178.518 Standards for woven plastic bags. 178.915 General Large Packaging standards. 178.519 Standards for bags. 178.920 Standards for metal Large Pack 178.520 Standards for textile bags. agings. 178.521 Standards for paper bags. 178.925 Standards for rigid plastic Large 178.522 Standards for composite packagings Packagings. with inner plastic receptacles. 178.930 Standards for 178.523 Standards for composite packagings fiberboard Large Packagings. with inner , porcelain, or stoneware receptacles. 178.935 Standards for wooden Large Pack agings. Subpart M—Testing of Non-bulk 178.940 Standards for flexible Large Pack Packagings and Packages agings. 178.600 Purpose and scope. Subpart Q—Testing of Large Packagings 178.601 General requirements. 178.602 Preparation of packagings and pack 178.950 Purpose and scope. ages for testing. 178.955 General requirements. 178.603 Drop test. 178.960 Preparation of Large Packagings for 178.604 Leakproofness test. testing. 178.605 Hydrostatic pressure test. 178.965 Drop test. 178.606 Stacking test. 178.970 Bottom lift test. 178.607 Cooperage test for bung-type wooden 178.975 Top lift test. barrels. 178.980 Stacking test. 178.608 Vibration standard. 178.985 Vibration test. 178.609 Test requirements for packagings for infectious substances. APPENDIX A TO PART 178—SPECIFICATIONS FOR STEEL Subpart N—IBC Performance-Oriented APPENDIX B TO PART 178—ALTERNATIVE Standards LEAKPR0OFNESs TEST METHODS APPENDIX C TO PART 178—NOMINAL AND MIN 178.700 Purpose, scope and definitions. IMUM THICKNESSES OF STEEL DRUMS AND 178.702 IBC codes. JERRICANS 178.703 Marking of IBCs. APPENDIX D TO PART 178—THERMAL RESIST 178.704 General IBC standards. ANCE TEST 178.705 Standards for metal IBCs. APPENDIX E TO PART 178—FLAME PENETRA 178.706 Standards for rigid plastic lBCs. TION RESISTANCE TEST 178.707 Standards for composite lBCs. 178.708 Standards for fiberboard IBCs. AUTHORITY: 49 U.S.C. 5101-5128; 49 CFR 1.53. 178.709 Standards for wooden IBCs. 178.710 Standards for flexible intermediate § 178.1 Purpose and scope. bulk containers. This part prescribes the manufac Subpart 0—Testing of IBCs turing and testing specifications for packaging and containers used for the 178.800 Purpose and scope. transportation of hazardous materials 178.801 General requirements. in commerce. 178.802 Preparation of fiberboard IBCs for testing. [Amdt. 178—40, 42 FR 2689, Jan. 13, 1977. Redes 178.803 Testing and certification of IBCs. ignated by Amdt. 178-97, 55 FR 52715, Dec. 21, 178.810 Drop test. 1990] 821 § 178.2 49 CFR Ch. I (10—1—10 Edition>

§ 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 § l73.24(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 (ii) Retain copies of each written no with the requirements of this part. tification for the amount of time that However, any person who performs a aligns with the packaging’s periodic function prescribed in this part shall retest date, i.e., every 12 months for perform that function in accordance single or composite packagings and with this part. every 24 months for combination pack (b) Specification markings. When this agings; and part requires that a packaging be (iii) Make copies of all written notifi marked with a DOT specification or UN cations available for inspection by a standard marking, marking of the representative of the Department. packaging with the appropriate DOT or (2) The notification required in ac UN markings is the certification that— cordance with this paragraph (c) may in (1) Except as otherwise provided be in writing or by electronic means, of the this section, all requirements including e-mailed transmission or standard, in DOT specification or UN transmission on a CD or similar device. are met; cluding performance tests, If a manufacturer or subsequent dis and tributor of the packaging utilizes elec functions performed by, or on (2) All tronic means to make the required no behalf of, the person whose name or tifications, the notification must be symbol appears as part of the marking specific to the packaging in question conform to requirements specified in and must be in a form that can be this part. printed in hard copy by the person re (c) Notification. (1) Except as specifi ceiving the notification. cally provided in § 178.337—18 and 178.345—10 of this part, the manufac (d) Except as provided in paragraph turer or other person certifying com (c) of this section, a packaging not con pliance with the requirements of this forming to the applicable specifica part, and each subsequent distributor tions or standards in this part may not of that packaging must: be marked to indicate such conform (1) Notify each person to whom that ance. packaging is transferred— (e) Definitions. For the purpose of this (A) Of all requirements in this part part— not met at the time of transfer, and Manufacturer means the person whose (B) With information specifying the name and address or symbol appears as type(s) and dimensions of the closures, part of the specification markings re including gaskets and any other com quired by this part or, for a packaging ponents needed to ensure that the marked with the symbol of an approval packaging is capable of successfully agency, the person on whose behalf the passing the applicable performance approval agency certifies the pack tests. This information must include aging. any procedures to be followed, includ Specification markings mean the pack ing closure instructions for inner pack- aging identification markings required

822 Pipeline and Hazardous Materials Safety Admin., DOT § 178.3

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 (I) 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 UN standard is not forth 21, 1990 and effective October 1, 1991. set in this part may be marked with the United [Amdt. 178—97, 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 178—106, 59 FR 67519, Dec. 29, 1994; Amdt. 178— in the ICAO Technical 117, 62 FR 14338, Mar. 26, 1997; 68 FR 45041, Instructions or 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: (I) 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 lAl, 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 entered. symbol of the packaging manufacturer be Symbols, if used, must be registered or, where specifically authorized, the with the Associate Adminis symbol of the approval agency certi trator. fying compliance with a UN standard. (3) The letters “USA” must be used Symbols, if used, must be registered to indicate the State authorizing the with the Associate Administrator. Du allocation of the specification marks if plicative symbols are not authorized. the packaging is manufactured in the (3) The markings must be stamped, United States. embossed, burned, printed or otherwise (c) Where a packaging conforms to marked on the packaging to provide more than one UN standard or DOT adequate accessibility, permanency, specification, the packaging may bear contrast, and legibility so as to be more than one marking, provided the readily apparent and understood. packaging meets all the requirements (4) Unless otherwise specified, letters of each standard or specification. and numerals must be at least 12.0 mm Where more than one marking appears (0.47 inches) in height except that for on a packaging, each marking must ap packagings of less than or equal to 30 L pear in its entirety. (7.9 gallons) capacity for liquids or 30 (d) No person may mark or otherwise kg (66 pounds) capacity for solids the certify a packaging or container height must be at least 6.0 mm (0.2 as meeting the requirements of a manu inches). For packagings having a ca facturing special pacity of 5 L (1 gallon) or 5 kg (11 permit unless that pounds) or less, letters and numerals person is the holder of or a party to must be of an appropriate size. that special permit, an agent of the (5) For packages with a gross mass of holder or party for the purpose of more than 30 kg (66 pounds), the mark ings or a duplicate thereof must appear 823 § 178.33 49 CFR Ch. 1(10—1—10 Edition) marking or certification, or a third plate; or nonferrous metal of uniform party tester. drawing quality. [Amdt. 178—97, 55 FR 52716, Dec. 21, 1990; 56 FR (b) Material with seams, cracks, lam 66284, Dec. 20, 1991, as amended by Amdt. No. inations or other injurious defects not 178—106, 59 FR 67519, Dec. 29, 1994; Amdt. 178— authorized. 113, 61 FR 21102, May 9, 1996; 65 FR 50462, Aug. 18, 2000; 66 FR 45386, Aug. 28, 2001; 67 FR 61015, § 178.33—6 Manufacture. Sept. 27, 2002; 68 FR 75748, Dec. 31, 2003; 70 FR 73166, Dec. 9, 2005] (a) By appliances and methods that will assure uniformity of completed Subpart A [Reserved] containers; dirt and scale to be re moved as necessary; no defect accept able that is likely to weaken the fin Subpart B—Specifications for ished container appreciably; reason Inside Containers, and Linings ably smooth and uniform surface finish required. SouRce: 29 FR 18823, Dec. 29, 1904, unless (b) Seams when used must be as fol otherwise noted. Redesignated at 32 FR 5606, lows: Apr. 5. 1967. (1) Circumferential seams; By weld § 178.33 Specification 2P; inner non- ing, swedging, brazing, soldering, or refillable metal receptacles. double seaming. (2) Side seams: By welding, brazing, § 178.33—1 Compliance. or soldering. (a) Required in all details. (c) Ends: The ends shall be of pres (b) [Reserved) sure design. § 178.33—2 Type and size. [29 FR 18823, Dec. 29, 1964, as amended by Order 71, 31 FR 9074, July 1, 1966. Redesig (a) Single-trip inside containers. nated at 32 FR 5606, Apr. 5, 1967] Must be seamless, or with seams, weld ed, soldered, brazed, double seamed, or § 178.33—7 Wall thickness. swedged. for (b) The maximum capacity of con (a) The minimum wall thickness tainers in this class shall not exceed any container shall be 0.007 inch. one liter (61.0 cubic inches). The max (b) [Reserved] imum inside diameter shall not exceed [Order 71, 31 FR 9074, July 1, 1966. Redesig 3 inches. nated at 32 FR 5606, Apr. 5, 1967] [29 FR 18813, Dec. 29, 1964, as amended by Order 71, 31 FR 9074, July 1, 1966. Redesig § 178.33—8 Tests. nated at 32 FR 5606, Apr. 5. 1967, and amended (a) One out of each lot of 25,000 con by Amdt. 178—101, 58 FR 50237, Sept. 24, 1993; tainers or less, successively produced 66 FR 45386, Aug. 28, 2001] per day shall be pressure tested to de § 178.33—3 Inspection. struction and must not burst below 240 psig gauge pressure. The container (a) By competent inspector. tested shall be complete with end as (b) [Reserved] sembled. § 178.33—4 Duties of inspector. (b) Each such 25,000 containers or less, successively produced per day, (a) To inspect material and com lot and if the test pleted containers and witness tests, shall constitute a and to reject defective materials or container shall fail, the lot shall be re containers. jected or ten additional containers may (b) [Reserved] be selected at random and subjected to the test under which failure occurred. § 178.33—5 Material. These containers shall be complete (a) Uniform quality steel plate such with ends assembled. Should any of the as black plate, electro-tin plate, hot ten containers thus tested fail, the en dipped tin plate, tern plate or other tire lot must be rejected. All con commercially accepted can making tainers constituting a lot shall be of

824 Pipeline and Hazardous Materials Safety Admin., DOT § 178.33a—8 like material, size, design construc (b) [Reserved] tion, finish, and quality. [Order 71, 31 FR 9074, July 1. 1966. Redesig [Order 71, 31 FR 9074, July 1, 1966. Redesig nated at 32 FR 5606. Apr. 5, 19671 nated at 32 FR 5606. Apr. 5, 1967. as amended by 66 FR 45387, Aug. 28, 20011 § 178.33a—5 Material. (a) Uniform quality steel plate such 178.33—9 Marking. § as black plate, electrotin plate, hot (a) By means of , dipped tinplate, template or other lithographing, embossing, or stamping, commercially accepted can making each container must be marked to plate; or nonferrous metal of uniform show: drawing quality. (1) DOT-2P. (b) Material with seams, cracks, lam (2) Name or symbol of person making inations or other injurious defects not the mark specified in paragraph (a)(l) authorized. of this section. Symbol, if used, must [Order 71, 31 FR 9074, July 1, 1966. Redesig be registered with the Associate Ad nated at 32 FR 5606, Apr. 5, 19671 ministrator. (b) [Reserved] § 178.33a—6 Manufacture. [Amdt. 178—40. 41 FR 38181, Sept. 9, 1976, as (a) By appliances and methods that amended by Amdt. 178-97, 56 FR 66287, Dec. will assure uniformity of completed 20, 1991; 66 FR 45386, Aug. 28, 20011 containers; dirt and scale to be re moved as necessary; no defect accept § 178.33a Specification 2Q; inner non- able that is likely to weaken the fin refillable metal receptacles. ished container appreciably; reason ably smooth and uniform surface finish § 178.33a—1 Compliance. required. (a) Required in all details. (b) Seams when used must be as fol (b) [Reserved] lows; (1) Circumferential seams. By weld [Order 71, 31 FR 9074. July 1, 1966. Redesig ing, swedging, brazing, soldering, nated at 32 FR 5606, Apr. 5, or 19671 double seaming. § 178.33a—2 Type and size. (2) Side seams. By welding, brazing or soldering. (a) Single-trip inside containers. (c) Ends. The ends shall be of pres Must be seamless, or with seams weld sure design. ed, soldered, brazed, double seamed, or swedged. [Order 71. 31 FR 9074, July 1, 1966. Redesig nated at 32 FR 5606. Apr. 5, (b) The maximum capacity of con 19671 tainers in this class shall not exceed 1 § 178.33a—7 Wall thickness. L (61.0 cubic inches). The maximum in (a) The minimum side diameter shall not exceed 3 inches. wall thickness for any container shall be 0.008 inch. [Order 71, 31 FR 9074, July 1, 1966. Redesig (b) [Reserved] nated at 32 FR 5606, Apr. 5, 1967, and amended by Amdt. 178—43, 42 FR 42208, Aug. 22, 1977; [Order 71, 31 FR 9074, July 1, 1966. Redesig Amdt. 178—101, 58 FR 50237, Sept. 24, 1993; 66 nated at 32 FR 5606, Apr. 5, 19671 FR 45387. Aug. 28, 2001[ § 178.33a—8 Tests. § 178.33a—3 Inspection. (a) One out of each lot of 25,000 con (a) By competent inspector. tainers or less, successively produced (b) [Reserved] per day. shall be pressure tested to de struction and must not burst below 270 [Order 71, 31 FR 9074, July 1, 1966. Redesig psig gauge pressure. The container nated at 32 FR 5606, Apr. 5, 19671 tested shall be complete with end as sembled. § 178.33a—4 Duties of inspector. (b) Each such 25,000 containers or (a) To inspect material and com less, successively produced per day, pleted containers and witness tests, shall constitute a lot and if the test and to reject defective materials or container shall fail, the lot shall be re containers. jected or ten additional containers may 825 § 1 78.33a—9 49 CR? Ch. I (10—1—10 Edition)

be selected at random and subjected to (b) [Reserved] the test under which failure occurred. [74 FR 2268, Jan. 14, 2009] These containers shall be complete of the with ends assembled. Should any § 178.33b—5 Material. ten containers thus tested fail, the en tire lot must be rejected. All con (a) The receptacles must be con tainers constituting a lot shall be of structed of terephthalate like material, size, design, construc (PET), polyethylene napthalate (PEN), tion, finish and quality. polyamide (Nylon) or a blend of PET, PEN, ethyl vinyl alcohol (EVOH) and! [Order 71, 31 FR 9074, July 1, 1966. Redesig or Nylon. nated at 32 FR 5606, Apr. 5, 1967, as amended by 66 FR 45387, Aug. 28, 2001] (b) Material with seams, cracks, lam inations or other injurious defects are § 178.33a—9 Marking. forbidden. (a) By means of printing, [74 FR 2268, Jan. 14, 2009] lithographing, embossing, or stamping, each container must be marked to § 178.33b—6 Manufacture. show: (a) Each container must be manufac (1) DOT-2Q. tured by thermoplastic processes that (2) Name or symbol of person making will assure uniformity of the com mark specified in paragraph (a)(1) the pleted container. No used material of this section. Symbol, if used, must other than production residues or be registered with the Associate Ad regrind from the same manufacturing ministrator. process may be used. The packaging (b) lReserved] must be adequately resistant to aging lAmdt. 178—40, 41 FR 38181, Sept. 9, 1976, as and to degradation caused either by amended by Amdt. 178—97. 56 FR 66287, Dec. the substance contained or by ultra 20, 1991: 66 FR 45386. Aug. 28, 2001] violet radiation. [Reserved] § 178.33b Specification 2S; inner non- (b) refillable plastic receptacles. [74 FR 2268, Jan. 14, 2009]

§ 178.33b—1 Compliance. § 178.33b—7 Design qualification test. in (a) Required all details. (a) Drop testing. (1) To ensure that (b) [Reserved] creep does not affect the ability of the 174 FR 2268, Jan. 14, 2009] container to retain the contents, each new design must be drop tested as fol § 178.33b—2 Type and size. lows: Three groups of twenty-five filled (a) Single-trip inside containers. containers must be dropped from 1.8 m (b) The maximum capacity of con (5.9 ft) on to a rigid, non-resilient, flat tainers in this class shall not exceed and horizontal surface. One group must one liter (61.0 cubic inches). The max be conditioned at 38 °C (100 F) for 26 imum inside diameter shall not exceed weeks, the second group for 100 hours 3 inches. at 50 C (122 °F) and the third group for 18 hours at 55 °C (131 °F), prior to per FR 2268, Jan. 14, 2009] 174 forming the drop test. The closure, or § 178.33b—3 Inspection. sealing component of the container, must not be protected during the test. (a) By competent inspector. The orientation of the test container (b) [Reserved] at drop must be statistically random, [74 FR 2268, Jan. 14. 2009] but direct impact on the valve or valve closure must be avoided. § 178.33b—4 Duties of inspector. (2) Criteria for passing the drop test: (a) To inspect material and com The containers must not break or leak. pleted containers and witness tests, (b) Design qualification testing must and to reject defective materials or be completed if the design is manufac containers. tured with a new mold or if there is 826 Pipeline and Hazardous Materials Safety Admin., DOT § 178.35

any change in the properties of the ma spections and verification must be per terial of construction. formed by—.- [75 FR 73, Jan. 4, 20101 (1) An independent inspection agency approved in writing by the Associate § 178.33b—8 Production tests. Administrator, in accordance with sub part I of part 107 of this chapter: (a) Burst Testing. (1) One out of each or (2) For DOT Specifications lot of 5,000 containers or less, succes 3B, 3BN, 3E, 4B, 4BA, 4D (water capacity sively produced per day must be pres less than 1,100 cubic inches), sure tested to destruction and must not 4B240ET, 4AA480, 4L, 8, 8AL, burst below 240 psig. The container 4BW, 39 (marked service pressure 900 p.s.i.g. or tested must be complete as intended lower) for transportation. and 4E manufactured in the United States, a competent (2) Each such 5,000 inspector of the containers or less, manufacturer. successively produced per day, shall (c) Duties of inspector. The constitute a lot and if the con inspector test shall determine that tainer shall fail, the lot each cylinder shall be re made is in conformance jected or ten additional containers with the appli may cable specification. Except be selected at random and as other subjected to wise specified in the test under which the applicable speci failure occurred. fication, These containers the inspector shall perform shall be complete as the following: intended for transportation. Should (1) Inspect all material and reject any of the ten containers thus tested any not meeting applicable require fail, the entire lot must be rejected. All ments. For cylinders made by the bil containers constituting a lot shall be let-piercing process, billets must of like material, size, design construc be in spected and shown free tion, finish, and quality. to be from pipe, cracks, excessive (b) [Reserved] segregation and other injurious defects after parting or, when [74 FR 2268, Jan. 14, 2009. as amended at 75 applicable, after nick and cold break. FR 74, Jan. 4, 2010] (2) Verify the material of construc tion meets the requirements of the 178.33b—9 ap § Marking. plicable specification by— (a) Each container must be clearly (i) Making a chemical analysis of and permanently marked to show: each heat of material; (1) DOT-2S. (ii) Obtaining a certified chemical (2) Name or symbol of person making analysis from the material manufac the mark specified in paragraph (a) (I) turer for each heat of material (a ladle of this section. Symbol, if used, must analysis is acceptable); or be registered with the Associate Ad (iii) If an analysis is not provided for ministrator. each heat of material by the material (b) [Reserved] manufacturer, by making a check anal ysis of a sample from [74 FR 2268, Jan. 14, 2009] each coil, sheet, or . (3) Verify compliance of cylinders Subpart C—Specifications for with the applicable specification by— Cylinders (i) Verifying identification of mate rial is proper; 178.35 General § requirements for (ii) Inspecting the inside specification cylinders. of the cyl inder before closing in ends; (a) Compliance. Compliance with the (iii) Verifying that the heat treat requirements of this subpart is re ment is proper; quired in all details. (iv) Obtaining samples for all tests (b) Inspections and analyses. Chemical and check chemical analyses (NOTE: analyses and tests required by this sub Recommended locations for test speci chapter must be made within the mens taken from welded cylinders are United States, unless otherwise ap depicted in Figures 1 through 5 in Ap proved in writing by the Associate Ad pendix C to this subpart for the specific ministrator, in accordance with sub construction design.): part I of part 107 of this chapter. In- (v) Witnessing all tests; 827 § 178.35 49 CFR Ch. I (10—1—10 Edition) (vi) Verify threads by gauge: must be placed near the serial number. (vii) Reporting volumetric capacity This information must be placed so and (see report form) and that dates of subsequent tests can be minimum thickness of wall noted: and easily added. An example of the mark (viii) Verifying that each cylinder is ings prescribed in this paragraph (f)(l) marked in accordance with the applica is as follows: ble specification. DOT-3A1800 (4) Furnish complete test reports re 1234 quired by this subpart to the maker of xY the cylinder and, upon request, to the AB 5-95 purchaser. The test report must be re Or: tained by the inspector for fifteen DOT-3A 1800-I 234-XY years from the original test date of the AB 5-95 cylinder. Where: (d) Defects and attachments. Cylinders DOT-3A = specification number must conform to the following: 1800 service pressure (1) A cylinder may not be constri,cted 1234 = serial number of material with seams, cracks or lam XY = symbol of manufacturer inations, or other injurious defects. AB = inspector’s mark (2) Metal attachments to cylinders 5—95 = 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 inspector’s mark or a serial number. and as required in § 173.301 of this sub (4) Unless otherwise specified in the chapter. applicable specification, the markings (f) Markings. Markings on a DOT on each cylinder must be stamped Specification cylinder must conform to plainly and permanently on the shoul applicable requirements. der, top head, or neck. (1) Each cylinder must be marked (5) The size of each marking must be with the following information: at least 0.25 inch or as space permits. (i) The DOT specification marking (6) Other markings are authorized must appear first, followed imme provided they are made in low stress diately by the service pressure. For ex areas other than the side wall and are ample, DOT-3Al800. not of a size and depth that will create (ii) The serial number must be placed harmful stress concentrations. Such just below or immediately following marks may not conflict with any DOT the DOT specification marking. required markings. (iii) A symbol (letters) must be (g) Inspector’s report. Each inspector placed just below, immediately before shall prepare a report containing, at a or following the serial number. Other minimum, the applicable information variations in sequence of markings are listed in CGA Pamphlet C-il (IBR, see authorized only when necessitated by a § 171.7 of this subchapter) or, until Oc lack of space. The symbol and numbers tober 1, 1997, in accordance with the ap must be those of the manufacturer. plicable test report requirements of The symbol must be registered with this subchapter in effect on September the Associate Administrator: duplica 30, 1996. Any additional information or tions are not authorized. markings that are required by the ap (iv) The inspector’s official mark and plicable specification must be shown date of test (such as 5-95 for May 1995) on the test report. The signature of the 828 Pipeline and Hazardous Materials Safety Admin., DOT § 178.36

inspector on the reports certifies that = length of cylinder-inches: the processes of manufacture and heat c = radius (D)I(2) of cylinder-inches; treatment of cylinders were observed I = moment of inertia—0.04909 (D4—d) inches and found satisfactory. fourth: (h) Report retention. The manufac D = outside diameter-inches; turer of the cylinders shall retain the d = inside diameter-inches; reports required by this subpart for 15 A internal area in cross section of cyl years from the original test date of the inder-square inches; cylinder. A2 = area of metal in cross section of cyl inder-square inches: [Amdt. 178—114, 61 FR 25942, May 23, 1996, as P=hydrostatic test pressure-psig. amended at 66 FR 45185. Aug. 28, 2001: 67 FR 51652, Aug. 8, 2002; 68 FR 75748, Dec. 31, 20031 (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 DOT—3AX 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 (1) Assuming the cylinder is to be appreciably. A reasonably smooth and supported horizontally at its two ends uniform surface finish is required. If only and to be uniformly loaded over not originally free from such defects, its entire length consisting of the the surface may be machined or other weight per unit of length of the wise treated to eliminate these defects. straight cylindrical portion filled with The thickness of the bottoms of cyl water and compressed to the specified inders welded or formed by spinning is, test pressure; the sum of two times the under no condition, to be less than two maximum tensile stress in the bottom times the minimum wall thickness of fibers due to bending, plus that in the the cylindrical shell; such bottom same fibers (longitudinal stress), due to thicknesses must be measured within hydrostatic test may not exceed 80 per an area bounded by a line representing cent of the minimum yield strength of the points of contact between the cyl the steel at such maximum stress. Wall inder and floor when the cylinder is in thickness must be increased when nec a vertical position. essary to meet requirement. the (e) Welding or brazing. Welding or (ii) To calculate the maximum longi brazing for any purpose whatsoever is tudinal tensile stress due to bending, prohibited except as follows: the following formula must be used: (I) Welding or brazing is authorized S=Mc/I for the attachment of neckrings and footrings which (iii) To calculate the maximum lon are non-pressure parts and only to gitudinal tensile stress due to hydro the tops and bottoms of cylinders having static test pressure, the following for a service pressure of mula must be used: 500 psig or less. Cylinders, neckrings, and footrings must be made of weldable S = A1 P/A2 steel, the carbon content of which may where: not exceed 0.25 percent except in the case of 4l30X steel S = tensile stress—psi.: which may be used M = bending moment-inch pounds—(w12)/8: with proper welding procedures. w = weight per inch of cylinder filled with (2) As permitted in paragraph (d) of water: this section.

829 § 178.36 49 CFR Ch. 1(10—1—10 Edition)

(3) Cylinders used solely in anhy cannot be maintained the test may be drous ammonia service may have a ½ repeated at a pressure increased by 10 inch diameter bar welded within their percent or 100 psig, whichever is the concave bottoms. lower. (f) Wail 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. minimum wall thickness of 0.100 inch A (4) Each cylinder must be tested to at is required for any cylinder over 5 least 5/3 times service pressure. inches outside diameter. Wall stress (j) Flattening test. A flattening calculation must be made by using the test must following formula: be performed on one cylinder taken at random out of each lot of 200 S = fP(1.3D2±0.4d2)]/(D2_d2) or less, by placing the cylinder between Where: wedge shaped knife edges having a 60° included angle, rounded 1/s-inch ra S = wall stress in psi: to 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 (g) Heat treatment. The completed cyl inches long cut from each cylinder and inder must be uniformly and properly subjected to same heat treatment as heat-treated prior to tests. the finished cylinder. (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 (I) 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 American Standard taper pipe threads. out of each lot of 200 or less. For lots (3) Straight threads having at least 6 of 30 or less, physical tests are au engaged threads are authorized. thorized to be made on a ring at least Straight threads must have a tight fit 8 inches long cut from each cylinder and calculated shear strength of at and subjected to same heat treatment least 10 times the test pressure of the as the finished cylinder. cylinder. Gaskets, adequate to prevent (2) Specimens must conform to the leakage, are required. following: (i) Hydrostatic test. Each cylinder (1) Gauge length of 8 inches with a must successfully withstand a hydro width of not over l’/2 inches, a gauge static test, as follows: length of 2 inches with a width of not (1) The test must be by water-jacket, over l’/2 inches, or a gauge Length of at or other suitable methods, operated so least 24 times thickness with width not as to obtain accurate data. The pres over 6 times thickness is authorized reading sure gauge must permit to an when cylinder wall is not over /16 inch accuracy of 1 percent. The expansion 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 1 inch of (2) Pressure must be maintained for each end of the reduced section. at least 30 seconds and sufficiently (iii) longer to ensure complete expansion. When size of cylinder does not Any internal pressure applied after permit securing straight specimens, heat-treatment and previous to the of the specimens may be taken in any lo ficial test may not exceed 90 percent of cation or direction and may be the test pressure. If, due to failure of the test apparatus the test pressure 830 Pipeline and Hazardous Materials Safety Admin., DOT § 178.37

straightened or flattened cold, by pres quired, without cracking, to 6 times sure only, not by blows. When speci the wall thickness. mens are so taken and prepared, the in (m) Leakage test. All spun cylinders spector’s report must show in connec and plugged cylinders must be tested tion with record of physical tests de for leakage by gas or air pressure after tailed information in regard to such the bottom has been cleaned and is free specimens. from all moisture subject to the fol (iv) Heating of a specimen for any lowing conditions and limitations: purpose is not authorized. (1) Pressure, approximately the same (3) The yield strength in tension as but no less than service pressure, must be the stress corresponding to a must be applied to one side of the fin permanent strain of 0.2 percent of the ished bottom over an area of at least gauge length. The following conditions 6 of the total area of the bottom but apply: not less than 3/4 inch in diameter, in (i) The yield strength must be deter cluding the closure, for at least 1 mined by either the “offset” method or minute, during which time the other the “extension under load” method as side of the bottom exposed to pressure prescribed in ASTM F 8 (IBR, see §171.7 must be covered with water and closely of this subchapter). examined for indications of leakage. (ii) In using the “extension under Except as provided in paragraph (n) of load” method, the total strain (or “ex this section, a cylinder that is leaking tension under load”) corresponding to must be rejected. the stress at which the 0.2-percent per (2) A spun cylinder is one in which an manent strain occurs may be deter end closure in the finished cylinder has mined with sufficient accuracy by cal been welded by the spinning process. culating the elastic extension of the (3) A plugged cylinder is one in which gauge length under appropriate load a permanent closure in the bottom of a and adding thereto 0.2 percent of the finished cylinder has been effected by a gauge length. Elastic extension cal plug. culations must be based on an elastic (4) As a safety precaution, if the modulus of 30,000,000. In the event of manufacturer elects to make this test controversy the entire stress-strain before the hydrostatic test, the manu diagram must be plotted and the yield facturer should design the test appa strength determined from the 0.2 per ratus so that the pressure is applied to cent offset. the smallest area practicable, around (iii) For the purpose of strain meas the point of closure, and so as to use urement, the initial strain must be set the smallest possible volume of air or while the specimen is under a stress of gas. 12,000 psig and the strain indicator (n) Rejected cylinders. Reheat treat reading must be set at the calculated ment is authorized for rejected cyl corresponding strain. inders. Subsequent thereto, cylinders (iv) Cross-head speed of the testing must pass all prescribed tests to be ac machine may not exceed ½ inch per ceptable. Repair by welding or spinning minute during yield strength deter is not authorized. Spun cylinders re mination. jected under the provisions of para (I) Acceptable results for physical and graph (m) of this section may be re flattening tests. Either of the following moved from the spun cylinder category is an acceptable result: by drilling to remove defective mate (1) An elongation at least 40 percent rial, tapping and plugging. for a 2-inch gauge length or at least 20 lAmdt. 178—114, 61 FR 25942, May percent in other cases and yield 23, 1996, as amended at 62 FR 51561, Oct. 1, 1997; strength not over 66 FR 73 percent of tensile 45185, 45386—45387, Aug. 28, 2001; 67 FR 51652, strength. In this instance, the flat Aug. 8, 2002; 68 FR 75748, Dec. 31, 2003; 73 FR tening test is not required. 57006, Oct. 1, 2008] (2) An elongation at least 20 percent for a 2-inch gauge length or 10 percent § 178.37 Specification 3AA and 3AAX in other cases and a yield strength not seamless steel cylinders. over 73 percent of tensile strength. In (a) Type, size and service pressure. In this instance, the flattening test is re addition to the requirements of § 178.35, 831 § 178.37 49 CFR Ch. I (10—1—10 Edition) cylinders must conform to the fol Where: lowing: S = tensile stress-psi.: (1) A DOT-3AA cylinder is a seamless M bending moment-inch pounds (w12)/8; steel cylinder with a water capacity w = weight per inch of cylinder filled with (nominal) of not over 1,000 pounds and water; a service pressure of at least 150 psig. length of cylinder-inches; (2) A DOT-3AAX cylinder is a seam c radius (D)J(2) of cylinder-inches; less steel cylinder with a water capac I moment of inertia-0.04909 (D4 — d4) inches ity of not less than 1,000 pounds and a fourth; service pressure of at least 500 psig, D = outside diameter-inches; conforming to the following require d inside diameter-inches; ments: A’ = internal area in cross section of cyl (i) Assuming the cylinder is to be inder-square inches; supported horizontally at its two ends A2 = area of metal in cross section of cyl only and to be uniformly loaded over inder-square inches; P pressure-psig. its entire length consisting of the hydrostatic test weight per unit of length of the (b) Authorized steel. Open-hearth, straight cylindrical portion filled with basic oxygen, or electric steel of uni water and compressed to the specified form quality must be used. A heat of test pressure; the sum of two times the steel made under the specifications in maximum tensile stress in the bottom table I of this paragraph (b), check fibers due to bending, plus that in the chemical analysis of which is slightly same fibers (longitudinal stress), due to out of the specified range, is accept hydrostatic test pressure may not ex able, if satisfactory in all other re ceed 80 percent of the minimum yield spects, provided the tolerances shown strength of the steel at such maximum in table 2 of this paragraph (b) are not stress. Wall thickness must be in exceeded. When a carbon-boron steel is creased when necessary to meet the re used, a hardenability test must be per quirement. formed on the first and last ingot of (ii) To calculate the maximum ten each heat of steel. The results of this sile stress due to bending, the following test must be recorded on the Record of formula must be used: Chemical Analysis of Material for Cyl

S = Mdl inders required by § 178.35. This hard ness test must be made 5/,e-inch from lon (iii) To calculate the maximum the quenched end of the Jominy quench hydro gitudinal tensile stress due to bar and the hardness must be at least for static test pressure, the following Rc 33 and no more than Rc 53. The fol mula must be used: lowing chemical analyses are author

S = A’P/A2 ized: TABLE 1—AUTHORIZED MATERIALs

Iae se0e (ecet) 9(125 Ca[bon-bcon Designation c(seNote (ece)

Carbon 0.25/0.35 0.28/0.33 0.10/0.20 0.20/0.30 0.27—0.37 0.40 max. Manganese 0.40/0.90 0.70/0.90 0.50/0.75 0.50/0.75 0.80-1.40 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 015/0.35 0.20/0,35 0.60/0.90 0.60/0.90 0.3 max 0.10/0.30. Chromium 0.80/110 0.40/0.60 0.50/0.65 0.50/0.65. Molybdenum 0.15/0.25 0.15/0.25 Zirconium 0.05/0.15 0.05/0.15 Nickel 0.40/0.70. Boron 0.0005/0.003.

NOTE 1: This designation may not be restrictive and the commercial steel is limited in analysis as shown in this table.

832 Pipeline and Hazardous Materials Safety Admin., DOT § 178.37

TABLE 2—CHECK ANALYsIs TOLERANCES

Tolerance (percent) over the maximum limit or E ernen Limit or maximum specified under the minimum limit (percent) Under erie- Over max imum limit imum limit

Carbon ...... , To 0.15 md 0.02 0.03 Over 0.15 to 0.40 nd .03 .04 Manganexe To 0.60 mcI .03 .03 Over 0.60 to 1.15 mcI 0.04 0.04 Over 1.15 to 2.50 mcI 0.05 0.05 Phosphorus1 All ranges .01 Sulphur All ranges .01 Silicon To 0.30 mcI .02 .03 Over 0.30 to 1.00 mcI 05 05 Nickel To 1.00 iricl .03 .03 Chromium To 0.90 mcI .03 .03 0.90 10 2.90 mcI .05 .05 Molybdenum To 0.20 mcI .01 .01 Over 0.20 to 0.40 .02 .02 Zirconium All ranges 01 05 1 Rephosphorized steels not subject to check analysis for phosphorus.

(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 processes adequate ensure that fol to each lowing: cylinder produced conforms to the re quirements of this subpart. No fissure (1) For cylinders with a service pres 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 (1) 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(l.3D2±0.4d2)]/(D2_d2) 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 footrings which are non-pressure parts, water jacket test or 450 psig whichever is the greater; and only to the tops and bottoms of D = outside diameter in inches; cylinders having a service pressure of d = inside diameter 500 psig or less. Cylinders, neckrings, in inches. and footrings must be made of weldable (g) Heat treatment. The completed cyl steel, the carbon content of which may inders must be uniformly and properly 833 § 178.37 49 CFR Ch. 1(10—1—10 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 4l30X 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 Any internal pressure applied after less than 1150 °F., and after heat treat heat-treatment and previous to the of ing each cylinder must be submitted to ficial test may not exceed 90 percent of a magnetic test to detect the presence the test pressure. If, due to failure of of quenching cracks. Cracked cylinders the test apparatus, the test pressure must be rejected and destroyed. cannot be maintained, the test may be (7) Except as otherwise provided in repeated at a pressure increased by 10 paragraph (g) (6) of this section, all cyl percent or 100 psig, whichever is the inders, if water quenched or quenched lower. with a liquid producing a cooling rate (3) Permanent volumetric expansion in excess of 80 percent of the cooling may not exceed 10 percent of total vol rate of water, must be inspected by the umetric expansion at test pressure. magnetic particle, dye penetrant or ul (4) Each cylinder must be tested to at trasonic method to detect the presence least 5/3 times the service pressure. of quenching cracks. Any cylinder de (j) Flattening test. A flattening test signed to the requirements for speci must be performed on one cylinder fication 3AA and found to have a taken at random out of each lot of 200 quenching crack must be rejected and or less, by placing the cylinder between may not be requalified. Cylinders de wedge shaped knife edges having a 60° signed to the requirements for speci included angle, rounded to 1/a-inch ra fication 3AAX and found to have dius. The longitudinal axis of the cyl cracks must have cracks removed to inder must be at a 90-degree angle to sound metal by mechanical means. knife edges during the test. For lots of Such specification 3AAX cylinders will 30 or less, flattening tests are author be acceptable if the repaired area is ized to be made on a ring at least 8 subsequently examined to assure no de inches long cut from each cylinder and fect, and it is determined that design subjected to same heat treatment as thickness requirements are met. the finished cylinder. (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 a length not less than as specified dom out of each lot of 200 or less. For 834 Pipeline and Hazardous Materials Safety Admin., DOT § 178.37 lots of 30 or less, physical tests are au (iii) For the purpose of strain meas thorized to be made on a ring at least urement, the initial strain must be set 8 inches long cut from each cylinder while the specimen is under a stress of and subjected to the same heat treat 12,000 psi, the strain indicator reading ment as the finished cylinder. being set at the calculated cor (2) Specimens must conform to the responding strain. following: (iv) Cross-head speed of the testing (i) Gauge length of 8 inches with a machine may not exceed /8 inch per width of not over 1’/2 inches, a gauge minute during yield strength deter length of 2 inches with a width of not mination. over 1½ inches, or a gauge length of at (1) Acceptable results for physical and least 24 times the thickness with width flattening tests. An acceptable result for not over 6 times thickness when the physical and flattening tests is elon thickness of the cylinder wall is not gation at least 20 percent for 2 inches over /l6 inch. of gauge length or at least 10 percent in (ii) The specimen, exclusive of grip other cases. Flattening is required, ends, may not be flattened. Grip ends without cracking, to 6 times the wall may be flattened to within 1 inch of thickness of the cylinder. each end of the reduced section. (m) Leakage test. All spun cylinders (iii) When size of cylinder does not and plugged cylinders must be tested permit securing straight specimens, for leakage by gas or air pressure after the specimens may be taken in any lo the bottom has been cleaned and is free cation or direction and may be from all moisture. Pressure, approxi straightened or flattened cold, by pres mately the same as but no less than sure only, not by blows. When speci the service pressure, must be applied to mens are so taken and prepared, the in one side of the finished bottom over an spector’s report must show in connec area of at least 1/is of the total area of tion with record of physical tests de the bottom but not less than ¾ inch in tailed information in regard to such diameter, including the closure, for at specimens. least one minute, during which time (iv) Heating of a specimen for any the other side of the bottom exposed to purpose is not authorized. pressure must be covered with water (3) The yield strength in tension and closely examined for indications of must be the stress corresponding to a leakage. Except as provided in para permanent strain of 0.2 percent of the graph (n) of this section, a cylinder gauge length. The following conditions must be rejected if there is any leak apply: ing. (1) The yield strength must be deter (I) A spun cylinder is one in which an mined by either the “offset” method or end closure in the finished cylinder has the “extension under load” method as been welded by the spinning process. prescribed in ASTM E 8 (IBR, see §171.7 (2) A plugged cylinder is one in which of this subchapter). a permanent closure in the bottom of a (ii) In using the ‘extension under finished cylinder has been effected by a load” method, the total strain (or “ex plug. tension under load”) corresponding to (3) As a safety precaution, if the the stress at which the 0.2 percent per manufacturer elects to make this test manent strain occurs may be deter before the hydrostatic test, the manu mined with sufficient accuracy by cal facturer should design the test appa culating the elastic extension of the ratus so that the pressure is applied to gauge length under appropriate load the smallest area practicable, around and adding thereto 0.2 percent of the the point of closure, and so as to use gauge length. Elastic extension cal the smallest possible volume of air or culations must be based on an elastic gas. modulus of 30,000,000. In the event of (n) Rejected cylinders. Reheat treat controversy, the entire stress-strain ment is authorized for rejected cyl diagram must be plotted and the yield inders. Subsequent thereto, cylinders strength determined from the 0.2 per must pass all prescribed tests to be ac cent offset. ceptable. Repair by welding or spinning

835 § 178.38 49 CFR Ch. 1(10—1—10 Edition)

is not authorized. Spun cylinders re 500 psig or less. Cylinders, neckrings, jected under the provision of paragraph and footrings must be made of weldable (m) of this section may be removed steel, carbon content of which may not from the spun cylinder category by exceed 0.25 percent except in the case drilling to remove defective material, of 4130X steel which may be used with tapping and plugging. proper welding procedure. (2) As permitted in paragraph (d) of [Amdt. 178—114, 61 FR 25942. May 23. 1996, as amended at 65 FR 58631. Sept. 29, 2000; 66 FR this section. 45386—45387, Aug. 28, 2001; 67 FR 51652, Aug. 8, (f) Wall thickness. The wall stress may 2002; 68 FR 75748, Dec. 31, 20031 not exceed 24,000 psi. The minimum wall thickness is 0.090 inch for any cyl § 178.38 Specification 3B seamless inder with an outside diameter of 6 steel cylinders. inches. Calculation must be made by (a) Type, size, and service pressure. A the following formula: DOT 3B cylinder is seamless steel cyl S = [P(l.3D2±0.4d2)1I(D2_d2) inder with a water capacity (nominal) of not over 1,000 pounds and a service Where: pressure of at least 150 to not over 500 S = wall stress in psi; psig. P at least two times service pressure or 450 (b) Steel. Open-hearth or electric steel psig, whichever is the greater; D = outside diameter in inches; of uniform quality must be used. Con d = inside diameter in inches. tent percent may not exceed the fol lowing: carbon, 0.55; phosphorus, 0.045; (g) Heat treatment. The completed cyl sulphur, 0.050. inders must be uniformly and properly (c) Identification of material. Material heat-treated prior to tests. must be identified by any suitable (h) Openings in cylinders and connec method except that plates and billets tions (valves, fuse plugs, etc.) for those for hot-drawn cylinders must be openings. Threads, conforming to the marked with the heat number. following, are required on all openings: (d) Manufacture. Cylinders must be (1) Threads must be clean cut, even, manufactured using equipment and without checks, and to gauge. processes adequate to ensure that each (2) Taper threads when used, must be cylinder produced conforms to the re of a length not less than as specified quirements of this subpart. No fissure for American Standard taper pipe or other defect is permitted that is threads. likely to weaken the finished cylinder (3) Straight threads having at least 4 appreciably. A reasonably smooth and engaged threads are authorized. uniform surface finish is required. If Straight threads must have a tight fit, not originally free from such defects, and calculated shear strength at least the surface may be machined or other 10 times the test pressure of the cyl wise treated to eliminate these defects. inder. Gaskets, adequate to prevent The thickness of the bottoms of cyl leakage, are required. inders welded or formed by spinning is, (i) Hydrostatic test. Cylinders must under no condition, to be less than two successfully withstand a hydrostatic times the minimum wall thickness of test, as follows: the cylindrical shell; such bottom (1) The test must be by water-jacket, thicknesses to be measured within an or other suitable method, operated so area bounded by a line representing the as to obtain accurate data. The pres points of contact between the cylinder sure gauge must permit reading to an and floor when the cylinder is in a accuracy of 1 percent. The expansion vertical position. gauge must permit reading of total ex (e) Welding or brazing. Welding or pansion to an accuracy either of 1 per brazing for any purpose whatsoever is cent or 0.1 cubic centimeter. prohibited except as follows: (2) Pressure must be maintained for (1) Welding or brazing is authorized at least 30 seconds and sufficiently for the attachment of neckrings and longer to insure complete expansion. footrings which are non-pressure parts, Any internal pressure applied after and only to the tops and bottoms of heat-treatment and previous to the of cylinders having a service pressure of ficial test may not exceed 90 percent of 836 Pipeline and Hazardous Materials Safety Admin., DOT § 178.38

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 spector’s 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 performed on one cylinder must be deter mined by either taken at random out of each lot of 200 the “offset” method or the ‘extension or less, by placing the cylinder between under load” method as prescribed ASTM wedge shaped knife edges having a 60° in E 8 (IBR, see §171.7 of this included angle, rounded to ½-inch ra subchapter). dius. The longitudinal axis of the cyl (ii) In using the “extension under inder must be at a 90-degree angle to load” method, the total strain (or “ex knife edges during the test. For lots of tension under load”) corresponding to 30 or less, flattening tests are author the stress at which the 0.2 percent per ized to be made on a ring at least 8 manent strain occurs may be deter inches long cut from each cylinder and mined with sufficient accuracy by cal subjected to same heat treatment as culating the elastic extension of the the finished 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 taken at ran strength determined from the 0.2 per dom out of each lot of 200 or less. For cent offset. lots of 30 or less, physical tests are au (iii) For the purpose of strain meas thorized to be made on a ring at least urement, the initial strain must be set 8 inches long cut from each cylinder while the specimen is under a stress of and subjected to same heat treatment 12,000 psi, and the strain indicator as the finished cylinder. reading being set at the calculated cor (2) Specimens must conform to the responding strain. following: (iv) Cross-head speed of the testing Ci) Gauge length of 8 inches with a machine may not exceed ½ inch per width of not over 1½ inches; or a gauge minute during yield strength deter length of 2 inches with a width of not mination. over 1½ inches: or a gauge length at (1) Acceptable results for physical and least 24 times the thickness with a flattening tests. Either of the following width not over 6 times thickness is au is an acceptable result: thorized when a cylinder wall is not (I) An elongation of at least 40 per over /16 inch thick. cent for a 2-inch gauge length or at (ii) The specimen, exclusive of grip least 20 percent in other cases and ends, may not be flattened, Grip ends yield strength not over 73 percent of may be flattened to within one inch of tensile strength. In this instance, the each end of the reduced section. flattening test is not required. 837 § 178.39 49 CFR Ch. I (10—1—10 EdiNon)

(2) An elongation of at least 20 per (2) Minimum wall thickness must be cent for a 2-inch gauge length or 10 per not less than 0.090 inch. cent in other cases and yield strength (3) Depth of stamping must be no not over 73 percent of tensile strength. greater than 15 percent of the min Flattening is required, without crack imum wall thickness, but may not ex ing, to 6 times the wall thickness. ceed 0.015 inch. (m) Leakage test. All spun cylinders (4) Maximum outside diameter of cyl and plugged cylinders must be tested inder may not exceed 5 inches. for leakage by gas or air pressure after (5) Carbon content of cylinder may the bottom has been cleaned and is free not exceed 0.25 percent. If the carbon from all moisture, subject to the fol content exceeds 0.25 percent, the com lowing conditions and limitations: plete cylinder must be normalized after (1) Pressure, approximately the same stamping. as but no less than service pressure, (6) Stamping must be adjacent to the must be applied to one side of the fin top head. ished bottom over an area of at least LAmdt. 178—114, 61 FR 25942, May 23, 1996, as /6 of the total area of the bottom but amended by 66 FR 45185, 45386-45388, Aug. 28, not less than ¾ inch in diameter, in 2001: 67 FR 51652, Aug. 8, 2002: 68 FR 75748, cluding the closure, for at least one Dec. 31, 20031 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 (nominal) and a service pressure at (2) A spun cylinder is one in which an least 150 to not over 500 psig. end closure in the finished cylinder has (b) Nickel. The percentage of nickel been welded by the spinning process. plus cobalt must be at least 99.0 per (3) A plugged cylinder is one in which cent. a permanent closure in the bottom of a (c) Identification of material. The ma finished cylinder has been effected by a terial must be identified by any suit plug. able method except that plates and bil (4) As a safety precaution, if the lets for hot-drawn cylinders must be manufacturer elects to make this test marked with the heat number. before the hydrostatic test, he should (d) Manufacture. Cylinders must be design his apparatus so that the pres manufactured using equipment and sure is applied to the smallest area processes adequate to ensure that each practicable, around the point of clo cylinder produced conforms to the re sure, and so as to use the smallest pos quirements of this subpart. No defect is sible volume of air or gas. permitted that is likely to weaken the (n) Rejected cylinders. Reheat treat finished cylinder appreciably. A rea ment of rejected cylinders is author sonably smooth and uniform surface ized. Subsequent thereto, cylinders finish is required. Cylinders closed in must pass all prescribed tests to be ac by spinning process are not authorized. ceptable. Repair by welding or spinning (e) Welding or brazing. Welding or is not authorized. Spun cylinders re brazing for any purpose whatsoever is jected under the provisions of para prohibited except that welding is au graph (m) of this section may be re thorized for the attachment of moved from the spun cylinder category neckrings and footrings which are non- by drilling to remove defective mate pressure parts, and only to the tops and rial, tapping and plugging. bottoms of cylinders. Neckrings and (o) Marking. Markings may be footrings must be of weldable material, stamped into the sidewalls of cylinders the carbon content of which may not having a service pressure of 150 psig if exceed 0.25 percent. Nickel welding rod all of the following conditions are met: must be used. (1) Wall stress at test pressure may (0 Wall thickness. The wall stress may not exceed 24,000 psi. not exceed 15,000 psi. A minimum wall 838 Pipeline and Hazardous Materials Safety Admin., DOT § 178.39

thickness of 0.100 inch is required for (4) Each cylinder must be tested to at any cylinder over 5 inches in outside least 2 times service pressure. diameter. Wall stress calculation must (j) Flattening test. A flattening test be made by using the following for- must be performed on one cylinder mu la: taken at random out of each lot of 200 or less, by placing the cylinder between S = P(1 3D2 ÷ 0.4d2)1 / (D2 — d2) wedge shaped knife edges having a 60° Where: included angle, rounded to ½-inch ra S = wall stress in psi; dius. The longitudinal axis of the cyl P = minimum test pressure prescribed for inder must be at a 90-degree angle to water jacket test or 450 psig whichever is knife edges during the test. For lots of the greater; 30 or less, flattening tests are author D outside diameter in inches; ized to be made on a ring at least 8 d = inside diameter in inches. inches long cut from each cylinder and (g) Heat treatment. The completed cyl subjected to same heat treatment as inders must be uniformly and properly the finished cylinder. heat-treated prior to tests. (k) Physical test. A physical test must (h) Openings in cylinders and connec be conducted to determine yield tions (valves, fuse plugs, etc.) for those strength, tensile strength, elongation, openings. Threads conforming to the and reduction of area of material, as following are required on openings: follows: (1) Threads must be clean cut, even, (1) The test is required on 2 speci without checks, and to gauge. mens cut from I cylinder taken at ran (2) Taper threads, when used, to be of dom out of each lot of 200 or less. For length not less than as specified for lots of 30 or less, physical tests are au American Standard taper pipe threads. thorized to be made on a ring at least (3) Straight threads having at least 6 8 inches long cut from each cylinder engaged threads are authorized. and subjected to same heat treatment Straight threads must have a tight fit as the finished cylinder. and a calculated shear strength of at (2) Specimens must conform to the least 10 times the test pressure of the following: cylinder. Gaskets, adequate to prevent (i) A gauge length of 8 inches with a leakage, are required. width of not over 1½ inches, a gauge (i) Hydrostatic test. Each cylinder length of 2 inches with a width of not must successfully withstand a hydro over 1½ inches, or a gauge length of at static test, as follows: least 24 times the thickness with a (1) The test must be by water-jacket, width not over 6 times thickness is au or other suitable method, operated so thorized when a cylinder wall is not as to obtain accurate data. The pres over 3/ inch thick. sure gauge must permit reading to an (ii) The specimen, exclusive of grip accuracy of 1 percent. The expansion ends, may not be flattened. Grip ends gauge must permit reading of total ex may be flattened to within one inch of pansion to an accuracy either of 1 per each end of the reduced section. cent or 0.1 cubic centimeter. (iii) When size of cylinder does not (2) Pressure must be maintained for permit securing straight specimens, at least 30 seconds and sufficiently the specimens may be taken in any lo longer to ensure complete expansion. cation or direction and may be Any internal pressure applied after straightened or flattened cold, by pres heat-treatment and previous to the of sure only, not by blows. When speci ficial test may not exceed 90 percent of mens are so taken and prepared, the in the test pressure. If, due to failure of spector’s report must show in connec the test apparatus, the test pressure tion with record of physical tests de cannot be maintained, the test may be tailed information in regard to such repeated at a pressure increased by 10 specimens. percent or 100 psig, whichever is the (iv) Heating of a specimen for any lower. purpose is not authorized. (3) Permanent volumetric expansion (3) The yield strength in tension may not exceed 10 percent of total vol must be the stress corresponding to a umetric expansion at test pressure. permanent strain of 0.2 percent of the 839 § 178.42 49 CFR Ch. I (10—1—10 Edition)

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 /8 inch per vertical position. minute during yield strength deter (e) Openings in cylinders and connec mination. tions (valves, fuse plugs, etc.) for those (1) Acceptable results for physical and openings. Threads conforming to the flattening tests. Either of the following following are required on openings. (1) Threads must is an acceptable result: be clean cut, even, without checks, and to gauge. (1) An elongation of at least 40 per (2) Taper threads, when used, must be cent for a 2 inch gauge length or at of length not less than as specified for least 20 percent in other cases and American Standard taper pipe threads. not over 50 percent of ten yield point (3) Straight threads having at least 4 this instance, the flat sile strength. In engaged threads are authorized. tening test is not required. Straight threads must have a tight fit (2) An elongation of at least 20 per and a calculated shear strength of at cent for a 2 inch gauge length or 10 per least 10 times the test pressure of the cent in other cases and a yield point cylinder. Gaskets, adequate to prevent not over 50 percent of tensile strength. leakage, are required. Flattening is required, without crack (f) Hydrostatic test. Cylinders must be ing, to 6 times the wall thickness. tested as follows: (m) Rejected cylinders. Reheat treat (1) One cylinder out of each lot of 500 ment is authorized for rejected cyl or less must be subjected to a hydro inders. Subsequent thereto, cylinders static pressure of 6,000 psig or higher. must pass all prescribed tests to be ac (2) The cylinder referred to in para ceptable. Repair by welding is not au graph (0(1) of this section must burst thorized. at a pressure higher than 6,000 psig [Amdt. 178—114, 61 FR 25942, May 23, 1996, as without fragmenting or otherwise amended by 66 FR 45185, 45386, 45388, Aug. 28, showing lack of ductility, or must hold 2001: 67 FR 51652, Aug. 8, 2002; 68 FR 75748, a pressure of 12,000 psig for 30 seconds Dec. 31, 20031 without bursting. In which case, it 840 Pipeline and Hazardous Materials Safety Admin., DOT § 178.44

must be subjected to a flattening test is not authorized. Spun cylinders re without cracking to six times wall jected under the provisions of para thickness between knife edges, wedge graph (g) of this section may be re shaped 60 degree angle, rounded out to moved from the spun cylinder category a V2 inch radius. The inspector’s report by drilling to remove defective mate must be suitably changed to show re rial, tapping and plugging. suits of latter alternate and flattening (i) Marking. Markings required by test. §178.35 must be stamped plainly and (3) Other cylinders must be examined permanently on the shoulder, top head, under pressure of at least 3,000 psig and neck or sidewall of each cylinder. not to exceed 4,500 psig and show no de jAmdt. 178—114, 61 FR 25942, May fect. Cylinders tested at a pressure in 23, 1996, as amended by 66 FR 45386. Aug. 28, 20011 excess of 3,600 psig must burst at a pressure higher than 7,500 psig when § 178.44 Specification 3HT seamless tested as specified in paragraph (0(2) of steel cylinders for aircraft use. section. this The pressure must be (a) Type, size and service pressure. A maintained for at least 30 seconds and DOT 3HT cylinder is a seamless steel sufficiently longer to ensure complete cylinder with a water capacity (nomi examination. nal) of not over 150 pounds and a serv (g) Leakage test. All spun cylinders ice pressure of at least 900 psig. and plugged cylinders must be tested (b) Authorized steel. Open hearth or for leakage by gas or air pressure after electric furnace steel of uniform qual the bottom has been cleaned and is free ity must be used. A heat of steel made from all moisture subject to the fol under the specifications listed in Table lowing conditions and limitations: 1 in this paragraph (b), a check chem (1) A pressure, approximately the ical analysis that is slightly out of the same as but not less than the service specified range is acceptable, if satis pressure, must be applied to one side of factory in all other respects, provided the finished bottom over an area of at the tolerances shown in Table 2 in this least /16 of the total area of the bottom paragraph (b) are not exceeded. The 3/4 but not less than inch in diameter, maximum grain size shall be 6 or finer. including the closure, for at least one The grain size must be determined in minute, during which time the other accordance with ASTM E 112-88 (IBR, of the side bottom exposed to pressure see § 171.7 of this subchapter). Steel of must be covered with water and closely the following chemical analysis is au examined for indications of leakage. thorized: Accept as provided in paragraph (h) of this section, a cylinder must be re TABLE 1—AUTHORIZED MATERIALS jected if there is any leakage. (2) A spun cylinder is one in which an Designation end closure in the finished cylinder has been welded by the spinning process. Carbon ...... 0.28/0.33 Manganese 0.4010.60 (3) A plugged cylinder is one in which Phosphorus 0.040 maximum a permanent closure in the bottom of a Sulfur 0.040 maximum finished cylinder has been effected by a Silicon 0.15/0.35 Chromium 0.80/1.10 plug. Molybdenum 0.15/0.25 (4) As a safety precaution, if the manufacturer elects to make this test TABLE 2—CHECK ANALYSIS ToLERANCEs before the hydrostatic test, the manu facturer shall design the test apparatus Tolerance so that the pressure is applied to the (percent) over the maximum limit or smallest area practicable, around the under the Element Limit or maximum minimum limit point of closure, and so as to use the specified (percent) smallest possible volume of air or gas. Under I Over (h) Rejected cylinders. Reheat treat mis- I max imum I mum ment is authorized for rejected cyl limit limit inders. Subsequent thereto, cylinders Carbon Over 0.15 to 0.40 mcI must pass all prescribed tests to be ac .03 .04 Manganese .... To 0.60 mcI .03 .03 ceptable. Repair by welding or spinning Phosphorus’ .. All ranges .01 841 § 178.44 49 CFR Ch. I (10-1—1O Edition)

TABLE 2—CHECK ANALYSIS TOLERANCES— grinding to produce proper surface fin Contjnued ish at point of closure is required. (f) Wall thickness. (1) Minimum wall Tolerance (percent) over the thickness for any cylinder must be maximum limit or 0.050 inch. The minimum wall thick under the Limit or maximum minimum limit ness must be such that the wall stress amen specified (percent) at the minimum specified test pressure Under Over mm- max may not exceed 75 percent of the min imum imum imum tensile strength of the steel as limit limit determined from the physical tests re Sulphur All ranges .01 quired in paragraph (m) of this section Silicon To 0.30 mcI .02 .03 and may not be over 105,000 psi. Over 0.30 to 1.00 md .05 .05 Chromium To 0.90 mcI .03 .03 (2) Calculations must be made by the Over 0.90 to 2.10 mcI .05 .05 formula:

Molybdenum -- To 0.20 mcI .01 .01

Over 0.20 to 0.40 mcI .02 .02 S = [P(l.3D2 ± 0.4d2)] / (D2 — d2) 1 Rephosphorzed steels not subject to check analysis for phosphorus. Where: S = Wall Stress in psi: (c) Identification of material. Material P = Minimum test pressure prescribed for must be identified by any suitable water jacket test; method. Steel stamping of heat identi D = Outside diameter in inches; fications may not be made in any area d = Inside diameter in inches. which will eventually become the side wall of the cylinder. Depth of stamping (3) Wall thickness of hemispherical may not encroach upon the minimum bottoms only permitted to 90 percent prescribed wall thickness of the cyl of minimum wall thickness of cylinder inder. sidewall but may not be less than 0.050 (d) Manufacture. Cylinders must be inch. In all other cases, thickness to be manufactured using equipment and no less than prescribed minimum wall. processes adequate to ensure that each (g) Heat treatment. The completed cyl cylinder produced conforms to the re inders must be uniformly and properly quirements of this subpart. No fissure heated prior to tests. Heat treatment or other defect is permitted that is of the cylinders of the authorized anal likely to weaken the finished container ysis must be as follows: appreciably. The general surface finish (1) All cylinders must be quenched by may not exceed a roughness of 250 oil, or other suitable medium. RMS. Individual irregularities such as (2) The steel temperature on quench draw marks, scratches, pits, etc., ing must be that recommended for the should be held to a minimum con steel analysis, but may not exceed sistent with good high stress pressure 1750°F vessel manufacturing practices. If the (3) The steel must be tempered at a cylinder is not originally free of such temperature most suitable for the par defects or does not meet the finish re ticular steel analysis but not less than quirements, the surface may be ma 850°F. chined or otherwise treated to elimi (4) All cylinders must be inspected by nate these defects. The point of closure the magnetic particle or dye penetrant of cylinders closed by spinning may not method to detect the presence of be less than two times the prescribed quenching cracks. Any cylinder found wall thickness of the cylindrical shell. to have a quenching crack must be re The cylinder end contour must be hem jected and may not be requalified. ispherical or ellipsoidal with a ratio of (h) Openings in cylinders and connec major-to-minor axis not exceeding two tions (valves, fuse plugs, etc.) for those to one and with the concave side to openings. Threads conforming to the pressure. following are required on openings: (e) Welding or brazing. Welding or (I) Threads must be clean cut, even, brazing for any purpose whatsoever is without cracks, and to gauge. prohibited, except that welding by (2) Taper threads, when used, must be spinning is permitted to close the bot of length not less than as specified for tom of spun cylinders. Machining or National Gas Tapered Thread (NGT) as 842 Pipeline and Hazardous Materials Safety Admin., DOT § 178.44 required by American Standard Com steel, manufactured by the same proc pressed Valve Outlet and ess and heat treated in the same equip Inlet Connections. ment under the same conditions of (3) Straight threads having at least 6 time, temperature, and atmosphere, engaged threads are authorized. and may not exceed a quantity of 200 Straight threads must have a tight fit cylinders. and a calculated shear stress of at least (4) All cylinders used in cycling tests 10 times the test pressure of the cyl must be destroyed. inder. Gaskets, adequate to prevent (k) Burst test. One cylinder taken at leakage, are required. random out of each lot of cylinders Ci) Hydrostatic test. Each cylinder must be hydrostatically tested to de must withstand a hydrostatic test, as struction. follows: (1) Flattening test. A flattening test (1) The test must be by water-jacket, must be performed on one cylinder or other suitable method, operated so taken at random out of each lot of 200 as to obtain accurate data. Pressure or less, by placing the cylinder between gauge must permit reading to an accu wedge shaped knife edges having a 60° racy of 1 percent. The expansion gauge included angle, rounded to ½-inch ra must permit reading of total expansion dius. The longitudinal axis of the cyl to an accuracy either of 1 percent of 0.1 inder must be at a 90-degree angle to cubic centimeter. knife edges during the test. For lots of (2) Pressure must be maintained for 30 or less, flattening tests are author at least 30 seconds and sufficiently ized to be made on a ring at least 8 longer to ensure complete expansion. inches long cut from each cylinder and Any internal pressure applied after subjected to same heat treatment as heat treatment and previous to the of the finished cylinder. ficial test may not exceed 90 percent of (m) Physical tests. A physical test the test pressure. If, due to failure of must be conducted to determine yield the test apparatus, the test pressure strength, tensile strength, elongation, cannot be maintained, the test may be and reduction of area of material, as repeated at a pressure increased by 10 follows: percent or 100 psig, which ever is the (1) Test is required on 2 specimens lower. cut from 1 cylinder taken at random (3) Permanent volumetric expansion out of each lot of cylinders. may not exceed 10 percent of total vol (2) Specimens must conform to the umetric expansion at test pressure. following: (4) Each cylinder must be tested to at (i) A gauge length of at least 24 times least 5/3 times service pressure. the thickness with a width not over six (j) Cycling tests. Prior to the initial times the thickness. The specimen, ex shipment of any specific cylinder de clusive of grip ends, may not be flat sign, cyclic pressurization tests must tened. Grip ends may be flattened to have been performed on at least three within one inch of each end of the re representative samples without failure duced section. When size of cylinder as follows: does not permit securing straight (1) Pressurization must be performed specimens, the specimens may be hydrostatically between approximately taken in any location or direction and 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 inspector’s report must show in to be left unattended for periods of connection with the record of physical time. tests detailed information in regard to (2) Tests prescribed in paragraph such specimens. (j) (I) of this section must be repeated (ii) Heating of a specimen for any on one random sample out of each lot purpose is not authorized. of cylinders. The cylinder may then be (3) The yield strength in tension subjected to a burst test. must be the stress corresponding to a (3) A lot is defined as a group of cyl permanent strain of 0.2 percent of the inders fabricated from the same heat of gauge length. 843 § 178.44 49 CFR Ch. I (10—1—10 Edition)

(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 (4) As a safety precaution, if the culating the elastic extension of the manufacturer elects to make this test gauge length under appropriate load before the hydrostatic test, the manu and adding thereto 0.2 percent of the facturer should design the test appa gauge length. Elastic extension cal ratus so that the pressure is applied to culations must be based on an elastic the smallest area practicable, around modulus of 30,000,000. In the event of the point of closure, and so as to use controversy, the entire stress-strain the smallest possible volume of air or diagram must be plotted and the yield gas. strength determined from the 0.2 per (p) Acceptable results of tests. Results cent offset. of the flattening test, physical tests, (iii) For the purpose of strain meas burst test, and cycling test must con urement, the initial strain must be set form to the following: stress while the specimen is under a of (1) Flattening required without strain indicator reading 12,000 psi, the cracking to ten times the wall thick being set at the calculated cor ness of the cylinder. responding strain. (2) Physical tests: (iv) Cross-head speed of the testing (i) An elongation of at least 6 percent machine may not exceed 1/8 inch per 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 psi. side of each container before closing (3) The burst pressure must be at and externally on each finished con least 4/3 times the test pressure. tainer after heat treatment. Evidence (4) Cycling-at least 10,000 pressuriza of discontinuities, which in the opinion tions. of a qualified inspector may appre (q) Rejected cylinders. Reheat treat ciably weaken or decrease the dura ment is authorized for rejected cyl bility of the cylinder, must be cause for inders. Subsequent thereto, cylinders rejection. must pass all prescribed tests to be ac (o) Leakage test. All spun cylinders ceptable. Repair by welding or spinning and plugged cylinders must be tested is not authorized. For each cylinder for leakage by dry gas or dry air pres subjected to reheat treatment during sure after the bottom has been cleaned original manufacture, sidewall meas and is free from all moisture, subject urements must be made to verify that to the following conditions and limita the minimum sidewall thickness meets tions: specification requirements after the (1) Pressure, approximately the same final heat treatment. as but not less than service pressure, (r) Marking. (1) Cylinders must be must be applied to one side of the fin marked by low stress type steel stamp ished bottom over an area of at least ing in an area and to a depth which 1/16 of the total area of the bottom but will insure that the wall thickness not less than ¾ inch in diameter, in measured from the root of the stamp cluding the closure, for at least one ing to the interior surface is equal to minute, during which time the other or greater than the minimum pre side of the bottom exposed to pressure scribed wall thickness. Stamping must must be covered with water and closely be permanent and legible. Stamping on examined for indications of leakage. side wall not authorized. 844 Pipeline and Hazardous Materials Safety Admin., DOT § 178.45

(2) The rejection elastic expansion aspects. However, the check analysis (REE), in cubic cm (cc), must be tolerances shown in the table in this marked on the cylinder near the date paragraph (b) may not be exceeded ex of test. The REE for a cylinder is 1.05 cept as approved by the Department. times its original elastic expansion. (2) Material with seams, cracks, lam (3) plates Name are authorized, pro inations, or other injurious defects is vided that they can be permanently not permitted. and securely attached to the cylinder. (3) Material used must be identified Attachment by either brazing or weld by any suitable method. ing is not permitted. Attachment by soldering is permitted provided steel (c) Manufacture. General manufac temperature does not exceed 500 CF. turing requirements are as follows: (s) Inspector’s report. In addition to (1) Surface finish must be uniform the requirements of § 178.35, the inspec and reasonably smooth. tor’s report must indicate the rejection (2) Inside surfaces must be clean, dry, elastic expansion (REE), in cubic cm and free of loose particles. (cc). (3) No defect of any kind is permitted if it is likely to weaken [Amdt. 178—114, 61 FR 25942, May 23. 1996, as a finished cyl amended at 62 FR 51561, Oct. 1, 1997; 65 FR inder. 58631, Sept. 29, 2000; 66 FR 45385, Aug. 28, 2001; (4) If the cylinder surface is not origi 67 FR 51652, Aug. 8, 2002; 68 FR 75748, 75749, nally free from the defects, the surface Dec. 31, 2003] may be machined or otherwise treated to eliminate these defects provided the § 178.45 Specification 3T seamless steel cylinder. minimum wall thickness is main tained. Type, (a) size, and service pressure. A (5) Welding or brazing on a cylinder DOT 3T cylinder is a seamless steel is not permitted. cylinder with a minimum water capac (d) Wall thickness. The minimum wall ity of 1,000 pounds and a minimum thickness must be such service pressure of 1,800 psig. Each cyl that the wall stress at the minimum inder must have integrally formed specified test pressure heads concave to pressure at both ends. does not exceed 67 percent of The inside head shape must be hemi the minimum tensile strength of the steel spherical, ellipsoidal in which the as determined by the physical major axis is two times the minor axis, tests required in paragraphs (j) and (k) or a dished shape falling within these of this section. A wall stress of more two limits. Permanent closures formed than 90,500 p.s.i. is not permitted. The by spinning are prohibited. minimum wall thickness for any cyl (b) Material, steel. Only open hearth, inder may not be less than 0.225 inch. basic oxygen, or electric furnace proc (1) Calculation of the stress for cyl ess steel of uniform quality is author inders must be made by the following ized. The steel analysis must conform formula: to the following: = S [P(1.3D2 + 0.4d2)] / (D2 — dZ) ANALYsIs ToLERANcEs Where:

Check Analysis S = Wall stress in psi: Element Ladle analysis P = Minimum test pressure, at least S/3 serv Under Over ice pressure; Carbon 0.35 to 0.50 0.03 0.04 D = Outside diameter in inches: Manganese 0.7510 1.05 0.04 0.04 d = Inside diameter in inches. Phosphorus (max) 0.035 0.01 Sulphur (may) 0.04 0.01 (2) Each cylinder must meet the fol Silicon 0.15 to 0.35 0.02 0.03 lowing additional Chromium 0.8010 1.15 0.05 0.05 requirement which Molybdenum 0.1510 0.25 0.02 0.02 assumes a cylinder horizontally sup ported at its two ends and uniformly (1) A heat of steel made under the loaded over its entire length. This load specifications in the table in this para consists of the weight per inch of graph (b), the ladle analysis of which is length of the straight cylindrical por slightly out of the specified range, is tion filled with water compressed to acceptable if satisfactory in all other the specified test pressure. The wall 845 § 178.45 49 CFR Ch. I (10—1—10 Edition) thickness must be increased when nec not less than 1050 °F., and must be held essary to meet this additional require at this temperature for at least one ment: hour per inch of thickness based on the (i) The sum of two times the max maximum thickness of the cylinder. imum tensile stress in the bottom fi Each cylinder must then be cooled bers due to bending (see paragraph under conditions recommended for the (d) (2) (ii) of this section), plus the max steel. imum tensile stress in the same fibers (f) Openings. Openings in cylinders due to hydrostatic testing (see para must comply with the following: (d)(2)(iii) of this section) graph may (1) Openings are permitted on heads percent of not exceed 80 the minimum only. yield strength of the steel at this max 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 aments between openings of at least S = Mc / I 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 (w12/8); (4) All openings must be circular. I = Moment of inertia—O.04909 (D4 — d4) in (5) All openings must be threaded. inches fourth: Threads c Radius (D12) of cylinder in inches: must be in compliance with the following; w = Weight per inch of cylinder filled with water; (1) Each thread must be clean cut, = 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 H—28 (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 H—28. inder in square inches; P Hydrostatic test pressure-psig; (iv) Straight threads conforming with A2 = Area of metal in cross section of cyl National Gas Straight thread inder in square inches. (NGS) standards are authorized. These threads must be in compliance with the (e) Heat treatment. Each completed requirements of NBS Handbook H-28. cylinder must be uniformly and prop erly heat treated prior to testing, as (g) Hydrostatic test. Each cylinder follows: must be tested at an internal pressure (1) Each cylinder must be heated and by the water jacket method or other held at the proper temperature for at suitable method, conforming to the fol least one hour per inch of thickness lowing requirements: based on the maximum thickness of (1) The testing apparatus must be op the cylinder and then quenched in a erated in a manner that will obtain ac suitable liquid medium having a cool curate data. Any pressure gauge used ing rate not in excess of 80 percent of must permit reading to an accuracy of water. The steel temperature on one percent. Any expansion gauge used quenching must be that recommended must permit reading of the total ex for the steel analysis, but it must pansion to an accuracy of one percent. never exceed 1750 °F. (2) Any internal pressure applied to (2) After quenching, each cylinder the cylinder after heat treatment and must be reheated to a temperature before the official test may not exceed below the transformation range but 90 percent of the test pressure. 846 Pipeline and Hazardous Materials Safety Admin., DOT § 178.45

(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 5/3 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 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 specimens must be tested from one of “extension under load” method de the cylinders or a test ring from each scribed in ASTM E 8 (IBR, see §171.7 of four hours or less of production. How this subchapter). ever, in no case may a test lot based on (ii) For the “extension under load” this production period exceed 200 cyl method, the total strain (or extension inders. under load) corresponding to the stress (3) Each specimen for the tension and at which the 0.2 percent permanent Charpy impact tests must be taken strain occurs may be determined with from the side wall of a cylinder or from sufficient accuracy by calculating the a ring which has been heat treated elastic extension of the gage length with the finished cylinders of which under appropriate load and adding the specimens must be representative. thereto 0.2 percent of the gage length. The axis of the specimens must be par- Elastic extension calculations must be 847 § 178.46 49 CFR Ch. I (10—1—10 Edition)

based on an elastic modulus of obtained in each retest may not exceed 30,000,000. However, when the degree of the maximum permitted. accuracy of this method is question (1) Rejected cylinders. Reheat treat able the entire stress-strain diagram ment is authorized for rejected cyl must be plotted and the yield strength inders. However, each reheat treated determined from the 0.2 percent offset. cylinder must subsequently pass all the (iii) For the purpose of strain meas prescribed tests. Repair by welding is urement, the initial strain must be set not authorized. with the specimen under a stress of (m) Markings. Marking must be done 12,000 p.s.i. and the strain indicator by stamping into the metal of the cyl reading set at the calculated cor inder. All markings must be legible and responding strain. located on a shoulder. (iv) The cross-head speed of the test (n) Inspector’s report. In addition to ing machine may not exceed ½ inch per the requirements of § 178.35, the inspec minute during the determination of tor’s report for the physical test re yield strength. port, must indicate the average value (4) Each impact specimen must be for three specimens and the minimum Charpy V-notch type size 10 mm x 10 value for one specimen for each lot mm taken in accordance with para number. graph 11 of ASTM A 333 (IBR, see §171.7 of this subchapter). When a reduced )Amdt. 178-114, 61 FR 25942, May 23, 1996, as size specimen is used, it must be the amended at 66 FR 45385, 43588, Aug. 28, 2001; largest size obtainable. 67 FR 51652, Aug. 8, 2002: 68 FR 48571, Aug. 14, 2003; 68 FR 75748, 75749, Dec. 31, (k) Acceptable physical test results. Re- 20031 suits of physical tests must conform to § 178.46 Specification 3AL seamless the following: aluminum cylinders. (1) The tensile strength may not ex ceed 155,000 psi. (a) Size and service pressure. A DOT (2) The elongation must be at least 16 3AL cylinder is a seamless aluminum percent for a two-inch gage length. cylinder with a maximum water capac (3) The Charpy V-notch impact prop ity of 1000 pounds and minimum service erties for the three impact specimens pressure of 150 psig. which must be tested at 0 °F may not (b) Authorized material and identifica be less than the values shown as fol tion of material. The material of con lows: struction must meet the following con ditions: Average value Minimum value (1) Starting stock must be cast stock Size of s ecimen for acceptance (1 specimen only mri (3 specimens) of the 3) or traceable to cast stock. (2) Material with seams, cracks, lam 10.OxlO.0 25.0 ft. lbs 20.0 ft. lbs. 10.0x7.5 21.0 ft. lbs 17.0 ft. lbs. inations, or other defects likely to 10.0x5.0 17.0 ft. lbs 14.0 ft. lbs. weaken the finished cylinder may not be used. (4) After the final heat treatment, (3) Material must be identified by a each vessel must be hardness tested on suitable method that will identify the the cylindrical section. The tensile alloy, the aluminum producer’s cast strength equivalent of the hardness number, the solution heat treat batch number obtained may not be more than number and the lot number. 165,000 p.s.i. (Rc 36). When the result of (4) The material must be of uniform a hardness test exceeds the maximum quality. Only the following heat treat permitted, two or more retests may be able aluminum alloys in table 1 and 2 made; however, the hardness number are permitted as follows:

848 Pipeline and Hazardous Materials Safety Admin., DOT § 178.46

TABLE 1—HEAT OR CAST ANALYSIS FOR ALUMINUM; SIMILAR TO ALUMINUM AsSOcIATION”1 ALLOY 6061 [CHEMICAL ANALYSIS IN WEIGHT PERCENT2]

Other Fe Cu Mn Mg mini mini Cr Zn Ti Pb Bi I max I mm/max I max mm/max max I max max I max I each I total Al I Imaxi I I I J I max I max 0.4/0.8 max 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. The “Aluminum Association refers to “Aluminum Standards and Data 1993, published by the Aluminum Association Inc. 2 for Pb” and “Bi’, the chemical composition corresponds with that of Table I of ASTM B 221 (IBR, see 171.7 of this subchapter) for Aluminum Association alloy 6061. §

TABLE 2—MECHANICAL PROPERTY LIMITS

Tensile strength—PSI Elongation—percent -Alloy and temper minimum for 2” or Ultimate—minimum Yield—minimum 4D 1 size specimen

6061—T6 38000 35000 214 1 “D” represents specimen diameters. When the cylinder wall is greater than I’ie inch thick, a retest without reheat treatment using the 40 size specimen is authorized if the test using the 2 inch size specimen fails to meet elongation requirements. 2when cylinder wall is not over lie-inch thick, 10 percent elongation is authorized when using a 24tx6t 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 5/54 I ipsoidal 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 (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 849 § 178.46 49 CFR Ch. I (10—1—10 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 H-28 (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 H-28; 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 NB5 Handbook H-28; 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 H—28; 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 H—28; or following formula: (D) Other straight threads con forming to other recognized standards S IP(l.3D ÷ 0.4d2)] / (D2 — d2) may be used provided that the require Where: ments in paragraph (e)(5)(iv) of this section are met. S = Wall Stress lfl psi: (iv) All straight threads must have P Prescribed minimum test pressure in at psig (see paragraph (g) of this section); least 6 engaged threads, a tight fit, and a factor of in shear of at least D = Outside diameter in inches; and safety 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. (0 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 (ii) Each opening is separated from with the following requirements: each other by a ligament; and (1) The testing apparatus must be op (iii) Each ligament which separates erated in a manner so as to obtain ac two openings must be at least three curate data. The pressure gauge used 850 Pipeline and Hazardous Materials Safety Admin., DOT § 178.46

must permit reading to an accuracy of wall thickness is authorized to qualify one percent. The expansion gauge must lots that fail the flattening test of this permit reading the total expansion to section without reheat treatment. If an accuracy of either one percent or 0.1 used, this test must be performed on cubic centimeter. two samples from one cylinder taken (2) The test pressure must be main at random out of each lot of 200 cyl tained for a sufficient period of time to inders or less. assure complete expansion of the cyl (3) Each test cylinder must withstand inder. In no case may the pressure be flattening to nine times the wall thick held less than 30 seconds. If, due to fail ness without cracking. When the alter of apparatus, ure the test the required nate bend test is used, the test speci test pressure cannot be maintained, mens must remain uncracked when the test may be repeated at pressure a bent inward around a mandrel in the increased by 10 percent or 100 psig, direction of curvature of the cylinder whichever is lower. If the test appa wall until the interior edges are at a ratus again fails to maintain the test distance apart not greater than the pressure, the cylinder being tested di ameter of the mandrel. must be rejected. Any internal pressure applied to the cylinder before any offi (i) Mechanical properties test. Two test cial test may not exceed 90 percent of specimens cut from one cylinder rep the test pressure. resenting each lot of 200 cylinders or (3) The minimum test pressure is the less must be subjected to the mechan greatest of the following: ical properties test, as follows: (i) 450 psig regardless of service pres (1) The results of the test must con sure; form to at least the minimum accept (ii) Two times the service pressure able mechanical property limits for for cylinders having service pressure aluminum alloys as specified in para less than 500 psig; or graph (b) of this section. (iii) Five-thirds times the service (2) Specimens must be 4D bar or pressure for cylinders having a service gauge length 2 inches with width not pressure of at least 500 psig. over l’/z inch taken in the direction of (4) Permanent volumetric expansion extrusion approximately 180° from each may not exceed 10 percent of total vol other; provided that gauge length at umetric expansion at test pressure. least 24 times thickness with width not (h) Flattening test. One cylinder taken over 6 times thickness is authorized, at random out of each lot must be sub when cylinder wall is not over 3/ inch jected to a flattening test as follows: thick. The specimen, exclusive of grip (1) The test must be between knife ends, may not be flattened. Grip ends edges, wedge shaped, having a 60° in may be flattened to within one inch of cluded angle, and rounded in accord each end of the reduced section. When ance with the following table. The lon the size of the cylinder does not permit gitudinal axis of the cylinder must be securing straight specimens, the speci an 90° knife at angle to the edges dur mens may be taken in any location or the flattening ing test. The test table direction and may be straightened or is as follows: flattened cold by pressure only, not by TABLE 3—FLATYENING TEST TABLE blows. When such specimens are used, the inspector’s report must show that Radius the specimens were so taken and pre Cylinder wall thickness in inches in inches pared. Heating of specimens for any purpose is forbidden. Under .150 .500 .150 to .249 .875 (3) The yield strength in tension .250 to .349 1.500 must be the stress corresponding to a .350 to 449 2.125 permanent strain of 0.2 percent of the .450 to .549 2.750 .550 to .649 3.500 gauge length. .650 to .749 4.125 (i) The yield strength must be deter mined by either the “offset” method or (2) An alternate bend test in accord the “extension under load” method as ance with ASTM E 290 using a mandrel prescribed in ASTM B 557 (IBR, see diameter not more than 6 times the § 171.7 of this subchapter). 851 § 178.47 49 CFR Ch. I (10—1—10 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 (1) Definitions. (I) 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; exceed ‘/8 inch per machine may not (ii) Specified material of construc during yield strength deter minute tion; mination. (iii) Process of manufacture and heat Rejected cylinder. Reheat treat (J) treatment; ment of rejected cylinders is author manufacture and ized one time. Subsequent thereto, cyl (iv) Equipment of 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) Inspector’s 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. 178—114, 61 FR 25942, May 23, 1996, as ysis on one cylinder out of each lot of amended at 66 FR 45386—45388, 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 20031 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 producer’s certificate of ultrasonic in DOT 4DS cylinder is either a welded spection. Ultrasonic inspection must be stainless steel sphere (two seamless performed or verified as having been hemispheres) or circumferentially performed in accordance with para welded cylinder both with a water ca graph (c) of this section. pacity of not over 100 pounds and a 852 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 I in this paragraph (b), check chemical yses are authorized: analysis of which is slightly out of the TABLE 1—AUTHORIZED MATERIALS

Stainless steels

304 (percent) 321 (percent) 347 (percent)

Carbon (max) 0.08 0.08 0.08

Manganese (max) ...... __...... _.. 2.00 2.00 2.00 Phosphorus (max) 030 .030 .030 Sulphur (max) 030 .030 .030 Silicon (max) 75 .75 .75 Nickel 8.0/11.0 9.0/13.0 9.0/13.0 Chromium 18.0/20.0 17.0/20.0 17.0/20.0 Molybdenum Titanium (1) Columbium (2) 1 Titanium may not be more than 5C and not more than 0.60%. 2Columbium may not be less than 1OC and not more than 1.0%.

TABLE 2—CHECK ANALYSIS ToLEtANcEs

Tolerance (percent) over thx maximum limit or Element Limit or maximum specified (percent) under the minimum limit Under mm- Over max imum limit imum limit

Carbon To 0.15 mcI 0.01 0.01 Manganese Over 1.15 to 2.50 mcI 0.05 0.05 Phosphorus1 All ranges .01 Sulphur All ranges .01 Silicon Over 0.30 to 1.00 mcI .05 .05 Nickel Over 5.30 to 10.00 mcI .10 .10 Over 10.00 to 14.00 mcI .15 .15 Chromium Over 15.00 to 20.00 mcI .20 .20 Titanium All ranges .05 .05 Columbium All ranges .05 .05 1Rephosphorizxd steels not subject to check analysis for phosphorus.

(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 that processes adequate to ensure 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 permitted that is likely to weaken the (b) of finished cylinder appreciably, a reason this section. 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 in accordance with CGA Pamphlet C-3 minimum wall thickness of 0.040 inch is (IBR, see §171.7 of this subchapter). All required for any diameter container. seams of the sphere or cylinder must be Calculations must be made by the fol fusion welded. Seams must be of the lowing formulas: 853 § 178.47 49 CFR Ch. I (10—1—10 Edition) (I) 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 I 4tE Total and permanent expansion must Where: be recorded and included in the inspec

S = Wall stress in psi; tor’s 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 = wall thickness in inches; Minimum so as to obtain accurate data. E 0.85 (provides 85 percent weld efficiency operated 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(l.3D2 ± old2)] / (D2 — d2) If, due to failure of the test apparatus, Where: the test pressure cannot be main tained, the test may be repeated at a S = Wall stress in psi; 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 j ection. 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 (1) 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 inspector’s report. prevent leakage. (m) Flattening test. A flattening test Ci) Process treatment. Each container must be performed as follows: must be hydraulically pressurized in a (1) For spheres the test must be at water jacket to at least 100 percent, the weld between parallel steel plates

854 Pipeline and Hazardous Materials Safety Admin., DOT § 178.50 on a press with welded seam at right (c) Identification of material. Material angles to the plates. Test one sphere must be identified by any suitable taken at random out of each lot of 200 method except that plates and billets or less after the hydrostatic test. Any for hotdrawn cylinders must be marked projecting appurtenances may be cut with the heat number. off (by mechanical means only) prior to (d) Manufacture. Cylinders must be crushing. manufactured using equipment and (2) For cylinders the test must be be processes adequate to ensure that each tween knife edges, wedge shaped, 60° cylinder produced conforms to the re angle, rounded to /2-inch radius. Test quirements of this subpart. No defect is one cylinder taken at random out of permitted that is likely to weaken the each lot of 200 or less, after the hydro finished cylinder appreciably. A rea static test. sonably smooth and uniform surface (n) Acceptable results for flattening and finish is required. Exposed bottom burst tests. Acceptable results for flat welds on cylinders over 18 inches long tening and burst tests are as follows: must be protected by footrings. Weld (I) Flattening required to 50 percent ing procedures and operators must be of the original outside diameter with qualified in accordance with CGA Pam out cracking. phlet C—3 (IBR, see §171.7 of this sub (2) Burst pressure must be at least 3 chapter). Seams must be made as fol times the service pressure. lows: (o) Rejected containers. Repair of weld (1) Welded or brazed circumferential ed seams by welding prior to process seams. Heads attached by brazing must treatment is authorized. Subsequent have a driving fit with the shell, unless thereto, containers must be heat treat the shell is crimped, swedged, or curled ed and pass all prescribed tests. over the skirt or flange of the head, (p) Duties of inspector. In addition to and be thoroughly brazed until com the requirements of § 178.35, the inspec plete penetration by the brazing mate tor must verify that all tests are con rial of the brazed joint is secured. ducted at temperatures between 60 °F Depth of brazing from end of shell must and 90 °F. be at least four times the thickness of (q) Marking. Markings must be shell metal. stamped plainly and permanently on a (2) Longitudinal seams in shells. Longi permanent attachment or on a metal tudinal seams must be forged lap weld nameplate permanently secured to the ed, by copper brazing, by copper alloy container by means other than soft sol brazing. or by silver alloy brazing. Cop der. per alloy composition must be: Copper, [Amdt. 178—114, 61 FR 25942, May 23. 1996, as 95 percent minimum; Silicon, 1.5 per amended at 66 FR 45386, 45388, Aug. 28, 2001; cent to 3.85 percent; Manganese, 0.25 67 FR 51653, Aug. 8, 2002; 68 FR 75748, Dec. 31. percent to 1.10 percent. The melting 20031 point of the silver alloy brazing mate rial must be in excess of 1000 °F. When § 178.50 Specification 4B welded or brazed, the plate edge must be lapped brazed steel cylinders. at least eight times the thickness of (a) Type, size, and service pressure. A plate, laps being held in position, sub DOT 4B is a welded or brazed steel cyl stantially metal to metal, by riveting inder with longitudinal seams that are or electric spot-welding; brazing must forged lap-welded or brazed and with be done by using a suitable flux and by water capacity (nominal) not over 1,000 placing brazing material on one side of pounds and a service pressure of at seam and applying heat until this ma least 150 but not over 500 psig. Cyl terial shows uniformly along the seam inders closed in by spinning process are of the other side. not authorized. (e) Welding or brazing. Only the at (b) Steel. Open-hearth. electric or tachment of neckrings, footrings, han 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 855 § 178.50 49 CFR Ch. I (1Q—1-10 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 permit forged lapped welded longitudinal gauge must 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(l.3D ± 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 cannot be maintained, the test may be D = outside diameter in inches; repeated at a pressure increased by 10 d = inside diameter in inches. 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 (1) (1), (1) (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) (1) 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 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 856 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 ‘/z-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 ½ inch per (1) A gauge length of 8 inches with a minute during yield strength deter width of not over 1½ inches, a gauge m ination. length of 2 inches with a width of not (1) Acceptable results for physical and over l’/2 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 /16 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 spector’s 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 apply: any of the following locations on the (i) The yield strength must be deter cylinder: mined by either the “offset” method or (1) On shoulders and top heads when the “extension under load” method as they are not less than 0.087-inch thick. 857 § 178.51 49 CFR Ch. 1(10—1—10 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 ‘/16-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. 178—114, 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 68 FR 75748, Dec. 31, 2002; 20031 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 /2 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 C—3 (IBR, see §171.7 of (c) Identification of material. Material this subchapter). 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

858 Pipeline and Hazardous Materials Safety Admin., DOT § 178.51 bottoms of cylinders is authorized. zone must extend a distance of 6 times wall Provided that such attachments and thickness from center line of weld); the portion of the container to which E 1.0 (for all other areas). they are made attached are of weldable (4) For a cylinder with a wall thick steel, the carbon of which content may ness less than 0.100 inch, the ratio of not exceed 0.25 percent except in the tangential length to outside diameter case of 4l30x steel which may be used may not exceed 4.1. with proper welding procedure. (g) Heat treatment. Cylinders must be (f) Wall thickness. The minimum wall heat treated in accordance with the thickness of the cylinder must meet following requirements: the following conditions: (1) Each cylinder must be uniformly (1) For any cylinder with an outside and properly heat treated prior to test diameter of greater than 6 inches, the by the applicable method shown in minimum wall 0.078 thickness is inch. table 1 of appendix A to this part. Heat In any case the minimum wall thick treatment must be accomplished after ness must be such that the calculated all forming and welding operations, ex wall stress at the minimum test pres cept that when brazed joints are used, sure may not exceed the lesser value of heat treatment must follow any form any of the following: ing and welding operations, but may be (i) The value shown in table 1 of ap done before, during or after the brazing pendix A to this part, for the particular operations. material under consideration: (2) Heat treatment is not required (ii) One-half of the minimum tensile after the welding or brazing of weldable strength of the material determined as low carbon parts to attachments of required in paragraph of this (j) sec similar material which have been pre tion; viously welded or brazed to the top or (iii) 35,000 psi; or bottom of cylinders and properly heat (iv) Further provided that wall stress treated, provided such subsequent for cylinders having copper brazed lon welding or brazing does not produce a gitudinal seams may not exceed 95 per temperature in excess of 400 °F in any cent of any of the above values. Meas part of the top or bottom material. ured wall thickness may not include (h) Openings in cylinders. Openings in galvanizing or other protective coat cylinders must comply with the fol ing. lowing requirements: Cylinders (2) that are cylindrical in (1) Any opening must be placed on shape must have the wall stress cal other than a cylindrical surface. culated by the formula: (2) Each opening in a spherical type

S fP(l.3D + 0.4d2)] / (D2 — d2) cylinder must be provided with a fit ting, boss, or pad of weldable Where: steel se curely attached to the container by fu S = wall stress in psi; sion welding. = minimum P test pressure prescribed for (3) Each waterjacket test: opening in a cylindrical type cylinder must be provided with a fit D = outside diameter in inches; ting, boss, or d = inside diameter in inches. pad, securely attached to container by brazing or by welding. (3) Cylinders that are spherical in (4) If threads are used, they must shape must have the wall stress cal comply with the following: culated by the formula: (i) Threads must be clean-cut, even, S = PD I 4tE without checks and tapped to gauge. (ii) Taper threads must be of Where: a length not less than that specified for Amer S wall stress in psi: ican Standard taper pipe threads. P minimum test pressure prescribed for waterjacket test; (iii) Straight threads, having at least 4 engaged threads, must have a tight D = outside diameter in inches; t minimum wall thickness in inches; fit and a calculated shear strength of E = 0.85 (provides 85 percent weld efficiency at least 10 times the test pressure of factor which must be applied in the girth the cylinder. Gaskets, adequate to pre weld area and heat affected zones which vent leakage, are required. 859 § 178.51 49 CFR Ch. I (10—1—10 Edition)

(i) Hydrostatic test. Each cylinder over l’/2 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 /16 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 I 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 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 outlined in para length. The following conditions graphs (i) (I), (i) (2), and (i) (3) of this sec gauge apply: tion to at least two times service pres 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 (1) (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. following: (iv) Cross-head speed of the testing (1) A gauge length of 8 inches with a machine may not exceed ½ inch per width not over 11/2 inches, or a gauge minute during yield strength deter length of 2 inches with a width not mination. 860 Pipehne and Hazardous Materials Safety Admin., DOT § 178.53

(k) Elongation. Physical test speci psig, as provided in paragraph (k) of mens must show at least a 40 percent this section. elongation for a 2-inch gauge length or (m) Rejected cylinders. Reheat treat at least 20 percent in other cases. Ex ment is authorized for rejected cyl cept that these elongation percentages inders. Subsequent thereto, cylinders may be reduced numerically by 2 for 2- must pass all prescribed tests to be ac inch specimens, and by 1 in other cases, ceptable. Repair of brazed seams by for each 7,500 psi increment of tensile brazing and welded seams by welding is strength above 50,000 psi to a maximum authorized. of four such increments. (n) Markings. Markings must be (I) Tests of welds. Except for brazed stamped plainly and permanently in seams, welds must be tested as follows: one of the following locations on the (1) Tensile test. A specimen must be cylinder: cut from one cylinder of each lot of 200 (1) On shoulders and top heads not or less, or welded test plate. The weld less than 0.087 inch thick. ed test plate must be of one of the (2) On side wall adjacent to top head heats in the lot of 200 or less which it for side walls not less than 0.090 inch represents, in the same condition and thick. approximately the same thickness as (3) On a cylindrical portion of the the cylinder wall except that in no case shell which extends beyond the re must it be of a lesser thickness than cessed bottom of the cylinder consti that required for a quarter size Charpy tuting an integral and non-pressure part of the cylinder. impact specimen. The weld must be (4) On a made by the same procedures and sub plate attached to the top of the cylinder or permanent jected to the same heat treatment as part thereof; sufficient space must the major weld on the cylinder. The be left on the plate to provide specimen must be taken from across for stamping at least six retest dates; the the major seam and must be prepared plate must be at least 1/ inch thick and must and tested in accordance with and be at tached by welding, or by brazing must meet the requirements of CGA at a temperature of at least 1100 CF., Pamphlet C—3 (IBR, see §171.7 of this throughout all edges of the plate. subchapter). Should this specimen fail (5) On the neck, neckring, valve to meet the requirements, specimens boss, valve protection sleeve, or similar part may be taken from two additional cyl permanently attached inders to the top of the or welded test plates from the cylinder. same lot and tested. If either of the lat (6) On the footring permanently at ter specimens fail to meet the require tached to the cylinder, provided the ments, the entire lot represented must water capacity of the cylinder does not be rejected. exceed 25 pounds. (2) Guided bend test. A root bend test specimen must be cut from the cyl lAnidt. 178—114, 61 FR 25942, May 23, 1996, as amended inder or welded test plate, used for the at 66 FR 4535, Aug. 28, 2001; 67 FR 16015, Sept. 27, 2002; 67 tensile test specified in paragraph FR 51653, Aug. 8, 2002: (l)(l) 68 FR 75748, Dec. 31, 20031 of this section. Specimens must be taken from across the major seam and § 178.53 Specification 4D welded steel must be prepared and tested in accord cylinders for aircraft use. ance with and must meet the require (a) Type, size, and service pressure. A ments of CGA Pamphlet C-3. DOT 4D cylinder is a welded steel (3) Alternate guided-bend test. This sphere (two seamless hemispheres) or test may be used and must be as re circumferentially welded cylinder (two quired by CGA Pamphlet C-3. The spec seamless drawn shells) with a water ca imen must be bent until the elongation pacity not over 100 pounds and a serv at the outer surface, adjacent to the ice pressure of at least 300 but not over root of the weld, between the lightly 500 psig. Cylinders closed in by spin scribed gage lines a to b, must be at ning process are not authorized. least 20 percent, except that this per (b) Steel. Open-hearth or electric steel centage may be reduced for steels hav of uniform and weldable quality must ing a tensile strength in excess of 50,000 be used. Content may not exceed the 861 § 178.53 49 CFR Ch. I (10—1—10 Edition) following: Carbon, 0.25; phosphorus, sociate Administrator. The following 0.045; sulphur, 0.050, except that the fol chemical analyses are authorized: lowing steels commercially known as 4130X and Type 304, 316, 321, and 347 TABLE 1—4130X STEEL stainless steels may be used with prop 4130X Percent er welding procedure. A heat of steel table 1 in this paragraph Carbon 0.25/0.35. made under Manganese 0.40/0.60. (b), check chemical analysis of which is Phosphorus 0.04 max. slightly out of the specified range, is Sulphur 0.05 max Silicon 0.15/0.35. acceptable, if satisfactory in all other Chromium 0.80/1.10. respects, provided the tolerances shown Molybdenum 0.15/0.25. in table 2 in this paragraph (b) are not Zirconium None. Nickel exceeded, except as approved by the As- None.

TABLE 2—AUTHORIZED STAINLESS STEELS

Stainless steels 304 316 321 347 (percent> (percent> (percent> (percent)

Carbon (max> 0.08 0.08 0.08 0.08 Manganese (max> 2.00 2.00 2.00 2.00 Phosphorus (max> .030 .045 .030 .030 Sulphur (max> .030 .030 .030 .030 Silicon (max> .75 1.00 .75 .75 Nickel 8.0/11.0 10.0/14.0 9.0/13.0 9.0/13.0 Chromium 18.0/20.0 16.0/18.0 17.0/20.0 17.0/20.0 Molybdenum 2.0/3.0 Titanium (1> Columbium >2> 1 Titanium may not be less than SC and not more than 0.60%. 2Columbium may not be less than bC and not more than 1.0%.

TABLE 3—CHECK ANALYSIS TOLERANCES

Tolerance (percent> over the maximum limit or Limit or maximum specitied under the minimum limit emen (percent> Under mis- Over max imum limit mum limit

Carbon To 0.15 mcI 0.01 0.01 Over 0.15 to 0.40 mcI .03 .04 Manganese To 0.60 mcI .03 .03 Over 1.15 to 2.50 mcI .05 .05 Phosphorus 1 All ranges .01 Sulphur All ranges .01 Silicon To 0.30 mcI .02 .03 Over 0.30 to 1.00 mcI .05 .05 Nickel Over 5.30 to 10.00 mcI .10 .10 Over 10.00 to 14.00 mcI .15 .15 Chromium To 0.90 mcI .03 .03 Over 0.90 to 2.10 mcI .05 .05 Over 15.00 to 20.00 mcI .20 .20 Molybdenum To 0.20 mcI .01 .01 Over 0.20 to 0.40 mcI .02 .02 Over 1.75 to 3.0 mcI .10 .10 Titanium All ranges .05 .05 Columbium All ranges .05 .05 1 Rephosphorized steels not subject to check analysis for phosphorus.

(c) Identification of material. Material (d) Manufacture. Cylinders must be must be identified by any suitable manufactured using equipment and method except that plates and billets processes adequate to ensure that each for hotdrawn cylinders must be marked cylinder produced conforms to the re with the heat number. quirements of this subpart. No defect is

862 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 C-3 (IBR, not less than that specified for Amer see § 171.7 of this subchapter). ican Standard taper pipe threads. (e) Wail 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 4l30X, 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 S PD / 4tE gauge must permit reading of total ex 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 t minimum wall thickness in inches: of ficial test may not exceed 90 percent of E = 0.85 (provides 85 percent weld efficiency 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(l.3D2 + 0.4d2)1 / (D2 — dTI2) volumetric expansion at test pressure. Where: (4) Containers must be tested as fol lows: S = wall stress in psi: 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 (0 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 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 (1) The test must be performed after brazing or by welding or by threads. If the hydrostatic test. 863 § 178.53 49 CFR Ch. I (10—1—10 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 ‘/z 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 l’/z 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 /16 (iv) Cross-head speed of the testing inch thick. machine may not exceed 1/8 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 1½ 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 11/2 inches, or a gauge length at quired to 50 percent of the original out least 24 times the thickness with a side diameter without cracking. width not over 6 times the thickness is (1) Rejected cylinders. Reheat-treat authorized when a cylinder wall is not ment is authorized for rejected cyl over /I6 inch thick. inders. Subsequent thereto, containers 864 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 [Arndt. 178—114, 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 20031 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 C—3 (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(l.3D2 + — processes adequate to ensure that each 0.4d2)] / (D2 d2) 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 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. 865 § 178.55 49 CFR Ch. I (10—1—10 Edition)

(h) Openings in cylinders. Openings in must be tested as outlined in para cylinders must comply with the fol graphs (1) (1), (i) (2), and (i) (3) of this sec lowing: tion to at least two times service pres (1) Each opening in cylinders, except sure. those for safety devices, must be pro (ii) All cylinders not tested as out vided with a fitting, boss, or pad, se lined in paragraph (i) (4) (i) of this sec curely attached to the cylinder by tion must be examined under pressure brazing or by welding or by threads. A of at least two times service pressure fitting, boss, or pad must be of steel and show no defect. suitable for the method of attachment (5) Each 1000 cylinders or less succes employed, and which need not be iden sively produced each day must con tified or verified as to analysis, except stitute a lot. One cylinder must be se that if attachment is by welding, car lected from each lot and bon content may not exceed 0.25 per hydrostatically tested to destruction. cent. If threads are used, they must If this cylinder bursts below five times comply with the following: the service pressure, then two addi (i) Threads must be clean cut, even tional cylinders must be selected and without checks, and tapped to gauge. subjected to this test. If either of these (ii) Taper threads to be of length not cylinders fails by bursting below five less than as specified for American times the service pressure then the en Standard taper pipe threads. tire lot must be rejected. All cylinders (iii) Straight threads, having at least constituting a lot must be of identical 4 engaged threads, to have tight fit and size, construction heat-treatment, fin calculated shear strength at least 10 ish, and quality. times the test pressure of the cylinder; 0) Flattening test. Following the hy gaskets required, adequate to prevent drostatic test, one cylinder taken at leakage. random out of each lot of 200 or less, (2) Closure of a fitting, boss, or pad must be subjected to a flattening test must be adequate to prevent leakage. that is between knife edges, wedge (i) Hydrostatic test. Each cylinder shaped, 60° angle, rounded to ½ inch ra must successfully withstand a hydro dius. static test as follows: (k) Physical test. A physical test must (1) The test must be by water-jacket, be conducted to determine yield or other suitable method, operated so strength, tensile strength, elongation, as to obtain accurate data. The pres and reduction of area of material, as sure gauge must permit reading to an follows: accuracy of 1 percent. The expansion (1) The test is required on 2 speci gauge must permit reading of total ex mens cut from 1 cylinder, or part pansion to an accuracy of either 1 per thereof heat-treated as required, taken cent or 0.1 cubic centimeter. at random out of each lot of 200 or less (2) Pressure must be maintained for in the case of cylinders of capacity at least 30 seconds and sufficiently greater than 86 cubic inches and out of longer to ensure complete expansion. each lot of 500 or less for cylinders hav Any internal pressure applied after ing a capacity of 86 cubic inches or heat-treatment and previous to the of less. ficial test may not exceed 90 percent of (2) Specimens must conform to the the test pressure. If, due to failure of following: the test apparatus, the test pressure (i) A gauge length of 8 inches with a cannot be maintained, the test may be width not over 1½ inches, a gauge repeated at a pressure increased by 10 length of 2 inches with a width not percent or 100 psig, whichever is the over l’/z inches, or a gauge length at lower. least 24 times the thickness with a (3) Permanent volumetric expansion width not over 6 times the thickness is may not exceed 10 percent of total vol authorized when a cylinder wall is not umetric expansion at test pressure. over /16 inch thick. (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.

866 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 spector’s 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 (I) Pressure, approximately the same permanent strain of 0.2 percent the of as but no less than service pressure, gauge length. The following conditions must be applied apply: to one side of the fin ished bottom over an area of at least (i) The yield strength must be deter 1/G of the total area of the bottom but mined by either the offset” method or not less than 3/4 inch in diameter, in the “extension under load” method as cluding the closure, for at prescribed in ASTM E 8 (IBR, see least 1 §171.7 minute, during of this subchapter). which time the other 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) the stress at which the 0.2 percent per of this section, cylinders which manent strain occurs may deter are leak be ing must be rejected. mined with sufficient accuracy by cal (2) A spun culating the elastic extension of the cylinder is one in which an end closure in the gauge length under appropriate load finished cylinder has been welded and adding thereto 0.2 percent of the by the spinning process. gauge length. Elastic extension cal (3) A plugged cylinder is one in which culations must be based on an elastic a permanent closure in the bottom of a finished modulus of 30,000,000. In the event of cylinder has been effected by a controversy, the entire stress-strain plug. 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 ½ inch per inders that are leaking must be re minute during yield strength deter jected, except that: mination. (1) Spun cylinders rejected under the (1) 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. over 73 percent of tensile strength. In (3) Subsequent to the operations this instance the flattening test is re noted in paragraphs (n)(l) and (n)(2) of quired, without cracking, to six times this section, acceptable cylinders must the wall thickness with a weld 90 from pass all prescribed tests. 867 § 178.56 49 CFR Ch. I (10—1—10 Edition)

(o) Marking. Markings on each cyl bottoms of cylinders is authorized. inder must be by stamping plainly and Provided that such attachments are permanently on shoulder, top head, made of weldable steel, the carbon con neck or valve protection collar which tent of which does not exceed 0.25 per is permanently attached to the cyl cent. inders and forming an integral part (f) Wall thickness. The wall thickness thereof, provided that cylinders not of the cylinder must conform to the less than 0.090 inch thick may be following: stamped on the side wall adjacent to (1) For cylinders with an outside di top head. ameter over 5 inches, the minimum [Amdt. 178—114, 61 FR 25942, May 23, 1996, as wall thickness is 0.078 inch. In any amended at 66 FR 45386, Aug. 28, 2001; 67 FR case, the minimum wall thickness 51653, Aug. 8, 2002; 68 FR 75748, 75749, Dec. 31, must be such that the calculated wall 20031 stress at the minimum test pressure (in paragraph (i) of this section) may not § 178.56 Specification 4AA480 welded exceed the lesser value of either of the steel cylinders. following: (a) Type, size, and service pressure. A (i) One-half of the minimum tensile DOT 4AA480 cylinder is a welded steel strength of the material determined as cylinder having a water capacity required in paragraph (j) of this sec (nominal) not over 1,000 pounds water tion; or capacity and a service pressure of 480 (ii) 35,000 psi. psig. Closures welded by spinning proc (2) Calculation must be made by the ess not permitted. formula: (b) Steel. The limiting chemical com = position of steel authorized by this S [P(1.3D + 0.4d2)] / (D2 — d2) specification must be as shown in table Where: A this part. I of appendix to S wall stress in psi; (c) Identification of material. Material P = minimum test pressure prescribed for must be identified by any suitable water jacket test; that plates and billets method except D = outside diameter in inches: for hotdrawn cylinders must be marked d inside diameter in inches. with the heat number. (d) Manufacture. Cylinders must be (3) The ratio of tangential length to manufactured using equipment and outside diameter may not exceed 4.0 for processes adequate to ensure that each cylinders with a wall thickness less cylinder produced conforms to the re than 0.100 inch. quirements of this subpart. No defect is (g) Heat treatment. Each cylinder permitted that is likely to weaken the must be uniformly and properly heat finished cylinder appreciably. A rea treated prior to tests. Any suitable sonably smooth and uniform surface heat treatment in excess of 1100 °F is finish is required. Exposed bottom authorized except that liquid quench welds on cylinders over 18 inches long ing is not permitted. Heat treatment must be protected by footrings. Min must be accomplished after all forming imum thickness of heads and bottoms and welding operations. Heat treat may not be less than 90 percent of the ment is not required after welding required thickness of the side wall. weldable low carbon parts to attach Seams must be made as follows: ments of similar material which have (I) Circumferential seams must be been previously welded to the top or welded. Brazing is not authorized. bottom of cylinders and properly heat (2) Longitudinal seams are not per treated, provided such subsequent mitted. welding does not produce a tempera (3) Welding procedures and operators ture in excess of 400 °F., in any part of must be qualified in accordance with the top or bottom material. CGA C—3 (IBR, see § 171.7 of this sub (h) Openings in cylinders. Openings in chapter). cylinders must conform to the fol (e) Welding. Only the welding of lowing: neckrings, footrings, bosses, pads, and (1) All openings must be in the heads valve protection rings to the tops and or bases. 868 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 must be adequate conform to the to prevent leakage. following: (i) Hydrostatic test. Each cylinder (1) A gauge length must successfully withstand a hydro of 8 inches with a static test as follows: width not over 1½ inches, a gauge length of 2 (1) The test must be by water jacket, inches with a width not over 1/z inches, or or other suitable method, operated so a gauge length at least 24 times as to obtain accurate data. The pres the thickness with a width not over 6 times sure gauge must permit reading to an thickness is au thorized when accuracy of 1 percent. The expansion the cylinder wall is not over /IG inch thick. gauge must permit reading of total ex pansion to an accuracy of either 1 per (ii) The specimen, exclusive of grip cent or 0.1 cubic centimeter. ends, may not be flattened. Grip ends (2) Pressure must be maintained for may be flattened to within one inch of at least 30 seconds or sufficiently each end of the reduced section. 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 spector’s 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 subjected to the prescribed test. If ei of this subchapter). ther of these fails the test, then each (ii) In using the “extension under cylinder in that lot must be so tested; load” method, the total strain (or “ex and tension under load”), corresponding to 869 § 178.56 49 CFR Ch. I (10—1—10 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 (1)(l) of this section. Specimens must culations must be based on an elastic be taken from across the major seam modulus of 30000,000. In the event of and must be prepared and tested in ac stress-strain controversy, the entire cordance with and must meet the re diagram must plotted and the yield be quirements of CGA Pamphlet C-3. strength determined from the 0.2 per This cent offset. (3) Alternate guided-bend test. (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 C—3. 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 /8 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. 1 other cases for each 7,500 psi in by 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 one of the following locations on the ments. (1) Tests of welds. Welds must be test cylinder: ed as follows: (I) 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 J/16 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. on cylinder. The major weld the speci (4) Variations in location of mark must be taken across the major mens 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 C-3. jAmdt. 178—114, 61 FR 25942, May 23. 1996, as Should this specimen fail to meet the amended at 66 FR 45386, Aug. 28, 2001; 67 FR 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 870 Pipeline and Hazardous Materials Safety Admin., DOT § 178.57

§ 178.57 Specification 4L welded insu thickness of heads may not be less lated cylinders. than 90 percent of the required thick (a) Type, size, service pressure, and de ness of the sidewall. The heads must be sign service temperature. A DOT 4L cyl reasonably true to shape, have no ab inder is a fusion welded insulated cyl rupt shape changes, and the skirts inder with a water capacity (nominal) must be reasonably true to round. not over 1,000 pounds water capacity (3) The surface of the cylinder must and a service pressure of at least 40 but be insulated. The insulating material not greater than 500 psig conforming to must be fire resistant. The insulation the following requirements: on non-evacuated jackets must be cov (1) For liquefied hydrogen service, ered with a steel jacket not less than the cylinders must be designed to stand 0.060-inch thick or an aluminum jacket on end, with the axis of the cylindrical not less than 0.070 inch thick, so con portion vertical. structed that moisture cannot come in (2) The design service temperature is contact with the insulating material. If the coldest temperature for which a a vacuum is maintained in the insula cylinder is suitable. The required de tion space, the evacuated jacket must sign service temperatures for each be designed for a minimum collapsing cryogenic liquid is as follows: pressure of 30 psig differential whether made of steel or aluminum. The con Cryogenic liquid Design service temperature struction must be such that the total Argon Minus 320 F or colder. heat transfer, from the atmosphere at Helium Minus 452 F or colder. ambient temperature to the contents Hydrogen Minus 42 3 F or colder. of the cylinder, will not exceed 0.0005 Neon Minus 411 F or colder. Nitrogen Minus 320 F or colder. Btu per hour, per Fahrenheit degree Oxygen Minus 320 F or colder. differential in temperature, per pound of water capacity of the cylinder. For (b) Material. Material use in the con hydrogen, cryogenic liquid service, the struction of this specification must total heat transfer, with a temperature conform to the following: differential of 520 Fahrenheit degrees, (1) Inner containment vessel (cylinder). may not exceed that required to vent Designations and limiting chemical 30 SCF of hydrogen gas per hour. compositions of steel authorized by (4) For a cylinder having a design this specification must be as shown in service temperature colder than minus table 1 in paragraph (o) of this section. 320 °F, a calculation of the maximum (2) Outer jacket. Steel or aluminum weight of contents must be made and may be used subject to the require that weight must be marked on the ments of paragraph (o)(2) of this sec cylinder as prescribed in § 178.35. tion. (5) Welding procedures and oper (c) Identification of material. Material ations must be qualified in accordance must be identified by any suitable with CGA Pamphlet C-3 (IBR, see method. §171.7 of this subchapter). In addition, (d) Manufacture. Cylinders must be an impact test of the weld must be per manufactured using equipment and formed in accordance with paragraph processes adequate to ensure that each (1) of this section as part of the quali cylinder produced conforms to the re fication of each welding procedure and quirements of this subpart and to the operator. following requirements: (e) Welding. Welding of the cylinder (1) No defect is permitted that is must be as follows: likely to weaken the finished cylinder (1) All seams of the cylinder must be appreciably. A reasonably smooth and fusion welded. A means must be pro uniform surface finish is required. The vided for accomplishing complete pene shell portion must be a reasonably true tration of the joint. Only butt or joggle cylinder. butt joints for the cylinder seams are (2) The heads must be seamless, con authorized. All joints in the cylinder 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 871 § 178.57 49 CFR Ch. I (10—1—10 Edition) weldable material complying with the curely attached to, the cylinder body impact requirements of paragraph (1) 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 C—3 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. of graph (1) of this section as part the (ii) Taper threads to be of a length procedure qualification of each welding not less than that specified for NPT. and operator. (iii) Straight threads (4) Brazing, soldering and threading must have at least 4 engaged threads, tight are permitted only for joints not made fit and calculated shear strength directly to the cylinder body. Threads at least 10 times the must comply with the requirements of test pressure of the cylinder. paragraph (h) of this section. Gaskets, which prevent leakage and (f) Wail 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 (1) 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 (1) 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 1½ inches, a gauge following formula: length of 2 inches with width not over 11/2 S = [P(l.3D ± 0.4d2)] / (D2 — d2) 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; inder wall is not over ‘/16 inch thick). P = minimum test pressure prescribed for 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 third of the cylinder diameter, which spector’s 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. 872 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 of this subchapter). the major 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 C-3. tension under load”), corresponding to Should this specimen fail the stress at which the 0.2 percent per to meet the require manent strain occurs may be deter ments, specimens may be taken from mined with sufficient accuracy by cal two additional cylinders or welded test 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 (1) (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 arid 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 C—3. machine may not exceed /8 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 C-3. 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)(l), 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 ten elongation for a 2-inch gage length. Ex a sile strength in excess cept that the percentage may be re of 100,000 psig, as provided in paragraph duced numerically by 2 for each 7,500 (c) of this sec 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— (1) Tests of welds. Welds must be test (1) As part of the qualification of the ed as follows: welding procedure. V (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. 873 § 17&57 49 CFR Ch. 1(10—1—10 Edition)

(iv) For each 1,000 feet of weld made Minimum Minimum . value with the same heat of welding rod or required for impact wire. Size of spemen avg. of each (v) All impact test specimens must be specimens setf1ree ( of the charpy type, keyhole or milled (ft-lb.) U-notch, and must conform in all re 10 mmxl0 mm 15 10 spects to ASTM E 23 (IBR, see §171.7 of 10 mmx7.5 mm 12.5 8.5 this subchapter). Each set of impact 10 mmx5 mm 10 7.0 10 mmx2.5 mm 5 3.5 specimens must be taken across the weld and have the notch located in the (viii) When the average value of the weld metal. When the cylinder mate three specimens equals or exceeds the rial thickness is 2.5 mm or thicker, im minimum value permitted for a single pact specimens must be cut from a cyl specimen and the value for more than inder or welded test plate used for the one specimen is below the required av tensile or bend test specimens. The di erage value, or when the value for one mension along the axis of the notch specimen is below the minimum value must be reduced to the largest possible permitted for a single specimen, a of 10 mm, 7.5 mm, 5 mm or 2.5 mm, de retest of three additional specimens pending upon cylinder thickness. When must be made. The value of each of the material in the cylinder or welded these retest specimens must equal or test plate is not of sufficient thickness exceed the required average value. to prepare 2.5 mm impact test speci When an erratic result is caused by a mens, 2.5 mm specimens must be pre defective specimen, or there is uncer pared from a welded test plate made tainty in test procedure, a retest is au thorized. from ‘/8 inch thick material meeting the requirements specified in para (m) Radiographic examination. Cyl graph (o)(l), table 1, of this section and inders must be subject to a radio as follows: having a carbon analysis of .05 min graphic examination (I) The and acceptability imum, but not necessarily from one of techniques of radiographic inspection must con the heats used in the lot of cylinders. form to the standards set forth in CGA piece must be welded by the The test Pamphlet C-3. procedure as used on the same welding (2) One finished longitudinal seam quali particular cylinder seam being must be selected at random from each fied and must be subjected to the same lot of 100 or less successively produced heat treatment. and be radiographed throughout its en (vi) Impact test specimens must be tire length. Should the radiographic cooled to the design service tempera examination fail to meet the require ture. The apparatus for testing the ments of paragraph (m) (I) of this sec specimens must conform to require tion, two additional seams of the same ments of ASTM Standard E 23. The test lot must be examined, and if either of piece, as well as the handling tongs, these fail to meet the requirements of must be cooled for a length of time suf (m) (1) of this section, only those pass ficient to reach the service tempera ing are acceptable. ture. The temperature of the cooling (n) Rejected cylinders. Reheat treat device must be maintained within a ment of rejected cylinders is author range of plus or minus 3 °F. The speci ized. Subsequent thereto, cylinders men must be quickly transferred from must pass all prescribed tests to be ac the cooling device to the anvil of the ceptable. Welds may be repaired by testing machine and broken within a suitable methods of fusion welding. time lapse of not more than six sec (o) Authorized materials of construc of construc onds. tion. Authorized materials tion are as follows: (vii) The impact properties of each (1) Inner containment vessel (cylinder). of impact specimens may not be set Electric furnace steel of uniform qual the values in the following less than ity must be used. Chemical analysis table: must conform to ASTM A 240/A 240M (IBR, see §171.7 of this subchapter), 874 ______

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)(l) is acceptable, even portation of flammable cryogenic liq though its check chemical analysis is uid must have an outer jacket made slightly of out of the specified range, if it steel. is satisfactory in all other respects, (p) Markings. (I) Markings provided the tolerances shown in table must be stamped plainly and permanently 3 in this paragraph (o)(l) are not ex on ceeded. The following chemical anal shoulder or top head of jacket or on a yses and physical properties are au permanently attached plate or head thorized: protective ring. (2) The letters ‘ST”, followed by the TABLE 1 —AUTHORIZED MATERIALs design service temperature (for exam ple, ST-423F), must be marked on anarss, cyl Designation ceTical inders having a design service tempera ture of colder than minus 320 CF Carbon 1 0.08 max. only. Manganese 2.00 max. Location to be just below the DOT Phosphorus 0.045 max. mark. Sulphur 0.030 max. Silicon 1.00 max. (3) The maximum weight of contents, Nickel 8.00—10.50. in pounds (for example. ‘ Max. Content Chromium 18.00—20.00. 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 TABLE 2—PHYSICAL PROPERTIES the cylinder (for example, THIS END UP), if the cyl Physical inder is used in an orientation other 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 3—CHECK ANALYSIS TOLERANCES (6) Except for serial number and jack Tolerance et material designation, each marking over the prescribed in this paragraph (p) must Elements Limit or specified range maximum (percent) limit or under be duplicated on each cylinder by any the minimum limit suitable means. (q) Inspector’s report. In addition to Carbon To 0.030, mcI 0.005 the information Over 0.30 to 0.20, mcI 0.01 required by § 178.35, the Manganese To 1.00 mcI .03 inspector’s reports must contain infor Over 1.00 to 3.00. nd 0.04 mation on: Phosphorus1 To 0.040, mcI 0.005 (I) The jacket material and insula Over 0.040 to 0.020 mcI .. 0.010 Sulphur To .40 mcI 0.005 tion type; Silicon To 1.00, mcI 0.05 (2) The design service temperature Nickel Over 5.00 to 10.00, mcI ... 0.10 Over 10.00 to 20.00, mcI 0.15 (vF); and Chromium Over 15.00 to 20.00, mcI 0.20 (3) The impact test results, on a lot 1 Rephosphorized steels not subject to check analysis for phosphorus. basis. (2) Outer jacket. (i) Nonflammable lAmdt. 178—114, 61 FR 25942, May 23, 1996, as cryogenic liquids. Cylinders intended amended at 66 FR 45386—45388, Aug. 28, 2001: 67 FR 51653, Aug. for use in the transportation of non 8, 2002; 68 FR 75748, Dec. 31, 20031 flammable cryogenic liquid must have

875 § 178.58 49 CFR Ch. I (10—1—10 Edition)

§ 178.58 Specification 4DA welded steel (d) Manufacture. Cylinders must be cylinders for aircraft use. manufactured in accordance with the (a) Type, size, and service pressure. A following requirements: DOT 4DA is a welded steel sphere (two (1) By best appliances and methods. seamless hemispheres) or a circum No defect is acceptable that is likely to ferentially welded cylinder (two seam weaken the finished container appre less drawn shells) with a water capac ciably. A reasonably smooth and uni ity not over 100 pounds and a service form surface finish is required. No ab pressure of at least 500 but not over 900 rupt change in wall thickness is per psig. mitted. Welding procedures and opera tors must be qualified in (b) Steel. Open-hearth or electric steel accordance with CGA Pamphlet of uniform quality must be used. A C—3 (IBR, see 171.7 of this subchapter). heat of steel made under table 1 in this § (2) All seams of the sphere or cyl paragraph (b), check chemical analysis inders must be fusion welded. of which is slightly out of the specified Seams must be of the butt or joggle butt type range, is acceptable, if satisfactory in and means must be provided for accom all other respects, provided the toler plishing complete penetration ances shown in table 2 in this para of the joint. graph (b) are not exceeded except as ap (e) Welding. Attachments to the con proved by the Associate Administrator. tainer are authorized by fusion welding The following chemical analyses are provided that such attachments are authorized: made of weldable steel, the carbon con TABLE 1—AuThoRIzED MATERIALS tent of which may not exceed 0.25 per cent except in the case of 4130 steel. 4130 Percent (f) Wall thickness. The minimum wall thickness must be such that the wall Carbon 0.28/0.33. stress at the minimum specified Manganese 0.40/0.60. test Phosphorus 0.040 max. pressure may not exceed 67 percent of Sulfur 0.040 max. the minimum tensile strength of the Silicon 0.15/0.35. steel as determined from the physical Chromium 0.80/1.10. and burst tests required and may not Molybdenum 0.15/0.25. be over 70,000 psi. For any diameter container, the minimum wall thickness TABLE 2—CHECK ANALYSIS TOLERANCES is 0.040 inch. Calculations must be made by the formulas in (f)(l) or (f1(2) Tolerance (per. cent) over the of this section: maximum limit or (1) Calculation for a sphere must be under the mm Limit or maximum imum limit made by the following formula: E amen specified (percent) Under Over S PD / 4tE mm- max imum mum Where: limit limit S = wall stress in pounds psi; Carbon Over 0.15 to 0.40 mcI .03 04 P = test pressure prescribed for water jacket Manganese To 0.60 mcI 03 test, i.e., at least 2 times service pressure, Phosphorus1 All ranges 01 in psig; Sulphur All ranges 01 D = outside diameter in inches; Silicon To 0.30 mcI 03 t = minimum wall thickness in inches; Over 0.30 to 1.00 mcI .05 05 E = 0.85 (provides 85 percent weld efficiency Chromium To 0.90 nd 03 factor which must be applied in the girth Over 0.90 to 2.10 mcI .05 05 weld area and heat affected zones which Molybdenum To 0.20 mcI 01 zone must extend a distance of 6 times wall Over 0.20 to 0.40, mcI .02 02 thickness from center line of weld); 1 Rephosphorized steels not subject to check analysis for E = 1.0 (for all other areas). phosphorus. (2) Calculation for a cylinder must be (c) Identification of material. Materials made by the following formula: must be identified by any suitable S = [P(1.3D ± — method except that plates and billets 0.4d2)] / (D2 d2) for hot-drawn containers must be Where: marked with the heat number. S = wall stress in pounds psi; 876 Pipeline and Hazardous Materials Safety Admin., DOT § 178.58

P = test pressure prescribed for water jacket (1) Hydrostatic test. Each cylinder test. i.e., at least 2 times service pressure. must successfully in psig; withstand a hydro 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 analysis except be 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 being of 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 (5) All cylinders, if water quenched or to at least 2 times service pressure. quenched with a liquid producing a Burst test. One cooling rate in excess of 80 percent of (j) container taken at random out the cooling rate of water, must be in of 200 or less must be hydrostatically spected by the magnetic particle or dye tested to destruction. The rupture pressure penetrant method to detect the pres must be included as part ence of quenching cracks. Any cylinder of the inspector’s report. 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 (h) Openings in container. Openings in tening test as follows: 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 he subjected to a must be provided with a fitting, boss, flattening test as follows: or pad of weldable steel securely at (1) 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. 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 ‘/2-inch ra prevent leakage. dius. 877 § 178.58 49 CFR Ch. I (10—1—10 Edition)

(1) Radiographic inspection. Radio the “extension under load’S method as graphic examinations is required on all prescribed in ASTM E 8 (IBR, see §171.7 welded joints which are subjected to in of this subchapter). ternal pressure, except that at the dis (ii) In using the “extension under cretion of the disinterested inspector, load” method, the total strain (or ‘ex openings less than 25 percent of the tension under load”) corresponding to sphere diameter need not be subjected the stress at which the 0.2 percent per to radiographic inspection. Evidence of manent strain occurs may be deter any defects likely to seriously weaken mined with sufficient accuracy by cal the container must be cause for rejec culating the elastic extension of the tion. gauge length under appropriate load (m) Physical test and specimens for and adding thereto 0.2 percent of the spheres and cylinders. Spheres and cyl gauge length. Elastic extension cal inders must be subjected to a physical culations must be based on an elastic test as follows: modulus of 30,000,000. In the event of (1) A physical test for a sphere is re controversy, the entire stress-strain quired on 2 specimens cut from a flat diagram must be plotted and the yield representative sample plate of the strength determined from the 0.2 per same heat taken at random from the cent offset. steel used to produce the sphere. This (iii) For the purpose of strain meas flat steel from which the 2 specimens urement, the initial strain must be set are to be cut must receive the same while the specimen is under a stress of heat-treatment as the spheres them 12,000 psi and the strain indicator read selves. Sample plates to be taken for ing being set at the calculated cor each lot of 200 or less spheres. responding strain. (2) Specimens for spheres have a (iv) Cross-head speed of the testing gauge length of 2 inches with a width machine may not exceed 1/g inch per not over l’/2 inches, or a gauge length minute during yield strength deter at least 24 times thickness with a mination. width not over 6 times thickness is au (n) Acceptable results for physical, flat thorized when wall of sphere is not tening, and burst tests. The following are over 3/io inch thick. acceptable results of the physical, flat (3) A physical test for cylinders is re tening and burst test: 2 specimens cut from 1 cyl quired on (1) Elongation must be at least 20 at random out of each lot inder taken percent for a 2-inch gauge length or 10 of 200 or less. percent in other cases. (4) Specimens for cylinder must con (2) Flattening is required to 50 per form to the following: cent of the original outside diameter (i) A gauge length of 8 inches with a without cracking. width not over 11/z inches, a gauge length of 2 inches with a width not (3) Burst pressure must be at least 3 over li/a inches, a gauge length at least times service pressure. 24 times thickness with a width not (o) Rejected containers. Reheat-treat over 6 times thickness is authorized ment of rejected cylinders is author ized. containers when a cylinder wall is not over /lG Subsequent thereto, inch thick. must pass all prescribed tests to be ac (ii) The specimen, exclusive of grip ceptable. Repair of welded seams by ends, may not be flattened. Grip ends welding prior to reheat-treatment is may be flattened to within 1 inch of authorized. each end of the reduced section. (p) Marking. Markings on each con (iii) Heating of a specimen for any tainer must be stamped plainly and purpose is not authorized. permanently on a permanent attach (5) The yield strength in tension ment or on a metal nameplate perma must be the stress corresponding to a nently secured to the container by permanent strain of 0.2 percent of the means other than soft solder. gauge length. The following conditions lAmdt. 178-114, 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, 20031 878 Pipeline and Hazardous Materials Safety Admin., DOT § 178.59 § 178.59 Specification 8 steel cylinders pansion to an accuracy of either 1 per with porous fillings for acetylene. cent or 0.1 cubic centimeter. (a) Type and service pressure. A DOT 8 (2) Pressure must be maintained for cylinder is a seamless cylinder with a at least 30 seconds and sufficiently service pressure of 250 psig. The fol longer to ensure complete expansion. lowing steel is authorized: Any internal pressure applied after (1) A longitudinal seam if forge lap heat-treatment and previous to the of welded; ficial test may not exceed 90 percent of (2) Attachment of heads by welding the test pressure. or by brazing by dipping process; or (3) Permanent volumetric expansion (3) A welded circumferential body may not exceed 10 percent of total vol seam if the cylinder has no longitu umetric expansion at test pressure. dinal seam. (4) One cylinder out of each lot of 200 (b) Steel. Open-hearth, electric or or less must be hydrostatically tested basic oxygen process steel of uniform to at least 750 psig. Cylinders not so quality must be used. Content percent tested must be examined under pres may not exceed the following: Carbon, sure of between 500 and 600 psig and 0.25; phosphorus, 0.045; sulphur, 0.050. show no defect. If hydrostatically test (c) Identification of steel. Materials ed cylinder fails, each cylinder in the must be identified by any suitable lot may be hydrostatically tested and method except that plates and billets those passing are acceptable. for hot-drawn cylinders must be (1) Leakage test. Cylinders with bot marked with the heat number. toms closed in by spinning must be (d) Manufacture. Cylinders must be subjected to a leakage test by setting manufactured using equipment and the interior air or gas pressure to not processes adequate to ensure that each less than the service pressure. Cyl cylinder produced conforms to the re inders which leak must be rejected. quirements of this subpart. No defect is (j) Physical test. A physical test must acceptable that is likely to weaken the be conducted as follows: finished cylinder appreciably. A rea (1) The test is required on 2 speci sonably smooth and uniform surface mens cut longitudinally from 1 cyl finish is required. Welding procedures inder or part thereof taken at random and operators must be qualified in ac out of each lot of 200 or less, after heat cordance with CGA Pamphlet C-3 (IBR, treatment. see § 171.7 of this subchapter). (2) Specimens must conform to a (e) Exposed bottom welds. Exposed bot gauge length of 8 inches with a width tom welds on cylinders over 18 inches not over 1½ inches, a gauge length of 2 long must be protected by footrings. inches with width not over l’/2, or a (f) Heat treatment. Body and heads gauge length at least 24 times thick formed by drawing or pressing must be ness with a width not over 6 times uniformly and properly heat treated thickness is authorized when a cylinder prior to tests. wall is not over /I6 inch thick. (g) Openings. Openings in the cyl (3) The yield strength in tension inders must comply with the following: must be the stress corresponding to a (1) Standard taper pipe threads are permanent strain of 0.2 percent of the required; gauge length. The following conditions (2) Length may not be less than as apply: specified for American Standard pipe (i) The yield strength must be deter threads; tapped to gauge; clean cut, mined by either the offset” method or even, and without checks. the ‘extension under load” method as (h) Hydrostatic test. Each cylinder prescribed in ASTM E 8 (IBR, see §171.7 must successfully withstand a hydro of this subchapter). static test as follows: (ii) In using the ‘extension under (1) The test must be by water-jacket, load” method, the total strain (or ‘ex or other suitable method, operated so tension under load”) corresponding to 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 879 § 178.59 49 CFR Ch. I (10—1—10 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 C-12. 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 ‘/8 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 tiller 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 (1) 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: is au ing material beneath the valve Masimum thorized if the well is filled with a ma acetone sol terial of such type that the functions Percent porosity of tiller 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 80to83 37.1 75 to 80 34.8 and filling material, after solvent has 70 to 75 32.5 been added, does not exceed ‘/z of 1 per 65 to 70 30.2 cent of the respective diameter or length, but not to exceed ‘/8 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— and (1) Certify chemical analyses of steel (vi) Porosity of filling material may used, signed by manufacturer thereof: not exceed 80 percent except that fill also verify by, check analyses of sam- ing material with a porosity of up to 92 pies taken from each heat or from 1 out 880 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 (3) Prepare report on manufacture of produced conforms to the re quirements this steel shells in form prescribed in of subpart. No defect is permitted that is §178.35. Furnish one copy to manufac likely to weaken the finished cylinder appreciably. turer and three copies to the company A rea sonably smooth and uniform that is to complete the cylinders. surface 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 C-3 (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 (I) 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 (0(1) of this section, of (3) Cylinders, not completed, when similar material which have been pre delivered must each be marked for viously welded or brazed to the top or bottom identification of each lot of 200 or less. of cylinders and properly heat treated, provided such subsequent [Amdt. 178—114, 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, 20031 (g) Wall thickness; wall stress. The wall thickness/wall stress of the cylinder 178.60 Specification steel § 8AL cyl must conform inders with porous fillings for acet to the following: 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 (I) of this section, whichever value is psig. However, the attachment of heads the smaller. The measured wall thick by welding or by brazing by dipping ness may not include galvanizing or process and a welded circumferential other protective coating. body seam is authorized. Longitudinal (i) Calculation of wall stress must be seams are not authorized. made by the formula: 881 § 178.60 49 CFR Ch. I (10—1—10 Edition)

S fP(1.3D2 ± 0.4d2)j I (D — d2) sure of between 500 and 600 psig and show no defect. If a hydrostatically Where: tested cylinder fails, each cylinder in S wall stress in pounds psi; the lot may be hydrostatically tested P = 750 psig (minimum test pressure); D outside diameter in inches; and those passing are acceptable. d = inside diameter in inches. (k) Leakage test. Cylinders with bot toms closed must be (ii) Either D or d must be calculated in by spinning leakage tested by setting the interior from the relation D = d ± 2t, where t = minimum wall thickness. air or gas pressure at not less than the (2) Cylinders with a wall thickness service pressure. Any cylinder that less than 0.100 inch, the ratio of leaks must be rejected. straight side wall length to outside di (1) Physical test. A physical test must ameter may not exceed 3.5. be conducted as follows; (3) For cylinders having outside di (1) The test is required on 2 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 1’/z inches, a gauge length 2 forming and welding operations, except inches with a width not over l’/z 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 /j6 inch thick. ing operations. Liquid quenching is not (3) The yield strength in tension authorized. must be the stress corresponding to a taper pipe (i) Openings. Standard permanent strain of 0.2 percent of the all openings. The threads required in gauge length. The following conditions may not be less length of the opening apply: than as specified for American Stand (i) The yield strength must be deter ard pipe threads; tapped to gauge; clean cut, even, and without checks. mined by either the “offset” method or the “extension under load” method as (j) Hydrostatic test. Each cylinder prescribed in must successfully withstand a hydro 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 (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. 882 Pipeline and Hazardous Materials Safety Admin., DOT § 178.60 (iv) Cross-head speed of the testing ized. Subsequent thereto, cylinders machine may not exceed ½ inch per must pass all prescribed tests to be ac minute during yield strength deter ceptable. Repair by welding is author mination. ized. Elongation. (m) Physical test speci (p) Porous filling. (1) Cylinders must mens must show at least a 40 percent be filled with a porous material in ac elongation for a 2 inch gauge length or cordance with the following: at least a 20 percent elongation in (i) The porous material may other cases. Except that these elon not dis integrate or sag when with gation percentages may be reduced nu wet solvent or when subjected merically by 2 for 2 inch specimens and to normal service; 1 in other cases for each 7,500 psi incre (ii) The filling material must be uni ment of tensile strength above 50,000 form in quality and free of voids, ex psi to a maximum of four such incre cept that a well drilled into the filling ments. material beneath the valve is author (n) Weld tests. Specimens taken ized if the well is filled with a material across the circumferentially welded of such type that the functions of the seam must be cut from one cylinder filling material are not impaired; taken at random from each lot of 200 or (iii) Overall shrinkage of the filling less cylinders after heat treatment and material is authorized if the total must pass satisfactorily the following clearance between the cylinder shell tests: and filling material, after solvent has Tensile (1) test. A specimen must be been added, does not exceed ‘/2 of 1 per cut from one cylinder of each lot of 200 cent of the respective diameter or or less, or welded test plate. The speci length but not to exceed i/ inch, meas men must be taken from across the ured diametrically and longitudinally; major seam and must be prepared and (iv) The clearance may not impair tested in accordance with and must the functions of the filling material; meet the requirements of CGA Pam (v) The installed phlet C-3. Should this specimen fail to filling material must meet meet the requirements, specimens may the requirements of CGA C— be taken from two additional cylinders 12 (IBR, see §171.7 of this subchapter); or welded test plates from the same lot and and tested. If either of the latter speci (vi) Porosity of filling material may mens fail to meet the requirements, not exceed 80 percent except that fill the entire lot represented must be re ing material with a porosity of up to 92 jected. percent may be used when tested with (2) Guided bend test. A root bend test satisfactory results in accordance with specimen must be cut from the cyl CGA Pamphlet C—12. inder or welded test plate, used for the (2) When the porosity of each cyl tensile test specified in paragraph inder is not known, a cylinder taken at (n)(l) of this section. Specimens must random from a lot of 200 or less must be prepared and tested in accordance be tested for porosity. If the test cyl with and must meet the requirements inder fails, each cylinder in the lot of CGA Pamphlet C-3. may be tested individually and those Alternate (3) guided-bend test. This cylinders that pass the test are accept test may be used and must be as re able. quired by CGA Pamphlet C-3. The spec (3) For filling that is molded imen must be bent until the elongation and dried before insertion at the outer surface, adjacent to the in cylinders, po rosity test root of the weld, between the lightly may be made on sample block taken scribed gage lines-a to b, must be at at random from material least 20 percent, except that this per to be used. centage may be reduced for steels hav (4) The porosity of the filling mate ing a tensile strength in excess of 50,000 rial must be determined; the amount of psi, as provided in paragraph (m) of solvent at 70 °F for a cylinder: this section. (i) Having shell volumetric capacity (o) Rejected cylinders. Reheat treat above 20 pounds water capacity (nomi ment of rejected cylinders is author- nal) may not exceed the following: 883 § 178.61 49 CFR Ch. I (10—1—10 Edition)

Maximum acetone upon request, to the purchaser. The Percent porosity of solvent percent shell in capacity by volume test reports must be retained by the spector for fifteen years from the origi 90 to 92 43.4 nal test date of the cylinder. 87 to 90 42.0 weight of cyl 83 to 87 40.0 (s) Marking. (1) Tare 80 to 83 38.6 inder, in pounds and ounces, must be 75 to 80 36.2 marked on the cylinder. 70 to 75 33.8 (2) Cylinders, not completed, when 65 to 70 31.4 delivered must each be marked for (ii) Having volumetric capacity of 20 identification of each lot of 200 or less. pounds or less water capacity (nomi (3) Markings must be stamped plainly nal), may not exceed the following: and permanently in locations in ac cordance with the following: Maximum acetone (i) On shoulders and top heads not Percent porosity of filler solvent percent shell capacity by volume less than 0.087 inch thick; or (ii) On neck, valve boss, valve protec 90 to 92 41.8 part perma 83 to 90 38.5 tion sleeve, or similar 80 to 83 37.1 nently attached to the top end of cyl 75 to8O 34.8 inder; or 70 to 75 32.5 plate of ferrous material at 65 to 70 30.2 (iii) On a tached to the top of the cylinder or (q) Tare weight. The tare weight is permanent part thereof; the plate must the combined weight of the cylinder be at least /i6 inch thick, and must be proper, porous filling, valve, and sol attached by welding, or by brazing at a vent, but without removable cap. temperature of at least 1,100 °F (r) Duties of inspector. In addition to throughout all edges of the plate. Suffi the requirements of § 178.35, the inspec cient space must be left on the plate to tor shall— provide for stamping at least four (4) (1) Certify chemical analyses of steel retest dates. used, signed by manufacturer thereof; [Amdt. 178—114, 61 FR 25942, May 23, 1996, as also verify by check analyses, of sam amended at 66 FR 45386, 45388, Aug. 28. 2001; ples taken from each heat or from 1 out 67 FR 51654, Aug. 8, 2002; 68 FR 75748, 75749, of each lot of 200 or less plates, shells, Dec. 31, 20031 or tubes used. (2) Verify compliance of cylinder § 178.61 Specification 4BW welded shells with all shell requirements, in steel cylinders with electric-arc seam. spect inside before closing in both ends, welded longitudinal verify heat treatment as proper; obtain (a) Type, size and service pressure. A all samples for all tests and for check DOT 4BW cylinder is a welded type analyses, witness all tests; verify steel cylinder cvith a longitudinal elec threads by gauge, report volumetric ca tric-arc welded seam, a water capacity pacity and minimum thickness of wall (nominal) not over 1,000 pounds and a noted. service pressure at least 225 and not (3) Report percentage of each speci over 500 psig gauge. Cylinders closed in fied alloying element in the steel. Pre by spinning process are not authorized. pare report on manufacture of steel (b) Authorized steel. Steel used in the shells in form prescribed in § 178.35. construction of the cylinder must con Furnish one copy to manufacturer and form to the following: three copies to the company that is to (1) The body of the cylinder must be complete the cylinders. constructed of steel conforming to the (4) Determine porosity of filling and limits specified in table 1 of appendix A tare weights; verify compliance of to this part. marking with prescribed requirements; (2) Material for heads must meet the obtain necessary copies of steel shell requirements of paragraph (a) of this reports prescribed in paragraph (b) of section or be open hearth, electric or 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 884 Pipeline and Hazardous Materials Safety Admin., DOT § 78.61 0.050. Heads must be hemispherical or completely. Maximum joint efficiency ellipsoidal in shape with a maximum must be 0.90 when one cylinder from ratio of 2.1. If low carbon steel is used, each lot of 50 consecutively welded cyl the thickness of such heads must be de inders is spot radiographed. In addi termined by using a maximum wall tion, one out of the first five cylinders stress of 24,000 psi. in the formula de welded following a shut down of weld scribed in paragraph (f)(4) of this sec ing operations exceeding four hours tion. must be spot radiographed. Spot (c) Identification of material. Material radiographs, when required, must be must be identified by any suitable made of a finished welded cylinder and method. must include the girth weld for 2 (d) Manufacture. Cylinders must be inches in both directions from the manufactured using equipment and intersection of the longitudinal and processes adequate to ensure that each girth welds and include at least 6 cylinder produced conforms to the re inches of the longitudinal weld. Max quirements of this subpart and the fol imum joint efficacy of 0.75 must be per lowing: missible without radiography. (1) No defect is permitted that is (4) Welding procedures and operators likely to weaken the finished cylinder must be qualified in accordance with appreciably. A reasonably smooth and CGA Pamphlet C-3 (IBR, see §171.7 of uniform surface is required. Exposed this subchapter). bottom welds on cylinders over 18 (e) Welding of attachments. The at inches long must be protected by tachment to the tops and bottoms only footrings. Minimum thickness of heads of cylinders by welding of neckrings, may not be less than 90 percent of the footrings, handles, bosses, pads and required thickness of the sidewall. valve protection rings is authorized Heads must be concave to pressure. provided that such attachments and (2) Circumferential seams must be by the portion of the container to which electric-arc welding. Joints must be they are attached are made of weldable butt with one member offset goggle steel, the carbon content of which may butt) or lap with minimum overlap of not exceed 0.25 percent. at least four times nominal sheet (f) Wall thickness. For outside diame thickness ters over 6 inches the minimum wall (3) Longitudinal seams in shells must thickness must be 0.078 inch. For a cyl conform to the following: inder with a wall thickness less than (1) Longitudinal electric-arc welded 0.100 inch, the ratio of tangential seams must be of the butt welded type. length to outside diameter may not ex Welds must be made by a machine ceed 4 tol (4:1). In any case the min process including automatic feed and imum wall thickness must be such that welding guidance mechanisms. Longi the wall stress calculated by the for tudinal seams must have complete mula listed in paragraph (0(4) of this joint penetration, and must be free section may not exceed the lesser value from undercuts, overlaps or abrupt of any of the following: ridges or valleys. Misalignment of mat (1) The value referenced in paragraph ing butt edges may not exceed ½ of (b) of this section for the particular material under consideration. nominal sheet thickness or ½2 inch One-half whichever is less. All joints with nomi (2) of the minimum tensile strength nal sheet thickness up to and including of the material determined as required in ‘/s inch must be tightly butted. When paragraph U) of this sec tion. nominal sheet thickness is greater (3) 35,000 psi. than ½ inch, the joint must be gapped (4) Stress must be calculated with maximum distance equal to one- by the following formula: half the nominal sheet thickness or ‘/3a = inch whichever is less. Joint design, S [2P(l.3D2 + 0.4d2)1 / IE(D2 — d2)] preparation and fit-up must be such where: that requirements of this paragraph (d) S wall stress, are satisfied. psi: P = service pressure, psig: (ii) Maximum joint efficiency must O = outside diameter, inches; be 1.0 when each seam is radiographed d = inside diameter, inches; 885 § 178.61 49 CFR Ch. I (10—1—10 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 (1) 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 (1) (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: (1) 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 l/z inches, a gauge accuracy of 1 percent. The expansion length of 2 inches with a width not gauge must permit readings of total over l’/z 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 3/ (2) Pressure must be maintained for inch thick. at least 30 seconds and sufficiently (ii) The specimen, exclusive of grip longer to ensure complete expansion. ends, may not be flattened. Grip ends Any internal pressure applied after may be flattened to within 1 inch of heat treatment and previous to the of- each end of the reduced section. 886 Pipeline and Hazardous Materials Safety Admin., DOT § 178.61 (iii) When size of the cylinder does (I) Tests of welds. Welds must be sub not permit securing straight speci jected to the following tests: mens, the specimens may be taken in (I) 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 spector’s report must show in connec ance with and must meet the require tion with record of physical tests de ments of CGA Pamphlet C-3. tailed information in regard such to (2) Guided bend specimens. test. A root test speci men must be cut from the (iv) Heating of a specimen for any cylinder purpose is not authorized. used for the tensile test specified in paragraph (3) The yield strength in tension (l)(l) of this section. Speci mens must be the stress corresponding to a must be taken from across the 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 C-3. 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 C-3. 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 (I) 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 C-3. When fluoroscopic cent offset. inspection is used, permanent film records (iii) For the purpose of strain meas need 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 ½ 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 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.

887 § 178.65 49 CFR Ch. I (10—1—10 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.5.1g. 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. (1) 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 0.12 015 least six retest dates: the plate must be Phosphorus, maximum percent .04 .05 at least ‘lie-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) Inspector’s 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 inspector’s 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 25942, May 23, 1996, as [Amdt. 178—114, 61 FR Association standard for alloys 1060, amended at 64 FR 51919, Sept. 27, 1999; 66 FR 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 (1) 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. (1,526 cubic inches) for a service pres (iii) No defect of any kind is per sure of 500 p.5.1g. 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: 888 Pipeline and Hazardous Materials Safety Admin., DOT § 178.65

(i) Brazing is not authorized on alu O = Outside diameter, in inches; minum cylinders. t = Minimum wall thickness, in inches. (ii) Brazing material must have a (e) Openings anti attachments. melting point not Open of lower than 1,000 ings and °F. attachments must conform to the following: (iii) Brazed seams must be assembled (1) Openings and attachments with proper fit to ensure complete pen are permitted on heads etration of the brazing material only. (2) throughout the brazed joint. All openings and their reinforce ments must (iv) Minimum width of brazed joints be within an imaginary circle, concentric must be at least four times the thick to the axis of the cyl inder. ness of the shell wall. The diameter of the circle may not exceed (v) Brazed seams must have design 80 percent of the outside di ameter of the strength equal to or greater than 1.5 cylinder. The plane of the circle must times the minimum strength of the be parallel to the plane shell wall. of a circumferential weld and normal to the long (vi) Welded seams must be properly axis of the cylinder. aligned and welded by a method that (3) Unless a head has adequate thick provides clean, uniform joints with ness, each opening must be reinforced adequate penetration. by a securely attached fitting, boss, pad, collar, (vii) Welded joints must have a or other suitable means. strength equal to or greater than the (4) Material used for welded openings minimum strength of the shell mate and attachments must be of weldable rial in the finished cylinder. quality and compatible with the mate (3) Attachments to the cylinder are rial of the cylinder. permitted by any means which will not (I) Pressure tests. (1) Each cylinder be detrimental to the integrity of the must be tested at an internal pressure cylinder. Welding or brazing of attach of at least the test pressure and must ments to the cylinder must be com be held at that pressure for at least 30 pleted prior to all pressure tests. seconds. (4) Welding procedures and operators (i) The leakage test must be con must be qualified in accordance with ducted by submersion under water or CGA Pamphlet C-3 (IBR, see §171.7 of by some other method that will be this subchapter). equally sensitive. (d) Wall thickness. The minimum wall (ii) If the cylinder leaks, evidences thickness must be such that the wall visible distortion, or any other defect, stress at test pressure does not exceed while under test, it must be rejected the yield strength of the material of (see paragraph (h) of this section). the finished cylinder wall. Calculations (2) One cylinder taken from the be must be made by the following for ginning of each lot, and one from each mulas: 1,000 or less successively produced (1) Calculation of the stress for cyl within the lot thereafter, must be inders must be made by the following hydrostatically tested to destruction. formula: The entire lot must be rejected (see paragraph (h) of this ± section) if: S = IP(1.3D2 0.4d2)] / (D — d2) (i) A failure occurs at a gage pressure Where: less than 2.0 times the test pressure; S = Wall stress, in psi: (ii) A failure initiates in a braze or a P Test pressure in psig; weld or the heat affected zone thereof; D Outside diameter. in inches: (iii) A failure is other than in the d Inside diameter, in inches. sidewall of a cylinder longitudinal with (2) Calculation of the stress for its long axis; or spheres must be made by the following (iv) In a sphere, a failure occurs in formula: any opening, reinforcement, or at a point of attachment. S = PD / 4t (3) A “lot” is defined as the quantity Where: of cylinders successively produced per S = Wall stress, in psi; production shift (not exceeding 10 P Test pressure i psig; hours) having identical size, design, 889 §178.68 49 CFR Ch. I (10—1—10 Edition)

construction, material, heat treat (2) Required markings are as follows: ment, finish, and quality. (i) DOT-39. (g) Flattening test. One cylinder must (ii) NRC. be taken from the beginning of produc (iii) The service pressure. tion of each lot (as defined in para (iv) The test pressure. graph (f)(3) of this section) and sub (v) The registration number (M****) jected to a flattening test as follows: of the manufacturer. (1) The flattening test must be made (vi) The lot number. on a cylinder that has been tested at (vii) The date of manufacture if the test pressure. lot number does not establish the date (2) A ring taken from a cylinder may of manufacture. be flattened as an alternative to a test (viii) With one of the following state on a complete cylinder. The test ring ments: may not include the heat affected zone (A) For cylinders manufactured prior or any weld. However, for a sphere, the to October 1, 1996: “Federal law forbids test ring may include the circumferen transportation if refilled-penalty up to tial weld if it is located at a 45 degree $25,000 fine and 5 years imprisonment angle to the ring, ±5 degrees. (49 U.S.C. 1809)” or “Federal law for (3) The flattening must be between 60 bids transportation if refilled-penalty degrees included-angle, wedge shaped up to $500,000 fine and 5 years imprison knife edges, rounded to a 0.5 inch ra ment (49 U.S.C. 5124).” dius. (B) For cylinders manufactured on or (4) Cylinders and test rings may not after October 1, 1996: “Federal law for crack when flattened so that their bids transportation if refilled-penalty outer surfaces are not more than six up to $500,000 fine and 5 years imprison times wall thickness apart when made ment (49 U.S.C. 5124).” of steel or not more than ten times (3) The markings required by para wall thickness apart when made of alu graphs (1) (2) (i) through (i) (2) (v) of this minum. section must be in numbers and letters (5) If any cylinder or ring cracks at least ‘/8 inch high and displayed se when subjected to the specified flat quentially. For example: tening test, the lot of cylinders rep DOT-39 NRC 250/500 Ml00l. resented by the test must be rejected (see paragraph (h) of this section). (4) No person may mark any cylinder (h) Rejected cylinders. Rejected cyl with the specification identification inders must conform to the following “DOT-39” unless it was manufactured requirements: in compliance with the requirements of (1) If the cause for rejection of a lot this section and its manufacturer has a is determinable, and if by test or in registration number (M****) from the spection defective cylinders are elimi Associate Administrator. nated from the lot, the remaining cyl [Amdt. 178—114, 61 FR 25942, May 23, 1996, as inders must be qualified as a new lot amended at 65 FR 58631, Sept. 29, 2000: 66 FR under paragraphs (f) and (g) of this sec 45389, Aug. 28, 2001; 67 FR 51654, Aug. 8, 2002; tion. 68 FR 75748, 75749, Dec. 31, 2003] (2) Repairs to welds are permitted. Following repair, a cylinder must pass § 178.68 Specification 4E welded alu the pressure test specified in paragraph minum cylinders. (f) of this section. (a) Type, size and service pressure. A (3) If a cylinder made from seamless DOT 4E cylinder is a welded aluminum steel tubing fails the flattening test de cylinder with a water capacity (nomi scribed in paragraph (g) of this section, nal) of not over 1,000 pounds and a serv suitable uniform heat treatment must ice pressure of at least 225 to not over be used on each cylinder in the lot. All 500 psig. The cylinder must be con prescribed tests must be performed structed of not more than two seamless subsequent to this heat treatment. drawn shells with no more than one (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

890 Pipeline and Hazardous Materials Safety Admin., DOT § 178.68 cylinder wall thickness. Cylinders or (ii) One-half of the minimum tensile shells closed in by spinning process and strength of the material as required in cylinders with longitudinal seams are paragraph (j) of this section. not authorized. (2) Calculation must be made by the (b) Authorized material. The cylinder following formula: must be constructed of aluminum of = S [P(l.3D ± 0.4d2)] / (D2 — d2) uniform quality. The following chem ical analyses are authorized: Where: S = wall stress in psi; TABLE 1—AUTHORIZED MATERIALS P = minimum test pressure prescribed for waterjacket test; Chemical analy s--limits in Designation D = outside diameter in inches; d = inside diameter in inches. Iron plus silicon 0.45 maximum. Copper 0.10 maximum. (3) Minimum thickness of heads and Manganese 0.10 maximum. bottoms may not be less than the min Magnesium 3.10/3.90. imum required thickness of the side Chromium 0.15/0.35. wall. Zinc 0.20 maximum. Titanium 0.20 maximum. (g) Opening in cylinder. Openings in Others, each 0.05 maximum. cylinders must conform to the fol Others, total 0.15 maximum. lowing: Aluminum remainder. (I) All openings must be in the heads ‘Analysis must regularly be made only for the elements or bases. specifically mentioned in this table. If, however, the presence of other elements is indicated in the course of routine anal (2) Each opening in cylinders, except ysis, further analysis should be made to determine conform those for safety devices, must be pro ance with the limits specified for other elements. vided with a fitting, boss, or pad, se (c) Identification. Material must be curely attached to cylinder by welding identified by any suitable method that by inert gas shielded arc process or by will identify the alloy and manufactur threads. If threads are used, they must er’s lot number. comply with the following: (d) Manufacture. Cylinders must be (i) Threads must be clean-cut, even, manufactured using equipment and without checks and cut to gauge. processes adequate to ensure that each (ii) Taper threads to be of length not cylinder produced conforms to the re less than as specified for American quirements of this subpart. No defect is Standard taper pipe threads. permitted that is likely to weaken the (iii) Straight threads, having at least finished cylinder appreciably. A rea 4 engaged threads, to have tight fit and sonably smooth and uniform surface calculated shear strength at least 10 finish is required. All welding must be times the test pressure of the cylinder; by the gas shielded arc process. gaskets required, adequate to prevent (e) Welding. The attachment to the leakage. tops and bottoms only of cylinders by (3) Closure of a fitting, boss, or pad welding of neckrings or flanges, must be adequate to prevent leakage. footrings, handles, bosses and pads and (h) Hydrostatic test. Each cylinder valve protection rings is authorized. must successfully withstand a hydro However, such attachments and the static test, as follows: portion of the cylinder to which it is (1) The test must be by water jacket, attached must be made of weldable alu or other suitable method, operated so minum alloys. as to obtain accurate data. The pres (f) Wall thickness. The wall thickness sure gauge must permit reading to an of the cylinder must conform to the accuracy of 1 percent. The expansion following: gauge must permit a reading of the (1) The minimum wall thickness of total expansion to an accuracy either the cylinder must be 0.140 inch. In any of 1 percent or 0.1 cubic centimeter. case, the minimum wall thickness (2) Pressure of 2 times service pres must be such that calculated wall sure must be maintained for at least 30 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 891 § 178.68 49 CFR Ch. 1(10—1—10 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 i/8 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 follows: as 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 be rejected. must be tested in accordance with paragraphs (h)(l), (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 Association’s 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 Vs 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 strength, tensile strength, elongation, no less in width than 30 times the cyl 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 1½ 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 l/2 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 l’/2 inches wide, edges be a minimum of may be flattened to within 1 inch of rounded with a must be parallel and each end of the reduced section. file, and back-up strip, if used, must be (iii) When size of cylinder does not removed by machining. The specimen permit securing straight specimens, shall be tested as follows: (i) The specimen must be bent to re the specimens may be taken in any lo fusal in the guided bend test jig as il cation or direction and may be lustrated in paragraph 6.10 of CGA C-3 892 Pipeline and Hazardous Materials Safety Admin., DOT § 178.69

straightened or flattened cold, by pres up strip, if used, must be removed by sure only, not by blows; when speci machining. The specimen must be bent mens are so taken and prepared, the in to refusal in the guided bend test jig il spector’s report must show in connec lustrated in paragraph 6.10 of CGA tion with record of physical test de Pamphlet C—3 (IBR, see § 171.7 of this tailed information in regard to such subchapter). The root of the weld (in specimens. side surface of the cylinder) must be lo (iv) Heating of a specimen for any cated away from the ram of the jig. No purpose is not authorized. specimen must show a crack or other (3) The yield strength in tension open defect exceeding ‘/8 inch in any di must be the stress corresponding to a rection upon completion of the test. permanent strain of 0.2 percent of the Should this specimen fail to meet the gauge length. The following conditions requirements, specimens may be taken apply: from each of 2 additional cylinders (i) The yield strength must be deter from the same lot and tested. If either mined by the offset” method as pre of the latter specimens fail to meet re scribed in ASTM F 8 (IBR, see §171.7 of quirements, the entire lot represented this subchapter). must be rejected. (ii) Cross-head speed of the testing (m) Rejected cylinders. Repair of weld machine may not exceed ‘/ inch per ed seams is authorized. Acceptable cyl minute during yield strength deter inders must pass all prescribed tests. mination. (n) Inspectors report. In addition to (k) Acceptable results for physical tests. the information required by § 178.35, the An acceptable result of the physical record of chemical analyses must also test requires an elongation to at least include applicable information on iron, 7 percent and yield strength not over 80 titanium, zinc, and magnesium used in percent of tensile strength. the construction of the cylinder. (1) Weld tests. Welds of the cylinder are required to successfully pass [Amdt. 178—114, 61 FR 25942, May 23, 1996, as the amended following tests: at 62 FR 51561, Oct. 1, 1997; 66 FR 45386, Aug. 28, 2001; 67 FR 51654, Aug. 8. 2002; (1) Reduced section tensile test. A speci 68 FR 75748, Dec. 31. 2003; 69 FR 54046, Sept. men must be cut from the cylinder 7, 2004; 74 FR 16143, Apr. 9, 2009] used for the physical tests specified in paragraph (j) of this section. The speci § 178.69 Responsibilities and require men must be taken from across the ments for manufacturers of UN seam, edges must be parallel for a dis pressure receptacles. tance of approximately 2 inches on ei (a) Each manufacturer of a UN pres ther side of the weld. The specimen sure receptacle marked with “USA” as must be fractured in tension. The ap a country of approval must comply parent breaking stress calculated on with the requirements in this section. the minimum wall thickness must be The manufacturer must maintain a at least equal to 2 times the stress cal quality system, obtain an approval for culated under paragraph (f)(2) of this each initial pressure receptacle design section, and in addition must have an type, and ensure that all production of actual breaking stress of at least 30,000 UN pressure receptacles meets the ap psi. Should this specimen fail to meet plicable requirements. the requirements, specimens may be (1) Quality system. The manufacturer taken from 2 additional cylinders from of a UN pressure receptacle must have the same lot and tested, If either of the its quality system approved by the As latter specimens fails to meet require sociate Administrator. The quality sys ments, the entire lot represented must tem will initially be assessed through be rejected. an audit by the Associate Adminis (2) Guided bend test. A bend test speci trator or his or her representative to men must be cut from the cylinder determine whether it meets the re used for the physical tests specified in quirements of this section. The Asso 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 1½ 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 893 § 178.70 49 CFR Ch. I (10—1—10 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 hA 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 documented quality onstrate a system. ble ISO design, construction and test Management must review the adequacy ing standard. of the quality system to assure that it (c) Production is effective and conforms to the re inspection and certifi cation. quirements in §178.70. The quality sys 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. (1) 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 assurance, and process control, quality 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 hA, 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) hA pre-audit. The manufacturer must submit an (viii) Production, processing and fab application for initial rication, including purchased compo design type approval to the hA for re nents, in-process and final materials; view. The hA will examine the manu and facturer’s 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 hA 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 trator will evaluate the proposed technical documentation shows that change to determine whether the the pressure receptacle prototype de amended quality system will satisfy sign conforms to the applicable stand the requirements. The Associate Ad- ards and requirements in § 178.70, the 894 Pipeline and Hazardous Materials Safety Admin., DOT § 178.70

manufacturer will fabricate a proto in accordance with subpart I of part 107 type lot of pressure receptacles in con of this chapter. formance with the technical docu (6) Documentation on the manufac mentation representative of the design. turing facility as specified in § 178.69. The hA will verify that the prototype (7) Design specifications and manu lot conforms to the applicable require facturing drawings, showing compo ments by selecting pressure receptacles nents and subassemblies if relevant, de and witnessing their testing. After pro sign calculations, and material speci totype testing has been satisfactorily fications necessary to verify compli completed, showing the pressure recep ance with the applicable pressure re tacles fully conform to all applicable ceptacle design standard. specification requirements, the certi (8) Manufacturing procedures and fying hA must prepare a letter of rec any applicable standards that describe ommendation and a design type ap in detail the manufacturing processes proval certificate. The design type ap and control. proval certificate must contain the (9) Design type approval test reports name and address of the manufacturer detailing the results of examinations the and hA certifying the design type, and tests conducted in accordance with the test results, chemical analyses, lot the relevant pressure receptacle stand identification, and all other supporting ard, to include any additional data, data specified in the applicable ISO de such as suitability for underwater ap sign, construction and testing stand plications or compatibility with hydro ard. The hA must provide the certifi gen embrittlement gases. cate and documentation to the manu (d) Modification of approved pressure facturer. receptacle design type. Modification of (c) Application for initial design type an approved UN pressure receptacle de approval. If the pre-audit is found satis sign type is not authorized without the factory by the hA, the manufacturer approval of the Associate Adminis will submit the letter of recommenda trator. A manufacturer seeking modi tion from the hA and an application fication of an approved UN pressure re for design type approval to the Asso ceptacle design type may be required ciate Administrator. An application for to submit design qualification test initial design type approval must be data to the Associate Administrator submitted for each manufacturing fa before production. An audit may be re cility. The application must be in quired as part of the process to modify English and, at a minimum, contain an approval. the following information: (e) Responsibilities of the production (I) The name and address of the man hA. The production hA is responsible ufacturing facility. If the application is for ensuring that each pressure recep submitted by an authorized representa tacle conforms to the design type ap tive on behalf of the manufacturer, the proval. The production hA must per application must include the represent form the following functions: ative’s name and address. (1) Witness all inspections and tests (2) The name and title of the indi specified in the UN pressure receptacle vidual responsible for the manufactur standard to ensure compliance with the er’s quality system, as required by standard and that the procedures § 178.69. adopted by the manufacturer meet the (3) The designation of the pressure requirements of the standard; receptacle and the relevant pressure re (2) Verify that the production inspec ceptacle standard. tions were performed in accordance (4) Details of any refusal of approval with this section; of a similar application by a designated (3) Select UN pressure receptacles approval agency of another country. from a prototype production lot and (5) The name and address of the pro witness testing as required for the de duction hA that will perform the func sign type approval; tions prescribed in paragraph (e) of this (4) Ensure that the various design section. The hA must be approved in type approval examinations and tests writing by the Associate Administrator are performed accurately; 895 § 178.70 49 CFR Ch. I (10—1—10 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 hA 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 manufacturer’s 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 Administrator’s 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 hA 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 hA 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 Administrator’s 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 hA 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 hA 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 tificate and certificate of compliance written evidence, and records for at least 20 years. (iii) Opportunity to demonstrate or (h) Denial of design type application. If achieve compliance with the applica the design type application is denied, tion requirement. 896 Pipeline and Hazardous Materials Safety Admin., DOT § 178.71

(3) If the Associate Administrator de be varied only if approved in writing by termines that a certificate of approval the Associate Administrator. must be withdrawn to preclude a sig (3) The test pressure of UN cylinders, nificant and imminent adverse affect tubes, and bundles of cylinders must on public safety, the procedures in conform to the requirements in part paragraph (j)(2)(ii) and (iii) of this sec 178 of this subchapter. tion need not be provided prior to with (d) Service equipment. (1) Except for drawal of the approval, but shall be pressure relief devices, UN pressure re provided as soon as practicable there ceptacle equipment, including valves, after. piping, fittings, and other equipment subjected [71 FR 33886, June 12, 2006, as amended at 71 to pressure must be designed FR 54397, Sept. 14, 20061 and constructed to withstand at least 1.5 times the test pressure of the pres § 178.71 Specifications for UN pressure sure receptacle. receptacles. (2) Service equipment must be config ured (a) General. Each UN pressure recep or designed to prevent damage that could tacle must meet the requirements of result in the release of the this section. Requirements for ap pressure receptacle contents during normal proval, qualification, maintenance, and conditions of handling and transport. testing are contained in §178.70, and Manifold piping leading to subpart C of part 180 of this subchapter. shut-off valves must be sufficiently flexible to (b) Definitions. The following defini protect the valves and the piping from shearing tions apply for the purposes of design or releasing the pressure receptacle contents. and construction of UN pressure recep The fill ing tacles under this subpart: and discharge valves and any pro tective caps must be secured against Alternative arrangement means an ap unintended opening. The proval granted by the Associate Ad valves must conform to ISO 10297 ministrator for a MEGC that (IBR, see §171.7 of has been this subchapter) designed, constructed and be protected as or tested to the specified technical requirements in § l73.3Olb(f) of this sub or testing chapter. methods other than those specified for (3) UN pressure receptacles UN pressure receptacles in part that can 178 or not be handled part 180 of this subchapter. manually or rolled, must be equipped with Bundle of cylinders. devices (e.g. See §171.8 of this skids, rings, straps) ensuring subchapter. that they can be safely handled by mechanical Design type means pressure a recep means and so arranged as not to impair tacle design as specified by a particular the strength of, nor cause undue pressure receptacle standard. stresses, in the pressure receptacle. Design type approval means an overall (4) Pressure receptacles filled by vol approval of the manufacturer’s quality ume must be equipped with a level in system and design type of each pres dicator. sure receptacle to be produced within (e) Bundles of cylinders. UN pressure the manufacturer’s facility. receptacles assembled in bundles must UN tube. See § 171.8 of this sub be structurally supported and held to chapter. gether as a unit and secured in a man Cc) General design and construction. ner that prevents movement in rela UN pressure receptacles and their clo tion to the structural assembly and sures must be designed, manufactured, movement that would result in the tested and equipped in accordance with concentration of harmful local the requirements contained in this sec stresses. The frame design must ensure tion. stability under normal operating con (1) Following the final heat treat ditions. ment, all cylinders, except those se (1) The frame must securely retain lected for batch testing must be sub all the components of the bundle and jected to a hydraulic volumetric expan must protect them from damage during sion test. conditions normally incident to trans (2) The standard requirements appli portation. The method of cylinder re cable to UN pressure receptacles may straint must prevent any vertical or 897 § 178.71 49 CFR Ch. I (10—1—10 Edition)

horizontal movement or rotation of the inders. In addition to the general re cylinder that could cause undue strain quirements of this section, UN refill on the manifold. The total assembly able seamless steel cylinders must con must be able to withstand rough han form to the following ISO standards, as dling, including being dropped or over applicable: turned. (1) ISO 9809—1: Gas cylinders—Refill (2) The frame must include features able seamless steel gas cylinders—De designed for the handling and transpor sign, construction and testing—Part 1: tation of the bundle. The lifting rings Quenched and tempered steel cylinders must be designed to withstand a design with tensile strength less than 1 100 load of 2 times the maximum gross MPa. (IBR, see §171.7 of this sub weight. Bundles with more than one chapter). lifting ring must be designed such that (2) ISO 9809—2: Gas cylinders—Refill a minimum sling angle of 45 degrees to able seamless steel gas cylinders—De the horizontal can be achieved during sign, construction and testing—Part 2: lifting using the lifting rings. If four Quenched and tempered steel cylinders lifting rings are used, their design with tensile strength greater than or must be strong enough to allow the equal to 1 100 MPa. (IBR, see §171.7 of bundle to be lifted by two rings. Where this subchapter). two or four lifting rings are used, dia (3) ISO 9809—3: Gas cylinders—Refill metrically opposite lifting rings must able seamless steel gas cylinders—De be aligned with each other to allow for sign, construction and testing—Part 3: correct lifting using shackle pins. If Normalized steel cylinders. (IBR, see the bundle is filled with forklift pock §171.7 of this subchapter). ets, it must contain two forklift pock (h) Design and construction require ets on each side from which it is to be ments for UN refillable seamless aluminum lifted. The forklift pockets must be po alloy cylinders. In addition to the gen sitioned symmetrically consistent with eral requirements of this section, UN the bundle center of gravity. refillable seamless aluminum cylinders (3) The frame structural members must conform to ISO 7866: Gas cyl must be designed for a vertical load of inders—Refillable seamless aluminum 2 times the maximum gross weight of alloy gas cylinders—Design, construc the bundle. Design stress levels may tion and testing. (IBR, see § 171.7 of this not exceed 0.9 times the yield strength subchapter). The use of Aluminum of the material. alloy 635 l-T6 or equivalent is prohib (4) The frame may not contain any ited. protrusions from the exterior frame (i) Design and construction require structure that could cause a hazardous ments for UN non-refillable metal cyl condition. inders. In addition to the general re (5) The frame design must prevent quirements of this section, UN non-re collection of water or other debris that fillable metal cylinders must conform would increase the tare weight of bun to ISO 11118: Gas cylinders—Non-refill dles filled by weight. able metallic gas cylinders—Specifica (6) The floor of the bundle frame tion and test methods. (IBR, see §171.7 must not buckle during normal oper of this subchapter.) ating conditions and must allow for the (j) Design and construction require drainage of water and debris from ments for UN refillable seamless steel around the base of the cylinders. tubes. In addition to the general re (7) If the frame design includes mov quirements of this section, UN refill able doors or covers, they must be ca able seamless steel tubes must conform pable of being secured with latches or to ISO 11120: Gas cylinders—Refillable other means that will not become dis seamless steel tubes of water capacity lodged by operational impact loads. between 150 L and 3000 L—Design, con Valves that need to be operated in nor struction and testing. (IBR, see § 171.7 mal service or in an emergency must of this subchapter). be accessible. (k) Design and construction require (f) jReserved] ments for UN acetylene cylinders. In ad (g) Design and construction require dition to the general requirements of ments for UN refillable seamless steel cyl this section, UN acetylene cylinders 898 Pipeline and Hazardous Materials Safety Admin., DOT § 178.71

must conform to the following ISO (1) ISO 11114—1: Transportable gas cyl standards, as applicable: inders—Compatibility of cylinder and (1) For the cylinder shell: valve materials with gas contents— (i) Iso 9809—1: Gas cylinders—Refill Part 1: Metallic materials. (IBR, see able seamless steel gas cylinders—De §171.7 of this subchapter). sign, construction and testing—Part 1: (2) Iso 11114—2: Transportable gas cyl Quenched and tempered steel cylinders inders—Compatibility of cylinder and with tensile strength less than 1 100 valve materials with gas contents— MPa. Part 2: Non-metallic materials. (IBR, (ii) ISO 9809—3: Gas cylinders—Refill see §171.7 of this subchapter). able seamless steel gas cylinders—De (n) Protection of closures. Closures and their protection sign, construction and testing—Part 3: must conform to the requirements Normalized steel cylinders. in § 173.301(f) of this sub chapter. (2) The porous mass in an acetylene (o) Marking of UN refillable pressure re cylinder must conform to ISO 3807—2: ceptacles. UN refillable pressure recep Cylinders for acetylene—Basic require tacles must be marked clearly and leg ments—Part 2: Cylinders with fusible ibly. The required markings must be plugs. (IBR, 171.7 see § of this sub permanently affixed by stamping, chapter). en graving, or other equivalent method, (1) Design and construction require on the shoulder, top end or neck of the ments for UN composite cylinders. (1) In pressure receptacle or on a perma addition to the general requirements of nently affixed component of the pres this section, UN composite cylinders sure receptacle, such as a welded col must be designed for unlimited service lar. Except for the “UN” mark, the life and conform to the following ISO minimum size of the marks must be 5 standards, as applicable: mm for pressure receptacles with a di (i) ISO 11119—I: Gas cylinders of com ameter greater than or equal to 140 mm posite construction—Specification and and 2.5 mm for pressure receptacles test methods—Part 1: Hoop-wrapped with a diameter less than 140 mm. The composite gas cylinders. (IBR, see minimum size of the “UN” mark must §171.7 of this subchapter). be 5 mm for pressure receptacles with a (ii) ISO 11119—2: Gas cylinders of com diameter less than 140 mm and 10 mm posite construction—Specification and for pressure receptacles with a diame test methods—Part 2: Fully-wrapped ter of greater than or equal to 140 mm. fibre reinforced composite gas cyl The depth of the markings must not inders with load-sharing metal liners. create harmful stress concentrations. (IBR, see §171.7 of this subchapter). A refillable pressure receptacle con (iii) ISO 11119—3: Gas cylinders of forming to the UN standard must be composite construction—Specification marked as follows: and test methods—Part 3: Fully (1) The UN packaging symbol. wrapped fibre reinforced composite gas cylinders with non-load sharing metal lic or non-metallic liners. (IBR, see § 171.7 of this subchapter). (2) 150 11119—2 and ISO 11119—3 gas cylinders of composite construction manufactured in accordance with the requirements for underwater use must bear the ‘UW” mark. (m) Material compatibility. In addition to the material requirements specified in the UN pressure receptacle design and construction ISO standards, and any restrictions specified in part 173 for the gases to be transported, the re (2) The ISO standard, for example quirements of the following standards ISO 9809—1, used for design, construc must be applied with respect to mate tion and testing. Acetylene cylinders rial compatibility: must be marked to indicate the porous 899 § 178J1 49 CFR Ch. 1(10—1—10 Edition) mass and the steel shell, for example: (8) The minimum wall thickness of ‘‘ISO 3807—2/ISO 9809—1.” the pressure receptacle in millimeters (3) The mark of the country where followed by the letters “MM”, This the approval is granted. The letters mark is not required for pressure re “USA” must be marked on UN pressure ceptacles with a water capacity less receptacles approved by the United than or equal to 1.0 L or for composite States. The manufacturer must obtain cylinders. an approval number from the Associate (9) For pressure receptacles intended Administrator. The manufacturer ap for the transport of compressed gases proval number must follow the country and UN 1001 acetylene, dissolved, the of approval mark, separated by a slash working pressure in bar, proceeded by (for example, USA/MXXXX). Pressure the letters “PW”. receptacles approved by more than one (10) For liquefied gases, the water ca national authority may contain the pacity in liters expressed to three sig mark of each country of approval, sep nificant digits rounded down to the arated by a comma. last digit, followed by the letter “L”. If (4) The identity mark or stamp of the the value of the minimum or nominal hA. water capacity is an integer, the digits (5) The date of the initial inspection, after the decimal point may be omit the year (four digits) followed by the ted. month (two digits) separated by a (11) Identification of the cylinder slash, for example “2006/04”. thread type (e.g., 25E). (6) The test pressure in bar, preceded (12) The country of manufacture. The by the letters “PH” and followed by letters “USA” must be marked on cyl the letters “BAR”. The test pressure inders manufactured in the United must be obtained from the results of a States. hydraulic volumetric expansion test. (13) The serial number assigned by (7) The empty or tare weight. Except the manufacturer. for acetylene cylinders, empty weight (14) For steel pressure receptacles, is the mass of the pressure receptacle the letter “H” showing compatibility in kilograms, including all integral of the steel, as specified in 1SO 11114-1. parts (e.g., collar, neck ring, foot ring, (15) Identification of aluminum alloy, etc.), followed by the letters “KG”. The if applicable. empty weight does not include the (16) Stamp for nondestructive test mass of the valve, valve cap or valve ing, if applicable. guard or any coating. The empty (17) Stamp for underwater use of weight must be expressed to three sig composite cylinders, if applicable. nificant figures rounded up to the last (p) Marking sequence. The marking re digit. For cylinders of less than 1 kg, quired by paragraph (o) of this section the empty weight must be expressed to must be placed in three groups as two significant figures rounded down shown in the example below: to the last digit. For acetylene cyl (1) The top grouping contains manu inders, the tare weight must be marked facturing marks and must appear con on the cylinders in kilograms (KG). secutively in the sequence given in The tare weight is the sum of the paragraphs (o)(l1) through (17) of this empty weight, mass of the valve, any section. coating and all permanently attached (2) The middle grouping contains parts (e.g. fittings and accessories) operational marks described in para that are not removed during filling. graphs (o)(6) through (10) of this sec The tare weight must be expressed to tion. two significant figures rounded down (3) The bottom grouping contains to the last digit. The tare weight does certification marks and must appear not include the cylinder cap or any consecutively in the sequence given in outlet cap or plug not permanently at paragraph (o) (1) through (5) of this sec tached to the cylinder. tion.

900 Pipeline and Hazardous Materials Safety Admin., DOT § 178.74

(11) (12) (13) (14) (15) (16) (17)

25E USA 765432 H Uw

(9) (6) (7) (10) (8)

PW200 PH300BAR 62.1KG 50L 5.8MM

(1) (2) (3) (4) (5)

U n ISO 9809-1 USAIMXXXX lB 2005/12

(q) Other markings. Other markings (3) A non-refillable pressure recep are allowed in areas other than the side tacle, because of its size, may sub wall, provided they are made in low stitute the marking required by this stress areas and are not of a size and paragraph with a label. Reduction in depth that will create harmful stress marking size is authorized only as pre concentrations. Such marks must not scribed in ISO 7225, Gas cylinders—Pre conflict with required marks. cautionary labels. (IBR, see §171.7 of (r) Marking of UN non-refillable pres this subchapter). sure receptacles. Unless otherwise speci (4) Each non-refillable pressure re ceptacle fied in this paragraph, each UN non-re must also be legibly marked by stenciling fillable pressure receptacle must be the following statement: “Federal law forbids transportation if clearly and legibly marked as pre refilled-penalty up to $500,000 fine and scribed in paragraph (o) of this section. 5 years in imprisonment (49 U.S.C. In addition, permanent stenciling is 5124).” authorized. Except when stenciled, the (5) No person may mark a non-refill marks must be on the shoulder, top end able pressure receptacle as meeting the or neck of the pressure receptacle or on requirements of this section unless it a permanently affixed component of was manufactured in conformance with the pressure receptacle, for example a this section. welded collar. 171 FR 33887, June 12, 2006, as amended at 71 (1) The marking requirements and se FR 54397, Sept. 14, 2006] quence listed in paragraphs (o)(l) through (17) of this section are re § 178.74 Approval of MEGCs. quired, except the markings in para (a) Application for design type ap graphs (o)(7), (8), (11) and (17) are not proval. (1) Each new MEGC design type applicable. The required serial number must have a design approval certifi marking in paragraph (o)(13) may be cate. An owner or manufacturer must replaced by the batch number. apply to an approval agency that is ap (2) Each receptacle must be marked proved by the Associate Administrator with the words DO NOT REFILL” in in accordance with subpart E of part letters of at least 5 mm in height. 107 of this chapter +to obtain approval 901 § 178.74 49 CFR Ch. I (10—1—10 Edition) of a new design. When a series of examination and necessary data for MEGCs is manufactured without identification of the design type. If the change in the design, the certificate is Associate Administrator approves the valid for the entire series. The design Design Type Approval Certificate ap approval certificate must refer to the plication, the approval agency and the prototype test report, the materials of manufacturer must each maintain a construction of the manifold, the copy of the approved drawings, calcula standards to which the pressure recep tions, and test data for at least 20 tacles are made and an approval num years. ber. The compliance requirements or (c) Approval agencys responsibilities. test methods applicable to MEGCs as The approval agency is responsible for specified in this subpart may be varied ensuring that the MEGC conforms to when the level of safety is determined the design type approval. The approval be equivalent to or exceed the re to agency must: quirements of this subchapter and is (1) approved in writing by the Associate Witness all tests required for the Administrator. A design approval may approval of the MEGC specified in this serve for the approval of smaller section and § 178.75. MEGCs made of materials of the same (2) Ensure, through appropriate in type and thickness, by the same fab spection, that each MEGC is fabricated rication techniques and with identical in all respects in conformance with the supports, equivalent closures and other approved drawings, calculations, and appurtenances. test data. (2) Each application for design ap (3) Determine and ensure that the proval must be in English and contain MEGC is suitable for its intended use the following information: and that it conforms to the require (i) Two complete copies of all engi ments of this subchapter. neering drawings, calculations, and (4) Apply its name, identifying mark test data necessary to ensure that the or identifying number, and the date the design meets the relevant specifica approval was issued, to the metal iden tion. tification marking plate attached to (ii) The manufacturer’s serial number the MEGC upon successful completion that will be assigned to each MEGC. of all requirements of this subpart. (iii) A statement as to whether the Any approvals by the Associate Admin design type has been examined by any istrator authorizing design or con approval agency previously and judged struction alternatives (Alternate Ar unacceptable. Affirmative statements rangements) of the MEGC (see para must be documented with the name of graph (a) of this section) must be indi the approval agency, reason for non-ac cated on the metal identification plate ceptance, and the nature of modifica as specified in § 178.75(j). tions made to the design type. (5) Prepare an approval certificate (b) Actions by the approval agency. The for each MEGC or, in the case of a se approval agency must review the appli ries of identical MEGCs manufactured approval, includ cation for design type to a single design type, for each series drawings and calculations, to ing all of MEGCs. The approval certificate that the design of the MEGC ensure must include all of the following infor meets all requirements of the relevant mation: specification and to determine whether it is complete and conforms to the re (i) The information displayed on the quirements of this section. An incom metal identification plate required by plete application will be returned to §178.75(j); the applicant with the reasons why the (ii) The results of the applicable application was returned. If the appli framework test specified in Iso 1496—3 cation is complete and all applicable (IBR, see §171.7 of this subchapter); requirements of this section are met, (iii) The results of the initial inspec the approval agency must prepare a tion and test specified in paragraph (h) MEGC design approval certificate con of this section; taining the manufacturer’s name and (iv) The results of the impact test address, results and conclusions of the specified in § 178.75(i) (4); 902 Pipeline and Hazardous Materials Safety Admin., DOT § 178.74

(v) Certification documents verifying (2) State in detail any alleged errors that the cylinders and tubes conform of fact and law; and to the applicable standards; and (3) Enclose any additional informa (vi) A statement that the approval tion needed to support the request to agency certifies the MEGC in accord reconsider. ance with the procedures in this sec (f) Appeal. (1) A manufacturer whose tion and that the MEGC is suitable for reconsideration request is denied may its intended purpose and meets the re appeal to the PHMSA Administrator. quirements of this subchapter. When a The appeal must— series of MEGCs is manufactured with (i) Be in writing and filed within 90 out change in the design type, the cer days of receipt of the Associate Admin tificate may be valid for the entire se istrator s decision on reconsideration; ries of MEGCs representing a single de (ii) State in detail any sign type. The approval number must alleged errors of fact and law; consist of the distinguishing sign or mark of the country (“USA” for the (iii) Enclose any additional informa tion United States of America) where the needed to support the appeal; and approval was granted and a registra (iv) State in detail the modification tion number. of the final decision sought. (6) Retain on file a copy of each ap (2) The Administrator will grant or proval certificate for at least 20 years. deny the relief and inform the appel (d) Manufacturers’ responsibilities. The lant in writing of the decision. The Ad manufacturer is responsible for compli ministrator’s decision is the final ad ance with the applicable specifications ministrative action. for the desigTl and construction of (g) Modifications to approved MEGCs. MEGCs. The manufacturer of a MEGC (1) Prior to modification of any ap must: proved MEGC that may affect conform (1) Comply with all the requirements ance and safe use, and that may in of the applicable ISO standard specified volve a change to the design type or af in §178.71; fect its ability to retain the hazardous (2) Obtain and use an approval agen material in transportation, the cy to review the design, construction MEGC’s owner must inform the ap and certification of the MEGC; proval agency that prepared the initial (3) Provide a statement in the manu approval certificate for the MEGC or, if facturers’ data report certifying that the initial approval agency is unavail each MEGC manufactured complies able, another approval agency, of the with the relevant specification and all nature of the modification and request the applicable requirements of this certification of the modification. The subchapter; and owner must supply the approval agency (4) Retain records for the MEGCs for with all revised drawings, calculations, at least 20 years. When required by the and test data relative to the intended specification, the manufacturer must modification. The MEGC’s owner must provide copies of the records to the ap also provide a statement as to whether proval agency, the owner or lessee of the intended modification has been ex the MEGC, and to a representative of amined and determined to be unaccept DOT, upon request. able by any approval agency. The writ (e) Denial of application for approval. ten statement must include the name If the Associate Administrator finds of the approval agency, the reason for that the MEGC will not be approved for non-acceptance, and the nature of any reason, the Associate Adminis changes made to the modification since trator will notify the applicant in writ its original rejection. ing and provide the reason for the de (2) The approval agency must review nial. The manufacturer may request the request for modification. If the ap that the Associate Administrator re proval agency determines that the pro consider the decision. The application posed modification does not conform to request must— the relevant specification, the approval (1) Be written in English and filed agency must reject the request in ac within 90 days of receipt of the deci cordance with paragraph (d) of this sec sion; tion. If the approval agency determines 903 § 178.75 49 CFR Ch. I (10—1—10 Edition) that the proposed modification con (3) An opportunity to demonstrate or forms fully with the relevant specifica achieve compliance with the applicable tion, the request is accepted. If modi requirements. fication to an approved MEGC alters (i) Imminent Danger. If the Associate any information on the approval cer Administrator determines that a cer tificate, the approval agency must pre tificate of approval must be terminated pare a new approval certificate for the to preclude a significant and imminent modified MEGC and submit the certifi adverse effect on public safety, the As cate to the Associate Administrator for sociate Administrator may terminate approval. After receiving approval the certificate immediately. In such from the Associate Administrator, the circumstances, the opportunities of approval agency must ensure that any paragraphs (h) (2) and (3) of this section necessary changes are made to the need not be provided prior to termi metal identification plate. A copy of nation of the approval, but must be each newly issued approval certificate provided as soon as practicable there must be retained by the approval agen after. cy and the MEGC’s owner for at least [71 FR 33890, June 12, 2006] 20 years. The approval agency must perform the following activities: § 178.75 Specifications for MEGCs. (i) Retain a set of the approved re vised drawings, calculations, and data (a) General. Each MEGC must meet as specified in §l78.69(b)(4) for at least the requirements of this section. In a 20 years; MEGC that meets the definition of a “container” within the terms of the (ii) Ensure through appropriate in International Convention for Safe Con spection that all modifications con tainers (CSC) must meet the require form to the revised drawings, calcula ments of the CSC as amended and 49 tions, and test data; and CFR parts 450 through 453, and must which (iii) Determine the extent to have a CSC approval plate. retesting of the modified MEGC is nec (b) Alternate Arrangements. The tech essary based on the nature of the pro nical requirements applicable to modification, and ensure that all posed MEGCs may be varied when the level of retests are satisfactorily per required safety is determined to be equivalent formed. to or exceed the requirements of this (h) Termination of Approval Certificate. subchapter. Such an alternate arrange (1) The Associate Administrator may ment must be approved in writing by terminate an approval issued under the Associate Administrator. MEGCs this section if he or she determines approved to an Alternate Arrangement that— must be marked as required by para (I) Because of a change in cir graph (j) of this section. cumstances, the approval no longer is (c) Definitions. The following defini needed or no longer would be granted if tions apply: applied for; Leakproofness test means a test using (ii) Information upon which the ap gas subjecting the pressure receptacles proval was based is fraudulent or sub and the service equipment of the MEGC stantially erroneous; to an effective internal pressure of not (iii) Termination of the approval is less than 20% of the test pressure. necessary to adequately protect Manifold means an assembly of piping against risks to life and property; or and valves connecting the filling and/or (iv) The MEGC does not meet the discharge openings of the pressure re specification. ceptacles. (2) Before an approval is terminated, Maximum permissible gross mass or the Associate Administrator will pro MPGM means the heaviest load author vide the person— ized for transport (sum of the tare (i) Written notice of the facts or con mass of the MEGC, service equipment duct believed to warrant the termi and pressure receptacle). nation; Service equipment means manifold sys (ii) An opportunity to submit oral tem (measuring instruments, piping and written evidence; and and safety devices). 904 Pipeline and Hazardous Materials Safety Admin., DOT § 178.75

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 lizing members external to the pres structed of a material that is compat sure receptacles. ible with the hazardous materials in (d) General design and construction re tended to be transported, as specified quirements. (1) The MEGC must be capa in this subchapter. ble of being loaded and discharged (5) Contact between dissimilar met without the removal of its structural als that could result in damage by gal equipment. It must possess stabilizing vanic action must be prevented by ap members external to the pressure re propriate means. ceptacles to provide structural integ (6) The materials of the MEGC, in rity for handling and transport. MEGCs cluding any devices, gaskets, and ac must be designed and constructed with cessories, must have no adverse effect supports to provide a secure base dur on the gases intended for transport in ing transport and with lifting and tie- the MEGC. down attachments that are adequate (7) MEGCs must be designed to with for lifting the MEGC including when stand, without loss of contents, at loaded to its maximum permissible least the internal pressure due to the gross mass. The MEGC must be de contents, and the static, dynamic and signed to be loaded onto a transport ve thermal loads during normal condi hicle or vessel and equipped with skids, tions of handling and transport. The mountings or accessories to facilitate design must take into account the ef mechanical handling. fects of fatigue, caused by repeated ap (2) MEGCs must be designed, manu plication of these loads through the ex factured and equipped to withstand, pected life of the MEGC. without loss of contents, all normal (8) MEGCs and their handling and transportation condi fastenings must, under the maximum permissible tions. The design must take into ac load, be capable of withstanding count the effects of dynamic loading the fol lowing and fatigue. separately applied static forces (for calculation purposes, acceleration (3) Each pressure receptacle of a due to gravity = 9.81 mIs2): MEGC must be of the same design type, (g) seamless steel, and constructed and (i) In the direction of travel: 2g tested according to one of the following (twice the MPGM multiplied by the ac ISO standards: celeration due to gravity); (i) ISO 9809—I: Gas cylinders—Refill (ii) Horizontally at right angles to able seamless steel gas cylinders—De the direction of travel: ig (the MPGM sign, construction and testing—Part 1: multiplied by the acceleration due to Quenched and tempered steel cylinders gravity. When the direction of travel is with tensile strength less than 1 100 not clearly determined, the forces must MPa. (IBR, see §171.7 of this sub be equal to twice the MPGM); chapter); (iii) Vertically upwards: lg (the (ii) ISO 9809—2: Gas cylinders—Refill MPGM multiplied by the acceleration able seamless steel gas cylinders—De due to gravity); and sign, construction and testing—Part 2: (iv) Vertically downwards: 2g (twice Quenched and tempered steel cylinders the MPGM (total loading including the with tensile strength greater than or effect of gravity) multiplied by the ac equal to 1 100 MPa. (IBR, see §171.7 of celeration due to gravity. this subchapter); (9) Under each of the forces specified (iii) ISO 9809—3: Gas cylinders—Refill in paragraph (d)(8) of this section, the able seamless steel gas cylinders—De stress at the most severely stressed sign, construction and testing—Part 3: point of the pressure receptacles must Normalized steel cylinders. (IBR, see not exceed the values given in the ap § 171.7 of this subchapter); or plicable design specifications (e.g., ISO (iv) ISO 11120: Gas cylinders—Refill 11120). able seamless steel tubes of water ca (10) Under each of the forces specified pacity between 150 L and 3000 L—De in paragraph (d) (8) of this section, the 905 § 178.75 49 CFR Ch. I (10—1--b Edition) 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 strength; or vices may be equipped to a manifold. (ii) For steels with no clearly defined (iii) For sections of piping which can yield point, a safety factor of 1.5 in re be closed at both ends and where a liq lation to the guaranteed 0.2 percent uid product can be trapped, a pressure- proof strength and, for austenitic relief valve must be provided to pre steels, the 1 percent proof strength. vent excessive pressure build-up. (11) MEGCs must be capable of being (iv) The main isolation valves on a electrically grounded to prevent elec MEGC must be clearly marked to indi trostatic discharge when intended for cate their directions of closure. All flammable gases. shutoff valves must close by a clock (12) The pressure receptacles of a wise motion of the handwheel. MEGC must be secured in a manner to (v) Each shut-off valve or other prevent movement that could result in means of closure must be designed and damage to the structure and con constructed to withstand a pressure centration of harmful localized equal to or greater than 1.5 times the stresses. test pressure of the MEGC. (e) Service equipment. (1) Service (vi) All shut-off valves with screwed equipment must be arranged so that it spindles must close by a clockwise mo is protected from mechanical damage tion of the handwheel. For other shut by external forces during handling and off valves, the open and closed posi transportation. When the connections tions and the direction of closure must between the frame and the pressure re be clearly shown. ceptacles allow relative movement be (vii) All shut-off valves must be de tween the subassemblies, the equip signed and positioned to prevent unin ment must be fastened to allow move tentional opening. ment to prevent damage to any work (viii) Ductile metals must be used in ing part. The manifolds, discharge fit the construction of valves or acces tings (pipe sockets, shut-off devices), sories. and shut-off valves must be protected (4) The piping must be designed, con from damage by external forces. Mani structed and installed to avoid damage fold piping leading to shut-off valves due to expansion and contraction, me must be sufficiently flexible to protect chanical shock and vibration. Joints in the valves and the piping from shear tubing must be brazed or have an ing, or releasing the pressure recep equally strong metal union. The melt tacle contents. The filling and dis ing point of brazing materials must be charge devices, including flanges or no lower than 525 °C (977 °F). The rated threaded plugs, and any protective caps pressure of the service equipment and must be capable of being secured of the manifold must be not less than against unintended opening. two-thirds of the test pressure of the (2) Each pressure receptacle intended pressure receptacles. for the transport of Division 2.3 gases (f) Pressure relief devices. Each pres must be equipped with an individual sure receptacle must be equipped with shut-off valve. The manifold for Divi one or more pressure relief devices as sion 2.3 liquefied gases must be de specified in § 173.301(f) of this sub signed so that each pressure receptacle chapter. When pressure relief devices can be filled separately and be kept are installed, each pressure receptacle isolated by a valve capable of being or group of pressure receptacles of a closed during transit. For Division 2.1 MEGC that can be isolated must be gases, the pressure receptacles must be equipped with one or more pressure re isolated by an individual shut-off valve lief devices. Pressure relief devices into assemblies of not more than 3,000 must be of a type that will resist dy L. namic forces including liquid surge and (3) For MEGC filling and discharge must be designed to prevent the entry openings: of foreign matter, the leakage of gas 906 Pipeline and Hazardous Materials Safety Admin., DOT § 178.75 and the development of any dangerous and to protect the devices from damage excess pressure. caused by rollover. (1) The size of the pressure relief de (g) Gauging devices. When a MEGC is vices: CGA S—l.l (IBR, see § 171.7 of this intended to be filled by mass, it must subchapter) must be used to determine be equipped with one or more gauging the relief capacity of individual pres devices. Glass level-gauges and gauges sure receptacles. made of other fragile material are pro (2) Connections to pressure-relief de hibited. vices: Connections to pressure relief (h) MEGC supports, frameworks, lifting devices must be of sufficient size to en and tie-down attachments. (1) MEGCs able the required discharge to pass un must be designed and constructed with restricted to the pressure relief device. a support structure to provide a secure A shut-off valve installed between the base during transport. MEGCs must be pressure receptacle and the pressure re protected against damage to the pres lief device is prohibited, except where sure receptacles and service equipment duplicate devices are provided for resulting from lateral and longitudinal maintenance or other reasons, and the impact and overturning. The forces shut-off valves serving the devices ac specified in paragraph (d) (8) of this sec tually in use are locked open, or the tion, and the safety factor specified in shut-off valves are interlocked so that paragraph (d)(lO) of this section must at least one of the duplicate devices is be considered in this aspect of the de always operable and capable of meeting sign. Skids, frameworks, cradles or the requirements of paragraph (f) (1) of other similar structures are accept this section. No obstruction is per able. If the pressure receptacles and mitted in an opening leading to or service equipment are constructed leaving from a vent or pressure-relief so as to withstand impact and over device that might restrict or cut-off turning, additional protective the flow from the pressure receptacle support structure is not required to that device. The opening through all (see para graph (h) (4) of this piping and fittings must have at least section). the same flow area as the inlet of the (2) The combined stresses caused by pressure relief device to which it is pressure receptacle mountings (e.g. connected. The nominal size of the dis cradles, frameworks, etc.) and MEGC charge piping must be at least as large lifting and tie-down attachments must as that of the pressure relief device. not cause excessive stress in any pres (3) Location of pressure-relief de sure receptacle. Permanent lifting and vices: For liquefied gases, each pres tie-down attachments must be sure relief device must, under max equipped to all MEGCs. Any welding of imum filling conditions, be in commu mountings or attachments Onto the nication with the vapor space of the pressure receptacles is prohibited. pressure receptacles. The devices, when (3) The effects of environmental cor installed, must be arranged to ensure rosion must be taken into account in the escaping vapor is discharged up the design of supports and frameworks. wards and unrestrictedly to prevent (4) When MEGCs are not protected impingement of escaping gas or liquid during transport as specified in para upon the MEGC, its pressure recep graph (h)(l) of this section, the pres tacles or personnel. For flammable, sure receptacles and service equipment pyrophoric and oxidizing gases, the es must be protected against damage re caping gas must be directed away from sulting from lateral or longitudinal im the pressure receptacle in such a man pact or overturning. External fittings ner that it cannot impinge upon the must be protected against release of other pressure receptacles. Heat resist the pressure receptacles’ contents upon ant protective devices that deflect the impact or overturning of the MEGC on flow of gas are permissible provided the its fittings. Particular attention must required pressure relief device capacity be paid to the protection of the mani is not reduced. Arrangements must be fold. Examples of protection include: made to prevent access to the pressure (i) Protection against lateral impact, relief devices by unauthorized persons which may consist of longitudinal bars: 907 ______

§ 178.75 49 CFR Ch. 1(10—1—10 Edition) (ii) Protection against overturning, the MEGC in a conspicuous place read which may consist of reinforcement ily accessible for inspection. The pres rings or bars fixed across the frame; sure receptacles must be marked ac (iii) Protection against rear impact, cording to this section. Affixing the which may consist of a bumper or metal plate to a pressure receptacle is frame; prohibited. At a minimum, the fol (iv) Protection of the pressure recep lowing information must be marked on tacles and service equipment against the plate by stamping or by any other damage from impact or overturning by equivalent method: of an ISO frame according to the use Country of manufacture relevant provisions of ISO 1496-3. (IBR, see § 171.7 of this subchapter). UN (i) Initial inspection and test. The pres sure receptacles and items of equip ment of each MEGC must be inspected and tested before being put into service for the first time (initial inspection and test). This initial inspection and test of an MEGC must include the fol lowing: (1) A check of the design characteris tics. (2) An external examination of the MEGC and its fittings, taking into ac count the hazardous materials to be transported. (3) A pressure test performed at the Approval Country test pressures specified in Approval Number § 173.304b(b) (1) and (2) of this sub chapter. The pressure test of the mani Alternate Arrangements (see § 178.75(b)) fold may be performed as a hydraulic MEGC Manufacturer’s name or mark test or by using another liquid or gas. MEGC’s serial number leakproofness test and a test of the A Approval agency (Authorized body for operation of all service satisfactory the design approval) equipment must also be performed be fore the MEGC is placed into service. Year of manufacture When the pressure receptacles and Test pressure: bar gauge their fittings have been pressure-tested Design temperature range °C to separately, ihey must be subjected to a leakproof test after assembly. (4) An MEGC that meets the defini Number of pressure receptacles tion of “container” in the CSC (see 49 Total water capacity liters CFR 450.3(a) (2)) must be subjected to an Initial pressure test date and identi impact test using a prototype rep fication of the Approval Agency resenting each design type. The proto Date and type of most recent periodic type MEGC must be shown to be capa tests ble of absorbing the forces resulting from an impact not less than 4 times (4 Year Month____ Type g) the MPGM of the fully loaded (e.g. 2004—05, AE/UE, where “AE” rep MEGC, at a duration typical of the me resents acoustic emission and “UE” chanical shocks experienced in rail represents ultrasonic examination) transport. A listing of acceptable Stamp of the approval agency who methods for performing the impact test performed or witnessed the most recent is provided in the UN Recommenda test tions (IBR, see §171.7 of this sub (2) The following information must chapter). be marked on a metal plate firmly se Marking. (1) Each MEGC must be (J) cured to the MEGC: equipped with a corrosion resistant metal plate permanently attached to Name of the operator 908 ______

Pipeline and Hazardous Materials Safety Admin., DOT Pt. 178, Subpt. C, App. A

Maximum permissible load mass Maximum permissible gross mass kg (MPGM) kg Working pressure at 15 °C: bar Unladen (tare) mass kg gauge [71 FR 33892, June 12, 2006, as amended at 73 FR 4719, Jan. 28, 20081

APPENDIX A TO SUBPART C OF PART 178—ILLUSTRATIONS: CYLINDER TENSILE SAMPLE

The following figures illustrate the recommended locations for test specimens taken from welded cylinders:

909 Pt. 178, Subpt. C, App. A 49 CFR Ch. I (10—1—10 Edition)

SEAMLESS BODY H \ SECTIONS REQUIRE ONLY ‘N ONE PARENT METAL TEST

5

OPTIONAL CONVEX HEAD

PARENT MATERIAL TEST SAMPLE 1 & 3 & 5

WELD TENSILE TEST SAMPLE 4

WELD BEND TEST SAMPLE 2

THIS FIGURE ILLUSTRATES THE PROPER TENSILE LOCATION FOR A 3 PIECE CYLINDER WITH THE HEADS HAVING STRAIGHT SIDEWALL.

FICURE #1

910 Pipeline and Hazardous Materials Safety Admin., DOT Pt. 178, Subpt. C, App. A

OPTIONAL CONVEX HEAD

PARENT MATERIAL TEST SAMPLE 1 & 3

r WELD TENSILE TEST I SAMPLE4

WELD BEND TEST SAMPLE 2

THIS FIGURE ILLUSTRATES THE PROPER TENSILE LOCATION FOR A 2 PIECE CYLINDER WITH THE HEADS HAVING STRAIGHT SIDEWALLS. F1CURE #2

911 Pt. 178, Subpt. C, App. A 49 CFR Ch. I (10—1—10 Edition)

2

4

OPTIONAL, CONVEX HEAD SAMPLE TO BE TAKEN FROM HEAD

PARENT MATERIAL TEST LZE1 SAMPLE 1 &3&5

WELD TENSILE TEST LDE1 SAMPLE 4

WELD BEND TEST SAMPLE 2

THIS FIGURE ILLUSTRATES THE PROPER TENSILE LOCATION FOR A 2 PIECE CYLINDER THAT HAVE DEEP DRAWN HEADS. FIGURE #3

912 Pipeline and Hazardous Materials Safety Admin., DOT Pt. 178, Subpt. C, App. A

SEAMLESS SIDEWALL TWO PIECE CONSTRUCTION CONSTRUCTION PARENT MATERIAL TEST SAMPLE 1 & 3

WELD TENSILE TEST SAMPLE 4

WELD BEND TEST SAMPLE 2

THIS FIGURE ILLUSTRATES THE PROPER TENSILE LOCATION FOR A 2 PIECE CYLINDER THAT HAVE DEEP DRAWN HEADS. FIGURE #4

913 Pt. 178, Subpt. C, App. A 49 CFR Ch. I (10—1—10 Edition)

PARENT MATERIAL TEST SAMPLE 1 & 3

WELD TENSILE TEST SAMPLE 4

WELD BEND TEST SAMPLE 2

THIS FIGURE ILLUSTRATES THE PROPER TENSILE LOCATION FOR A 2 PIECE CYLINDER. FIGURE #5 167 FR 51654, Aug. 8, 2002]

914 Pipeline and Hazardous Materials Safety Admin., DOT § 178.255—6

Subparts D-G [Reserved] § 178.255-3 Expansion domes. (a) Expansion domes, if applied, must Subpart H—Specifications for have a minimum capacity of one per Portable Tanks cent of the combined capacity of the tank and dome. SOURCE: 29 FR 18972, Dec. 29, 1964. unless (b) [Reserved] otherwise noted. Redesignated at 32 FR 5606. Apr. 5, 1967. § 178.255—4 Closures for manholes and domes. § 178.251—178.253—5 [Reserved] (a) The manhole cover shall be de § 178.255 Specification 60; steel port signed to provide a secure closure of able tanks. the manhole. All covers, not hinged to the tanks, shall be attached to the out § 178.255—1 General requirements. side of the dome by at least ‘/ inch chain (a) Tanks must be of fusion welded or its equivalent. Closures shall be made construction, cylindrical in shape with tight against leakage of vapor and seamless heads concave to the pres liquid by use of gaskets of suitable sure. Tank shells may be of seamless material. construction. (b) [Reserved] (b) Tanks must be designed, con § 178.255—5 Bottom structed, certified, and stamped in ac discharge outlets. cordance with Section VIII of the (a) Bottom discharge outlets prohib ASME Code (IBR, see §171.7 of this sub ited, except on tanks used for ship chapter). rnents of sludge acid and alkaline cor (c) Tanks including all permanent at rosive liquids. tachments must be postweld heat (b) If installed, bottom outlets or treated as a unit. bottom washout chambers shall be of (d) Requirements concerning types of metal not subject to rapid deteriora valves, retesting, and qualification of tion by the lading, and each shall be portable tanks contained in § 173.32 provided with a valve or plug at its and 173.315 of this chapter must be ob upper end and liquid-tight closure at it served. lower end. Each valve or plug shall be designed to insure against unseating FR 18972, Dec. 29, 1964. Redesignated 129 at 32 due FR 5606, Apr. 5, 1967, and amended by Arndt. to stresses or shocks incident to 178—7, 34 FR 18250, Nov. 14, 1969; 68 FR 75750, transportation. Bottom outlets shall be Dec. 31, 2003] adequately protected against handling damage and outlet equipment must not § 178.255—2 Material. extend to within less than one inch of the (a) Material used in the tank must be bottom bearing surface of the skids or steel of good weldable quality and con tank mounting. form with the requirements in Sections 129 FR 18972, Dec. 29, 1964. Redesignated at 32 V, VIII, and IX of the ASME Code (IBR, FR 5606, Apr. 5, 1967, as amended by Amdt. see §171.7 of this subchapter). 178—104, 59 FR 49135, Sept. 26, 1994] (b) The minimum thickness of metal, exclusive of lining material, for shell § 178.255-6 Loading and unloading ac and heads of tanks shall be as follows: cessories. (a) When installed, gauging, loading Minimum Tank capacity thickness and air inlet devices, including their (inch) valves, shall be provided with adequate means for their secure Not more than 1,200 gallons ¼ closure; and Over 1,20010 1,800 gallons means shall also be provided for the Over 1,800 gallons ¼ closing of pipe connections of valves. (b) Interior heater coils, if installed, [29 FR 18972, Dec. 29, 1964. Redesignated at 32 must be of extra heavy pipe and so con FR 5606, Apr. 5, 1967, and amended by Amdt. structed that breaking off of exterior 178—7, 34 FR 18250, Nov. 14, 1969; 68 FR 75750, connections will not cause leakage of Dec. 31, 2003] tanks.

915 § 178.255—7 49 CFR Ch. I (10—1—10 Edition)

§ 178.255—7 Protection of valves and devices shall be deemed to comply with accessories. this requirement. (a) All valves, fittings, accessories, (b) All tank mountings such as skids, safety devices, gauging devices, and the fastenings, brackets, cradles, lifting like shall be adequately protected lugs, etc., intended to carry loadings against mechanical damage by a hous shall be permanently secured to tanks ing closed with a cover plate. in accordance with the requirements (b) Protective housing shall comply under which the tanks are fabricated, with the requirements under which the and shall be designed with a factor of tanks are fabricated with respect to de safety of four, and built to withstand sign and construction, and shall be de loadings in any direction equal to two signed with a minimum factor of safety times the weight of the tanks and at of four to withstand loadings in any di tachments when filled to the maximum rection equal to two times the weight permissible loaded weight. of the tank and attachments when (c) Lifting lugs or side hold-down filled with water. lugs shall be provided on the tank mountings in a manner suitable for at § 178.255—8 Safety devices. taching lifting gear and hold-down de (a) See § 173.315(i) of this subchapter. vices. Lifting lugs and hold-down lugs (b) [Reserved] welded directly to the tank shall be of the pad-eye type. Doubling plates weld [Amclt. 178-83, 50 FR 11066, Mar. 19, 1985] ed to the tank and located at the § 178.255—9 Compartments. points of support shall be deemed to comply with this requirement. (a) When the interior of the tank is (d) All tank mountings shall be so de divided into compartments, each com signed as to prevent the concentration partment shall be designed, con of excessive loads on the tank shell. structed and tested as a separate tank. Thickness of shell and compartment § 178.255—12 Pressure test. heads shall be determined on the basis of total tank capacity. (a) Each completed portable tank (b) [Reserved] prior to application of lining shall be tested before being put into transpor § 178.255—10 Lining. tation service by completely filling the tank with water or other liquid having (a) If a lining is required, the mate a similar viscosity, the temperature rial used for lining the tank shall be of which shall not exceed 100 homogeneous, nonporous, imperforate °F during the test, and applying a pressure when applied, not less elastic than the of 60 psig. The tank shall be capable metal of the tank proper. It shall be of of hold ing the prescribed pressure for at substantially uniform thickness, not least 10 minutes without leakage, evidence less than 1/32 inch thick if metallic, and of impending failure, or failure. All clo not less than 1/16 inch thick if non sures shall be in place while the metallic, and shall be directly bonded test is made and the pressure shall be or attached by other equally satisfac gauged at the top of the tank. Safety devices tory means. Rubber lining shall be not and/or vents shall be plugged during less than /lo inch thick. Joints and this test. seams in the lining shall be made by (b) [Reserved] fusing the material together or by other equally satisfactory means. The [29 FR 18972, Dec. 29, 1964. Redesignated at 32 interior of the tank shall be free from FR 5606, Apr. 5, 1967, as amended by Amdt. scale, oxidation, moisture and all for 178—104, 59 FR 49135, Sept. 26, 1994] eign matter during the lining oper ation. § 178.255—13 Repair of tanks. (b) [Reserved] (a) Tanks failing to meet the test may be repaired and retested, provided § 178.255-11 Tank mountings. that repairs are made in complete com (a) Tanks shall be designed and fab pliance with the requirements of this ricated with mountings to provide a se specification. cure base in transit. “Skids” or similar (b) [Reserved] 916 ______

Pipeline and Hazardous Materials Safety Admin., DOT § 178.273

§ 178.255—14 Marking. § 178.273 Approval of Specification UN (a) In addition to markings required portable tanks. by Section VIII of the ASME Code (a) Application for approval. (1) An (IBR, see §171.7 of this subchapter), owner or manufacturer of a portable every tank shall bear permanent marks tank shall apply for approval to a des at least 1/8-inch high stamped into the ignated approval agency authorized to metal near the center of one of the approve the portable tank in accord tank heads or stamped into a plate per ance with the procedures in subpart E, manently attached to the tank by part 107 of this subchapter. means of brazing or welding or other (2) Each application for approval suitable means as follows: must contain the following informa tion: Manufacturer’s name Serial (i) Two complete copies No. of all engi neering drawings, calculations, and DOT specification Nominal capacity (gallons) test data necessary to ensure that the Tare weight (pounds) design meets the relevant specifica

Date of manufacture tion. (ii) The manufacturer’s serial number (b) [Reserved] that will be assigned to each portable [29 FR 18972, Dec. 29, 1964. Redesignated at 32 tank. FR 5606, Apr. 5, 1967, and amended by Amdt. (iii) A statement as to whether the 178—67, 46 FR 49906, Oct. 8, 1981; 68 FR 75750, design type has been examined by any Dec. 31, 2003] approval agency previously and judged unacceptable. § 178.255—15 Report. Affirmative statements must be documented with the name of (a) A copy of the manufacturer’s data the approval agency, reason for non- report required by Section VIII of the acceptance, and the nature of modifica ASME Code (IBR, see § 171.7 of this sub tions made to the design type. chapter) under which the tank is fab (b) Action by approval agency. The ap ricated must be furnished to the owner proval agency must perform the fol for each new tank. lowing activities: Place (1) Review the application for ap Date proval to determine whether it is com Portable tank plete and conforms with the require Manufactured for Company ments of paragraph (a) of this section. Location If an application is incomplete, it will Manufactured by Company be returned to the applicant Location with an Consigned to Company explanation as to why the application is incomplete. Location Size feet outside diameter by (2) Review all drawings and calcula long. tions to ensure that the design is in Marks on tank as prescribed by § 178.255-14 of compliance with all requirements of this specification are as follows: the relevant specification. If the appli Manufacturer’s name cation is approved, one set of the ap Serial number proved drawings, Owner’s serial number calculations, and test DOT specification data shall be returned to the applicant. ASME Code Symbol (par U-201) The second (inspector’s copy) set of ap Date of manufacture proved drawings, calculations, and test Nominal capacity gallons. data shall be retained by the approval It is hereby certified that this tank is in agency. Maintain drawings and ap complete compliance with the requirements proval records for as long as the port of DOT specification No. 60. able tank remains in service. (Signed) The draw ings Manufacturer or owner and records must be provided to the Department of Transportation (b) [Reserved] (DOT) upon request. [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 178—83, 50 FR 11066. Mar. 19, 1985; 68 FR 75750, in this section and part 180, subpart G Dec. 31, 2003] of this subchapter.

917 § 178.273 49 CFR Ch. I (10—1—10 Edition)

(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 (1) 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 (see § 178.274(a) (2)) must be indicated on thorized inspector, if applicable, are the plate as specified in §178.274(i). qualified, reputable and competent. (ii) Issue an approval certificate for The manufacturer of a portable tank each portable tank or, in the case of a shall— 918 Pipeline and Hazardous Materials Safety Admin., DOT § 178.273

(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 re proval agency, the owner or lessee of as quired in §l07.404(a)(3) the tank. Upon request, provide of this sub these chapter. records to a representative of DOT. (d) Denial of application for approval. (ii) Ensure through appropriate in If an approval agency finds that a port spection that all modifications con able tank cannot be approved for any form to the revised drawings, calcula tions, reason, it shall notify the applicant in and test data. 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 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

919 § 178.274 49 CFR Cli. 1(10—1—10 Edition)

(ii) Termination of the approval is tanks may be varied if approved by the necessary to adequately protect Associate Administrator and the port against risks to life and property; or able tank is shown to provide a level of (iii) The approval was not issued by safety equal to or exceeding the re the approval agency in good faith; or quirements of this subchapter. Port (iv) The portable tank does not meet able tanks approved to alternative the specification. technical requirements must be (2) Before an approval is terminated, marked “Alternative Arrangement” as the Associate Administrator gives the specified in paragraph (I) of this sec interested party(ies): tion. (i) Written notice of the facts or con (3) DefInitions. The following defini duct believed to warrant the termi tions apply for the purposes of design nation; and construction of UN portable tanks (ii) Opportunity to submit oral and under this subpart: written evidence; and Alternate Arrangement portable tank (Hi) Opportunity to demonstrate or means a UN portable tank that has achieve compliance with the applicable been approved to alternative technical requirements. requirements or testing methods other (3) If the Associate Administrator de than those termines that a certificate of approval specified for UN portable tanks in part 178 must be terminated to preclude a sig or part 180 of this sub chapter. nificant and imminent adverse affect on public safety, he may terminate the Approval agency means the des certificate immediately. In such cir ignated approval agency authorized to cumstances, the opportunities of para approve the portable tank in accord graphs (f)(2) (ii) and (Hi) of this section ance with the procedures in subpart E need not be provided prior to termi of part 107 of this subchapter. nation of the approval, but shall be Design pressure is defined according provided as soon as practicable there to the hazardous materials intended to after. be transported in the portable tank. See §5178.275, 178.276 and 178.277, as ap [66 FR 33439, June 21, 2001, as amended at 67 plicable. 61016, Sept. 27, 68 FR 75748, 75751, FR 2002; Design Dec. 31, 2003; 72 FR 55695, Oct. 1, 20071 type means a portable tank or series of portable tanks made of mate § 178.274 Specifications for UN port. rials of the same material specifica able tanks. tions and thicknesses, manufactured (a) General. (1) Each UN portable by a single manufacturer, using the tank must meet the requirements of same fabrication techniques (for exam this section. In addition to the require ple, welding procedures) and made with ments of this section, requirements equivalent structural equipment, clo specific to UN portable tanks used for sures, and service equipment. liquid and solid hazardous materials, Fine grain steel means steel that has a non-refrigerated liquefied gases and re ferritic grain size of 6 or finer when de frigerated liquefied gases are provided termined in accordance with ASTM E in §5178.275, 178.276 and 178.277, respec 112—96 (IBR, see § 171.7 of this sub tively. Requirements for approval, chapter). maintenance, inspection, testing and Fusible element means a non-reclosing use are provided in §178.273 and part pressure relief device that is thermally 180, subpart G, of this subchapter. Any activated and that provides protection portable tank which meets the defini against excessive pressure buildup in tion of a ‘container” within the terms the portable tank developed by expo of the International Convention for sure to heat, such as from a fire (see Safe Containers (CSC) must meet the § 178.275(g)). requirements of the CSC as amended Jacket means the outer insulation and 49 CFR parts 450 through 453 and cover or cladding which may be part of must have a CSC safety approval plate. the insulation system. (2) In recognition of scientific and Leakage test means a test using gas to technological advances, the technical subject the shell and its service equip requirements applicable to UN portable ment to an internal pressure. 920 Pipeline and Hazardous Materials Safety Admin., DOT § 178.274

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 §5178.275, 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)(l0) 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 ified in the applicable portable tank T make it necessary, the shells must be codes (such as Tl-T23) 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 921 § 178.274 49 CFR Ch. I (10—1—10 Edition)

material, the design temperature range perforations, sufficiently elastic and must be taken into account with re compatible with the thermal expansion spect to risk of brittle fracture, stress characteristics of the shell. The lining corrosion cracking, resistance to im of every shell, shell fittings and piping pact, and suitability for the hazardous must be continuous and must extend materials intended for transportation around the face of any flange. Where in the portable tank. When fine grain external fittings are welded to the steel is used, the guaranteed value of tank, the lining must be continuous the yield strength must be not more through the fitting and around the face than 460 N/mm2 and the guaranteed of external flanges. Joints and seams in value of the upper limit of the tensile the lining must be made by fusing the strength must be not more than 725 NI material together or by other equally mm2 according to the material speci effective means. fication. Aluminum may not be used as (5) Contact between dissimilar met a construction material for the shells als which could result in damage by of portable tanks intended for the galvanic action must be prevented by transport of non-refrigerated liquefied appropriate measures. gases. For portable tanks intended for (6) The construction materials of the the transport of liquid or solid haz portable tank, including any devices, ardous materials, aluminum may only gaskets, linings and accessories, must be used as a construction material for not adversely affect or react with the portable tank shells if approved by the hazardous materials intended to be Associate Administrator. Portable transported in the portable tank. tank materials must be suitable for the (7) Portable tanks must be designed external environment where they will and constructed with supports that be transported, taking into account the provide a secure base during transpor determined design temperature range. tation and with suitable lifting and tie- Portable tanks shall be designed to down attachments. withstand, without loss of contents, at (c) Design criteria. (1) Portable tanks least the internal pressure due to the and their fastenings must, under the contents and the static, dynamic and maximum permissible loads and max thermal loads during normal condi imum permissible working pressures, tions of handling and transportation. be capable of absorbing the following The design must take into account the separately applied static forces (for effects of fatigue, caused by repeated calculation purposes, acceleration due application of these loads through the to gravity (g) =9.8lm/s2): expected life of the portable tank. (i) In the direction of travel: 2g (2) Portable tank shells, fittings, and (twice the MPGM multiplied by the ac pipework shall be constructed from celeration due to gravity); materials that are: (ii) Horizontally at right angles to (i) Compatible with the hazardous the direction of travel: ig (the MPGM materials intended to be transported; multiplied by the acceleration due to or gravity); (ii) Properly passivated or neutral (iii) Vertically upwards: ig (the ized by chemical reaction, if applica MPGM multiplied by the acceleration ble; or due to gravity); and (iii) For portable tanks used for liq (iv) Vertically downwards: 2g (twice uid and solid materials, lined with cor the MPGM multiplied by the accelera rosion-resistant material directly tion due to gravity). bonded to the shell or attached by (2) Under each of the forces specified equivalent means. in paragraph (c)(l) of this section, the (3) Gaskets and seals shall be made of safety factor must be as follows: materials that are compatible with the (i) For metals having a clearly de hazardous materials intended to be fined yield point, a design margin of 1.5 transported. in relation to the guaranteed yield (4) When shells are lined, the lining strength; or must be compatible with the hazardous (ii) For metals with no clearly de materials intended to be transported, fined yield point, a design margin of 1.5 homogeneous, non-porous, free from in relation to the guaranteed 0.2% 922 Pipeline and Hazardous Materials Safety Admin., DOT § 178.274

proof strength and, for austenitic Re = yield strength in N/mm2, or 0.2% steels, the 1% proof strength. proof strength or, for austenitic (3) The values of yield strength or steels, 1% proof strength; proof strength must be the values ac Rm = minimum tensile strength in NI cording to recognized material stand mm2. ards. When austenitic steels are used, (8) The values of Re and Rm to be the specified minimum values of yield used must be the specified minimum strength or proof strength according to values according to recognized mate the material standards may be in rial standards. When austenitic steels creased by up to 15% for portable tanks are used, the specified minimum values used for liquid and solid hazardous ma for Re and Rm according to the mate terials, other than toxic by inhalation rial standards may be increased by up liquids meeting the criteria of Hazard to 15% when greater values are at Zone A or Hazard Zone B (see §173.133 tested in the material inspection cer of this subchapter), when these greater tificate. values are attested in the material in (9) Steels which have a Re/Rm ratio spection certificate. of more than 0.85 are not allowed for (4) Portable tanks must be capable of the construction of welded shells. The being electrically grounded to prevent values of Re and Rm to be used in de dangerous electrostatic discharge when termining this ratio must be the values they are used for Class 2 flammable specified in the material inspection gases or Class 3 flammable liquids, in certificate. cluding elevated temperature mate (10) Steels used in the construction of rials transported at or above their shells must have an elongation at frac flash point. ture, in percentage, of not less than (5) For shells of portable tanks used lO,000/Rm with an absolute minimum of for liquefied compressed gases, the 16% for fine grain steels and 20% for shell must consist of a circular cross other steels. section. Shells must be of a design ca (11) For the purpose of determining pable of being stress-analyzed mathe actual values for materials for sheet metal, matically or experimentally by resist the axis of the tensile test speci men ance strain gauges as specified in UG— must be at right angles (trans versely) 101 of Section VIII of the ASME Code, to the direction of rolling. The permanent or other methods approved by the As elongation at fracture must sociate Administrator. be measured on test specimens of rec tangular cross sections in accordance (6) Shells must be designed and con with ISO 6892 (IBR, see 171.7 of structed to withstand a hydraulic test § this subchapter), using a 50 mm gauge pressure of not less than 1.5 times the length. design pressure for portable tanks used (d) Minimum shell thickness. (1) The for liquids and 1.3 times the design minimum shell thickness must be the pressure for portable tanks used for liq greatest thickness of the following: uefied compressed gases. Specific re (i) the minimum thickness deter quirements are provided for each haz mined in accordance with the require ardous material in the applicable T ments of paragraphs (d) (2) through Code or portable tank special provision (d) (7) of this section; specified in the § 172.101 Table of this (ii) the minimum thickness deter subchapter. The minimum shell thick mined in accordance with Section VIII ness requirements must also be taken of the ASME Code or other approved into account. pressure vessel code; or (7) For metals exhibiting a clearly (iii) the minimum thickness specified defined yield point or characterized by in the applicable T code or portable a guaranteed proof strength (0.2% proof tank special provision indicated for strength, generally, or 1% proof each hazardous material in the § 172.101 strength for austenitic steels), the pri Table of this subchapter. mary membrane stress u (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 923 § 178.274 49 CFR Ch. 1(10—1—10 Edition) equivalent thickness in the metal to be = l.8rn, 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 inches) thick in the reference steel or quired to have a minimum thickness of 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 l.8m; thickness requirement may be reduced Rm1 = guaranteed minimum tensile strength to 5 mm in the reference steel or of (in N/mm2) 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 2 1.4e0d1 threaded plugs) and any protective e1 = l.8m JRm1 xA1 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. e0 = minimum thickness (in mm) of the ref erence steel specified in the applicable T (3) Each stop-valve or other means of code or portable tank special provision in closure must be designed and con dicated for each material in the §172.101 structed to a rated pressure not less Table of this subchapter; than the MAWP of the shell taking 924 Pipeline and Hazardous Materials Safety Admin., DOT § 178.274

into account the temperatures ex (vi) when practicable, the device pected during transport. All stop- must show the manufacturer’s 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.—(l) 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. (m3/s). For spring loaded pressure relief (g) Gauging devices. Unless a portable device the rated flow capacity shall be tank is intended to be filled by weight, determined according to Iso 4126-1 it must be equipped with one or more (IBR, see § 171.7 of this subchapter); and gauging devices. Glass level-gauges and 925 § 178.274 49 CFR Ch. I (10—1—10 Edition) 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)(l) 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 1496—3 (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 Manufacturer’s name or mark tings, are well protected from being hit Manufacturer’s serial number the forklift blades; and by Approval Agency (Authorized body for the (ii) The distance between forklift design approval) pockets (measured from the center of Owner’s registration number each pocket) is at least half of the Year of manufacture 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 pressure bar gauge. damage to the shell, and service equip- MAWP bar gauge. 926 Pipeline and Hazardous Materials Safety Admin., DOT § 178.274 External design pressure (not required for (1) A check of the design characteris portable tanks used for refrigerated lique tics. fied gases) bar gauge. (2) An internal Design temperature range______and external examina tion to______°C. (For portable tanks used for of the portable tank and its fit 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/ liters. UN portable tanks used for refrigerated Water capacity of each compartment at 20 liquefied gases, a pressure test using an °C liters. 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 system______bar gauge. used for the dedicated transportation 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 steel mm. 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 Month Year______Test ation of all service equipment includ pressure bar gauge. ing pressure relief devices must Stamp of approval agency that performed or also be witnessed the most recent test. performed. When the shell and its fit tings have been For portable tanks used for refrigerated pressure-tested sepa liquefied gases: rately, they must be subjected to a leakage test after reassembly. Either “thermally insulated” or “vacuum in All sulated” welds, subject to full stress level in the Effectiveness of the insulation system (heat shell, must be inspected during the ini influx) Watts (W). tial test by radiographic, ultrasonic, or Reference holding time days or hours another suitable non-destructive test and initial pressure bar/kPa gauge method. This does not apply to the and degree of filling in kg for each jacket. refrigerated liquefied gas permitted for (6) Effective January 1, transportation. 2008, each 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 Name of the operator. test prescribed in Part IV, Sec Name of hazardous materials being trans tion 40 of the UN Manual of Tests and 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) kg. portable Unladen (tare) mass kg. tanks used for the dedicated transportation of “Helium, refrigerated NOTE TO PARAGRAPH (1)(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 chapter. marked “NOT FOR RAIL TRANS 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 be marked on the identification plate. portable tanks designed and con (j) Initial inspection and test. The ini structed to a single design type that is tial inspection and test of a portable also a CSC container without leakage tank must include the following: or deformation that would render the 927 § 178.275 49 CFR Ch. I (10—1—10 Edition) 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 and lateral re ture providing vertical §178.274(c) of this subchapter, but not and support at the upper end straint by less than 0.35 bar (35 kPa). of the base structure providing lateral (2) Maximum allowable working pres restraint only. (ii) Lateral inertia. The portable tank sure (MA WP) 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 (1) 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) Tn 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 FR 55696, Oct. 1, 2007; 73 FR 4719, Jan. 28, § 72 intended for fill 2008] openings in the shell, ing or discharging the portable tank EDITORIAL NOTE: At 68 FR 57633, Oct. 6, must be fitted with a manually oper 2003, §178.274 was amended in paragraph ated stop-valve located as close to the (b)(l); however, the amendment could not be 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 hazardous tation of liquid and solid 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 liquid solid haz transportation of and cess for maintenance and repair of the ardous materials. interior. Compartmented portable (b) Definitions and requirements—(l) 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 spill the highest of the following pressures: fittings must be surrounded by a (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 bar) of the hazardous material at 65 °C, and contraction, mechanical shock and minus 1 bar (149 °F, minus 100 kPa); vibration. All piping must be of a suit (B) The partial pressure (in bar) of able metallic material. Welded pipe air or other gases in the ullage space, joints must be used wherever possible. 928 Pipeline and Hazardous Materials Safety Admin., DOT § 178.275

(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 ; and must be accomplished by internally (iv) For UN portable and externally welding one plate to the tanks, with bot shell. tom outlets, used for the transpor tation of liquid (2) Bottom discharge outlets for port hazardous materials that are Class able tanks carrying certain solid, crys 3, PG I or II, or PG III with tallizable or highly viscous hazardous a flash point of less than 100 F (38 °C); Division materials must be equipped with at 5.1, PG I or II; or Division PG I least two serially fitted and mutually 6.1, or II, the remote means of clo sure must independent shut-off devices. Use of be capable of thermal acti vation. only two shut-off devices is only au The thermal means of activa thorized when this paragraph is ref tion must activate at a temperature of erenced in the applicable T Code indi not more than 250 °F (121 °C). 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-valvd 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 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 929 § 178.275 49 CFR Ch. I (10—1—10 Edition)

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). Fusi able tank operator to check to deter ble elements used on portable tanks in mine if the disc is leak free. The fran tended for the transport of elevated gible disc must rupture at a nominal temperature hazardous materials must pressure 10% above the start-to-dis be designed to operate at a tempera charge pressure of the reclosable pres ture higher than the maximum tem sure relief device. perature that will be experienced dur (4) Every portable tank with a capac ing transport and must be designed to ity less than 1,900 liters (501.9 gallons) the satisfaction of the approval agency. 930 Pipeline and Hazardous Materials Safety Admin., DOT § 178.275

(i) Capacity of pressure relief devices. T = absolute temperature in Kelvin ( °C + (I) The reclosing pressure relief device 273) above the pressure relief devices in the required by paragraph (g) (1) of this sec accumulating condition; tion must have a minimum cross sec L the latent heat of vaporization of the liq uid, in kJ/kg, in the accumulating condi tional flow area equivalent to an ori tion; fice of 31.75 mm (1.3 inches) diameter. M = molecular weight of the hazardous mate Vacuum-relief devices, when used, rial. must have a cross sectional flow area (B) The constant not less than 284 mm2 (11.2 inches2). C, as shown in the formula in paragraph (i) (2) (i) (A) of this (2) The combined delivery capacity of section, is derived from one of the fol the pressure relief system (taking into lowing formulas as a function of the account the reduction of the flow when ratio k of specific heats: the portable tank is fitted with fran gible-discs preceding spring-loaded pressure-relief devices or when the C k= — spring-loaded pressure-relief devices Cv are provided with a device to prevent the passage of the flame), in condition Where: of complete fire engulfment of the r, is the specific heat at constant pressure; portable tank must be sufficient to and limit the pressure in the shell to 20% c is the specific heat at constant volume. above the start to discharge pressure (C) When k >1: limiting device (pressure relief device). The total required capacity of the re k+1 lief devices may be determined using I 1 2 the formula in paragraph (i) (2) (i) (A) of C = 41k1 this section or the table in paragraph ‘ k+1 Ci) (2) (iii) of this section. (D) When k = 1 or k is unknown, a (i)(A) To determine the total re value of 0.607 may be used for the con quired capacity of the relief devices, stant C. C may also be taken from the which must be regarded as being the following table: sum of the individual capacities of all the contributing devices, the following C CONSTANT VALUE TABLE formula must be used: k C

1.00 0.607 FA°52 f 1.02 0.611 Q124 I— 1.04 0.615 LC VM 1.06 0.620 Where: 1.08 0.624 1.10 0.628 Q = minimum required rate of discharge in 1.12 0.633 cubic meters of air per second (3/,) at con 1.14 0.637 ditions: 1 bar and 0 °C (273 °K); 1.16 0.641 1.18 0.645 F = for uninsulated shells: 1; for insulated 1.20 0.649 shells: U(649—t)/13.6 but in no case is less 1.22 0.652 than 0.25 1.24 0.656 Where: 1.26 0.660 1.28 0.664 U = thermal conductance of the insulation, 1.30 0.667 in kWm2K’, at 38 C (100 °F); and t = ac 1.32 0.671 tual temperature of the hazardous mate 1.34 0.674 rial during filling (in °C) or when this tem 1.36 0.678 1.38 0.681 perature is unknown, let t = 15 °C (59 °F). The value of F given in this paragraph 1.40 0.685 1.42 0.688 (i) (2) (i) (A) for insulated shells may only be 1.44 0.691 used if the insulation is in conformance 1.46 0.695 with paragraph (i)(2)(iv) of this section; 1.48 0.698 1.50 A = total external surface area of shell in 0.701 square meters: 1.52 0,704 1.54 0.707 Z = the gas compressibility factor in the ac 1.56 0.710 cumulating condition (when this factor is 1.58 0.713 unknown, let Z equal 1.0); 1.60 0.716

931 § 178.276 49 CFR Ch. 1(10—1—10 Edition)

C CONSTANT VALUE TABLE—Continued (B) Be jacketed with a material hav ing a melting point of 700 C (1292 F) or k C greater. 1.62 0.719 (j) Approval, inspection and testing. 1.64 0.722 Approval 1.66 0.725 procedures for UN portable 1.68 0.728 tanks are specified in §178.273. Inspec 1.70 0.731 tion and testing requirements are spec 2.00 0.770 2.20 0.793 ified in § 180.605 of this subchapter. [66 FR 33445, June 21, 2001, as amended at 68 FR 32414, May 30, 2003; 69 FR 76185, Dec. 20, (ii) As an alternative to the formula 2004; 73 FR 57006, Oct. 1, 2008] in paragraph (i) (2) (i) (A) of this section, relief devices for shells used for trans § 178.276 Requirements for the design, porting liquids may be sized in accord construction, inspection and testing ance with the table in paragraph of portable tanks intended for the (i)(2)(iii) of this section. The table in transportation of non-refrigerated paragraph (i)(2)(iii) of this section as liquefied compressed gases. sumes an insulation value of F = I and (a) In addition to the requirements of adjusted accordingly the must be when §178.274 applicable to UN portable shell is insulated. Other values used in tanks, the following requirements determining the table in paragraph apply to UN portable tanks used for (i)(2)(iii) of this section are: L = 334.94 non-refrigerated liquefied compressed kJ/kg; M 86.7: T = 394 °K; Z 1; and gases. In addition the definitions C 0.607. to in 178.274, (iii) Minimum emergency vent capac § the following definitions ity, Q, in cubic meters of air per second apply: at 1 bar and 0 °C (273 °K) shown in the (1) Design pressure means the pressure following table: to be used in calculations required by the ASME Code, Section VIII (IBR, see MINIMUM EMERGENCY VENT CAPACITY §171.7 of this subchapter). The design [0 Values) pressure must be not less than the highest of the following pressures: A 0 A 0 Exposed area (Cubic me- Exposed area (Cubic me- (i) The maximum effective gauge (square me- ters of air (square me- ters of air pressure ters) per second) ters) per second) allowed in the shell during filling or discharge; or 2 0.230 37.5 2.539 (ii) The sum of: 3 0.320 40 2.677 4 0.405 42.5 2.814 (A) The maximum effective gauge 5 0.487 45 2.949 pressure to which the shell is designed 6 0.565 47.5 3.082 7 0.641 50 3.215 as defined in this paragraph under 8 0.715 52.5 3.346 ‘MAWP”; and 9 0.788 55 3.476 (B) A head pressure determined on 10 0.859 57.5 3.605 12 0.998 60 3.733 the basis of the dynamic forces speci 14 1.132 62.5 3.860 fied in paragraph (h) of this section, 16 1,263 65 3.987 but not less than 0.35 bar (35 kPa). 18 1.391 67.5 4.112 20 1.517 70 4.236 (2) Design reference temperature means 22.5 1.670 75 4.483 the temperature at which the vapor 25 1.821 80 4.726 pressure of the determined 27.5 1.969 85 4.967 contents is 30 2.115 90 5.206 for the purpose of calculating the 32.5 2.258 95 5,442 MAWP. The value for each portable 35 2.400 100 5.676 tank type is as follows: (i) Shell of 1.5 (iv) Insulation systems, used for the with a diameter meters (4.9 purpose of reducing venting capacity, ft.) or less: 65 °C (149 °F); or must be specifically approved by the (ii) Shell with a diameter of more approval agency. In all cases, insula than 1.5 meters (4.9 ft.): tion systems approved for this purpose (A) Without insulation or sun shield: must— 60 °C (140 5F); (A) Remain effective at all tempera (B) With sun shield: 55 °C (131 °F); and tures up to 649 °C (1200 °F); and (C) With insulation: 50 xc (122 5F).

932 Pipeline and Hazardous Materials Safety Admin., DOT § 178.276

(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/i). 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 manufacturer’s 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 (I) 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 ( 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 (tr 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 1 iq 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 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 roust not inhibit access to the after completion of all the welds in fittings and discharge devices. In addi and/or to the shell and heads. The tion, the thermal insulation systems method must be as prescribed in the must satisfy the following require ASME Code. Welded attachments to ments: pads may be made after postweld heat (i) consist of a shield covering not treatment is made. A portable tank less than the upper third, but not more 933 § 178.276 49 CFR Ch. 1(10—1—10 Edition)

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 (W.m2.K’) 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 Fine portable tanks. The inlet and dis stop-valve and the third being a blank charge outlets on portable tanks used flange, thread cap, plug or equivalent to transport chlorine must meet the re tight liquid closure device. quirements of § l78.337—l(c)(2) and must (2) When a portable tank is fitted be fitted with an internal excess flow with an excess flow valve, the excess valve. In addition to the internal ex flow valve must be so fitted that its cess flow valve, the inlet and discharge seating is inside the shell or inside a outlets must be equipped with an ex welded flange or, when fitted exter ternal stop valve (angle valve). Excess nally, its mountings must be designed flow valves must conform to the stand so that in the event of impact it main ards of The Chlorine Institute, Inc. tains its effectiveness. The excess flow (IBR, see § 171.7 of this subchapter) as valves must be selected and fitted so as follows: to close automatically when the rated (i) A valve conforming to Drawing flow, specified by the manufacturer, is 101-7, dated July 1993, must be installed reached. Connections and accessories under each liquid angle valve. leading to or from such a valve must (ii) A valve conforming to Drawing have a capacity for a flow more than 106—6, dated July 1993, must be installed the excess flow valve’s rated flow. under each gas angle valve. For port (3) For filling and discharge openings able tanks used to transport non-re that are located below the liquid level, frigerated liquefied gases. the first shut-off device must be an in (8) External fittings must be grouped ternal stop-valve and the second must together as close as reasonably prac be a stop-valve placed in an accessible ticable. The following openings may be position on each discharge and filling installed at locations other than on the pipe. top or end of the tank: (4) For filling and discharge openings (i) The openings for liquid level gaug located below the liquid level of port ing devices, pressure gauges, or for able tanks intended for the transpor safety devices, may be installed sepa tation of flammable and/or toxic lique rately at the other location or in the fied compressed gases, the internal side of the shell; stop-valve must be a self-closing safety (ii) One plugged opening of 2-inch Na device that fully closes automatically tional Pipe Thread or less provided for during filling or discharge in the event maintenance purposes may be located of fire engulfment. The device shall elsewhere; 934 Pipeline and Hazardous Materials Safety Admin., DOT § 178.276 (iii) An opening of 3-inch National subchapter must have a pressure relief Pipe Size or less may be provided at device which conforms to the require another location, when necessary, to ments of this subchapter. Unless a facilitate installation of condensing portable tank, in dedicated service, is coils. fitted with a relief device constructed (9) Filling and discharge connections of materials compatible with the haz are not required to be grouped and may ardous material, the relief device must be installed below the normal liquid be comprised of a frangible disc pre level of the tank if: ceded by a reclosing device. The space (i) The portable tank is permanently between the frangible disc and the mounted in a full framework for con de vice must tainerized transport; be provided with a pressure gauge or (ii) For each portable tank design, a a suitable tell-tale indicator. prototype portable tank, meets the re This arrangement must facilitate the quirements of parts 450 through 453 of detection of disc rupture, pinholing or this title for compliance with the re leakage which could cause a malfunc quirements of Annex II of the Inter tion of the pressure relief device. The national Convention for Safe Con frangible disc must rupture at a nomi tainers; and nal pressure 10% above the start-to-dis (iii) Each filling and discharge outlet charge pressure of the relief device. meets the requirements of paragraph (4) In the case of portable tanks used (c) (4) of this section. for more than one gas, the pressure re (d) Bottom openings. Bottom openings lief devices must open at a pressure in are prohibited on portable tanks when dicated in paragraph (e) (1) of this sec the UN Portable Tank Table for Lique tion for the gas having the highest fied Compressed Gases in §173313 of maximum allowable pressure of the this subchapter indicates that bottom gases allowed to be transported in the openings are not allowed. In this case, portable tank. there may be no openings located (0 Capacity of relief devices. The com below the liquid level of the shell when bined delivery capacity of the relief de it is filled to its maximum permissible vices must be sufficient filling limit. so that, in the event of total fire engulfment, Ce) Pressure relief devices. (1) Portable the pressure inside the tanks must be provided with one or shell cannot exceed 120% of more reclosing pressure relief devices. the MAWP. Reclosing relief de The pressure relief devices must open vices must be used to achieve the full automatically at a pressure not less relief capacity prescribed. In the case than the MAWP and be fully open at a of portable tanks used for more than pressure equal to 110% of the MAWP. gas. the combined delivery capacity of These devices must, after discharge, the pressure relief devices must be close at a pressure not less than 10% taken for the liquefied compressed gas below the pressure at which discharge which requires the highest delivery ca starts and must remain closed at all pacity of the liquefied compressed lower pressures. The pressure relief de gases allowed to be transported in the vices must be of a type that will resist portable tank. The total required ca dynamic forces including liquid surge. pacity of the relief devices must be de A frangible disc may only be used in se termined according to the require ries with a reclosing pressure relief de ments in §178.275(i). These require vice. ments apply only to liquefied com (2) Pressure relief devices must be de pressed gases which have critical tem signed to prevent the entry of foreign peratures well above the temperature matter, the leakage of gas and the de at the accumulating condition. For velopment of any dangerous excess gases that have critical temperatures pressure. near or below the temperature at the (3) A portable tank intended for the accumulating condition, the calcula transportation of certain liquefied tion of the pressure relief device compressed gases identified in the UN deliv ery capacity Portable Tank Table for Liquefied must consider the addi tional Compressed Gases in § 173.313 of this thermodynamic properties of the 935 § 178277 49 CFR Ch. I (10—1—10 Edition)

gas, for example see CGA S-l.2 (IBR, (2) A jacket and an inner shell with see § 171.7 of this subchapter). an intermediate layer of solid ther mally insulating material (for exam [66 FR 33448, June 21, 2001, as amended at 68 FR 75748. 75752, Dec. 31, 2003; 69 FR 54046, ple, solid foam). Sept. 7, 2004; 69 FR 76185, Dec. 20, 2004] (b) General design and construction re quirements. (1) Portable tanks must be § 178.277 Requirements for the design, of seamless or welded steel construc construction, inspection and testing tion and have a water capacity of more of portable tanks intended for the than 450 liters (118.9 gallons). Portable transportation of refrigerated lique tanks must be designed, constructed, fied gases. certified and stamped in accordance (a) In addition to the requirements of with Section VIII of the ASME Code. §178.274 applicable to UN portable (2) Portable tanks must be postweld tanks, the following requirements and heat treated and radiographed as pre definitions apply to UN portable tanks scribed in Sections V and VIII of the used for refrigerated liquefied gases: ASME Code except that each tank con Design pressure For the purpose of structed in accordance with part UHT this section the term “design pressure” in Section VIII of the ASME Code must is consistent with the definition for de be postweld heat treated. Where sign pressure in the ASME Code, Sec postweld heat treatment is required, tion VIII (IBR, see §171.7 of this sub the tank must be treated as a unit chapter). after completion of all the welds to the shell and heads. The method must be as Holding time is the time, as deter prescribed in the ASME Code. Welded mined by testing, that will elapse from attachments to pads may be made after loading until the pressure of the con postweld heat treatment is made. The tents, under equilibrium conditions, postweld heat treatment must be as the lowest set pressure of the reaches prescribed in Section VIII of the ASME limiting device(s) (for exam pressure Code, but in no event at less than 1,050 ple, pressure control valve or pressure °F tank metal temperature. Holding time must be de relief device). (3) Welding procedure and welder per specified in 178.338—9. termined as § formance tests must be made annually Maximum allowable working pressure in accordance with Section IX of the (MA WP) means the maximum effective ASME Code (IBR, see §171.7 of this sub gauge pressure permissible at the top chapter). In addition to the essential of the shell of a loaded portable tank in variables named in the ASME Code, the its operating position including the following must be considered as essen highest effective pressure during filling tial variables: number of passes, thick and discharge; ness of plate, heat input per pass, and Minimum design temperature means the specified rod and flux. The number the temperature which is used for the of passes, thickness of plate and heat design and construction of the shell input per pass may not vary more than not higher than the lowest (coldest) 25% from the procedure qualification. service temperature of the contents Records of the qualification must be during normal conditions of filling, dis retained for at least 5 years by the charge and transportation. portable tank manufacturer and made Shell means the part of the portable available to the approval agency and tank which retains the refrigerated liq the owner of the portable tank as spec uefied gas intended for transport, in ified in § 178.273. cluding openings and their closures, (4) Shells and jackets must be made but does not include service equipment of metallic materials suitable for form or external structural equipment. ing. Jackets must be made of steel. Tank means a construction which Non-metallic materials may be used normally consists of either: for the attachments and supports be (1) A jacket and one or more inner tween the shell and jacket, provided shells where the space between the their material properties at the min shell(s) and the jacket is exhausted of imum design temperature are proven air (vacuum insulation) and may incor to be sufficient. In choosing the mate porate a thermal insulation system; or rial, the minimum design temperature 936 Pipeline and Hazardous Materials Safety Admin., DOT § 178.277

must be taken into account with re (11) The effectiveness of the insula spect to risk of brittle fracture, to hy tion system (heat influx in watts) may drogen embrittlement, to stress corro be determined by type testing the port sion cracking and to resistance to im able tank in accordance with a proce pact. dure specified in § 178.338—9(c) or by (5) Any part of a portable tank, in using the holding time test in §178.338— cluding fittings, gaskets and pipe- 9(b). This test must consist of either: work, which can be expected normally (i) A constant pressure test (for ex to come into contact with the refrig ample, at atmospheric pressure) when erated liquefied gas transported must the loss of refrigerated liquefied gas is be compatible with that refrigerated measured over a period of time; or liquefied gas. (ii) A closed system test when the (6) The thermal insulation system rise in pressure in the shell is measured must include a complete covering of over a period of time. the shell with effective insulating ma (12) When performing the constant terials. External insulation must be pressure test, variations in atmos protected by a jacket so as to prevent pheric pressure must be taken into ac the ingress of moisture and other dam count. When performing either test, age under normal transport conditions. corrections must be made for any vari (7) When a jacket is so closed as to be ation of the ambient temperature from gas-tight, a device must be provided to the assumed ambient temperature ref prevent any dangerous pressure from erence value of 30°C (86 °F). developing in the insulation space. (13) The jacket of a vacuum-insulated (8) Materials which may react with double-wall tank must have either oxygen or oxygen enriched an external design pressure not less than atmospheres in a dangerous manner 100 kPa (1 bar) gauge pressure cal may not be used in portable tanks in culated in accordance with Section tended for the transport of refrigerated VIII of the ASME Code or a calculated liquefied gases having a boiling point critical collapsing pressure of not below minus 182 °C at atmospheric less than 200 kPa (2 bar) gauge pressure. pressure in locations with the thermal In ternal and external reinforcements insulation where there is a risk of con may be included in calculating tact with oxygen or the with oxygen en ability of the jacket riched fluid. to resist the exter nal pressure. (9) Insulating materials must not de teriorate to an extent that the effec NOTE TO PARAGRAPH (b): For the deter tiveness of the insulation system, as mination of the actual holding time, as indi determined in accordance with para cated by paragraphs (b)(1O), (11), (12), and graph (b)(ll) of this section, (13), before each journey, refer to §178.338— would be 9(b). reduced in service. (10) A reference holding time must be (c) Design criteria. For shells with determined for each refrigerated lique vacuum insulation, the test pressure fied gas intended for transport in a must not be less than 1.3 times the sum portable tank. The reference holding of the MAWP and 100 kPa (I bar). In no time must be determined by testing in case may the test pressure be less than accordance with the requirements of 300 kPa (3 bar) gauge pressure. § 178.338—9, considering the following (d) Service equipment. (1) Each filling factors; and discharge opening in portable (i) The effectiveness of the insulation tanks used for the transport of flam system, determined in accordance with mable refrigerated liquefied gases must paragraph (b)(ll) of this section; be fitted with at least three mutually (ii) The lowest set pressure of the independent shut-off devices in series: pressure limiting device; the first being a stop-valve situated as (iii) The initial filling conditions; close as reasonably practicable to the (iv) An assumed ambient tempera jacket, the second being a stop-valve ture of 30 °C (86 °F); and the third being a blank flange or (v) The physical properties of the in equivalent device. The shut-off device dividual refrigerated liquefied gas in closest to the jacket must be a self- tended to be transported. closing device, which is capable of 937 § 178.277 49 CFR Ch. I (10—1—10 Edition) being closed from an accessible posi (2) Except for portable tanks used for tion on the portable tank that is re oxygen, portable tanks for non-flam mote from the valve within 30 seconds mable refrigerated liquefied gases (ex of actuation. This device must actuate cept oxygen) and hydrogen may in ad at a temperature of not more than 121 dition have frangible discs in parallel °C (250 °F). with the reclosing devices as specified (2) Each filling and discharge opening in paragraphs (e)(4)(ii) and (e)(4)(iii) of in portable tanks used for the trans this section. port of non-flammable refrigerated liq (3) Pressure relief devices must be de uefied gases must be fitted with at signed to prevent the entry of foreign least two mutually independent shut matter, the leakage of gas and the de off devices in series: the first being a velopment of any dangerous excess stop-valve situated as close as reason pressure. ably practicable to the jacket and the (4) Capacity and setting of pressure re blank flange or equivalent second a de lief devices. (i) In the case of the loss of vice. vacuum in a vacuum-insulated tank or (3) For sections of piping which can of loss of 20% of the insulation of a be closed at both ends and where liquid portable tank insulated with solid ma product can be• trapped, a method of terials, the combined capacity of all automatic pressure relief must be pro pressure relief devices installed must vided to prevent excess pressure build up within the piping. be sufficient so that the pressure (in cluding accumulation) inside the shell (4) Each filling and discharge opening on a portable tank must be clearly does not exceed 120% of the MAWP. marked to indicate its function. (ii) For non-flammable refrigerated (5) When pressure-building units are liquefied gases (except oxygen) and hy used, the liquid and vapor connections drogen, this capacity may be achieved to that unit must be provided with a by the use of frangible discs in parallel valve as close to the jacket as reason with the required safety-relief devices. ably practicable to prevent the loss of Frangible discs must rupture at nomi contents in case of damage to the pres nal pressure equal to the test pressure sure-building unit. A check valve may of the shell. be used for this purpose if it is located (iii) Under the circumstances de on the vapor side of the pressure build scribed in paragraphs (e) (4) (i) and up coil. (e) (4) (ii) of this section, together with (6) The materials of construction of complete fire engulfment, the com valves and accessories must have satis bined capacity of all pressure relief de factory properties at the lowest oper vices installed must be sufficient to ating temperature of the portable limit the pressure in the shell to the tank. test pressure. (7) Vacuum insulated portable tanks (iv) The required capacity of the re are not required to have an inspection lief devices must be calculated in ac opening. cordance with CGA Pamphlet S-l.2 (e) Pressure relief devices. (1) Every (IBR, see §171.7 of this subchapter). shell must be provided with not less than two independent reclosing pres [66 FR 33450, June 21, 2001, as amended at 68 FR 75748, 75752. Dec. 31, 20031 sure relief devices. The pressure relief devices must open automatically at a pressure not less than the MAWP and Subpart I [Reserved] be fully open at a pressure equal to 110% of the MAWP. These devices Subpart J—Specifications for Con must, after discharge, close at a pres tainers for Motor Vehicle sure not lower than 10% below the pres Transportation sure at which discharge starts and must remain closed at all lower pres sures. The pressure relief devices must SOURCE: 29 FR 18975, Dec. 29, 1964, unless be of the type that will resist dynamic otherwise noted. Redesignated at 32 FR 5606, forces including surge. Apr. 5. 1967. 938 Pipeline and Hazardous Materials Safety Admin., DOT § 178.318—2

§ 178.318 Specification MC 201; con cussion caps may be carried, provided tainer for detonators and percus that such space may be closed with a sion caps. screw cap, and further provided that each or any § 178.318—1 Scope. such space is entirely sepa rate from any space provided for any (a) This specification pertains to a detonator. Each cellular space into container to be used for the transpor which a detonator is to be inserted and tation of detonators and percussion carried shall be capable of being cov caps in connection with transpor the ered by a rotary cover so arranged as tation of liquid nitroglycerin, desen to expose not more than one cell at any sitized liquid nitroglycerin or time, and capable of rotation to such a diethylene glycol dinitrate, where any place that all cells will be covered or all of such types of caps may be used at the same time, for the detonation of liquid nitroglyc at which place means shall be provided erin, desentitized liquid nitroglycerin to lock the cover in place. Means or diethylene glycol dinitrate in blast shall be provided to lock place ing operations. This specification is in the cover for the cells provided not intended to take the place of any for the carrying of detonators. The re shipping or packing requirements of quirement that not more than one cell this Department where the caps in be exposed at one time need not apply question are themselves articles of in the case of detonators, although commerce. spaces for such caps and detonators (b) [Reserved] shall be separate. Sufficient annular space shall be provided inside the cover [29 FR 29, 1964. 18975, Dec. Redesignated at 32 for such detonators FR 5606, Apr. 5, 1967, and amended by Amdt. that, when the 178—60, 44 FR 70733, Dec. 10, 19791 cover is closed, there will be sufficient space to accommodate the wires cus §178.318-2 Container. tomarily attached to such caps. If the (a) Every container for detonators material is of such a nature as to re and percussion caps coming within the quire treatment to prevent the absorp scope of this specification shall be con tion of moisture, such treatment shall structed entirely of hard rubber, be applied as shall be necessary in phenoiresinous or other resinous mate order to provide against the penetra rial, or other nonmetallic, nonsparking tion of water by permeation. A suitable material, except that metal parts may carrying handle shall be provided, ex be used in such locations as not in any cept for which handle no part of the event to come in contact with any of container may project beyond the exte the caps. Space shall be provided so rior of the body. that each detonator of whatever nature (b) Exhibited in plates I and II are may be inserted in an individual cell in line drawings of a container for deto the body of the container, into which nators and percussion caps, illustrative each such cap shall snugly fit. There of the requirements set forth in shall be provided no more than twenty §178.318—2(a). These plates shall not be (20) such cellular spaces. Space may be construed as a part of this specifica provided into which a plurality of per- tion.

939 § 178.318—3 49 CFR Ch. 1(10—1—10 Edition)

BLASTING CAP CONTAINER PLATE

pocket required PLAN Handle removed

PLATE II

[29 FR 18975, Dec. 29, 1964. Redesignated at 32 FR 5606, Apr. 5, 1967, and amended by Amdt. 178—60, 44 FR 70733, Dec. 10, 1979]

§ 178.318—3 Marking. tention or containment function and provides no structural support the Each container must be marked as to cargo tank. prescribed in §178.2(b). Baffle means a non-liquid-tight trans [Amdt. 178—40, 41 FR 38181, Sept. 9, 1976, as verse partition device that deflects, amended at 66 FR 45185, Aug. 28, 2001] checks or regulates fluid motion in a tank. § 178.320 General requirements appli Bulkhead means a liquid-tight trans cable to all DOT specification cargo verse closure at the ends of tank motor vehicles. or between cargo tanks. (a) Definitions. For the purpose of this Cargo tank means a bulk packaging subchapter: that: Appurtenance means any attachment (1) Is a tank intended primarily for to a cargo tank that has no lading re the carriage of liquids, gases, solids, or 940 Pipeline and Hazardous Materials Safety Admin., DOT § 178.320 semi-solids and includes appur variations in piping that do not affect tenances, reinforcements, fittings, and the lading retention capability of the closures (for tank, see §l78.337—l, cargo tank; 178.338—1, or 178.345—1, as applicable); (4) Of the same materials of construc (2) Is permanently attached to or tion; forms a part of a motor vehicle, or is (5) To the same cross-sectional di not permanently attached to a motor mensions; vehicle but that, by reason of its size, (6) To a length varying by no more construction, or attachment to a than 5 percent; motor vehicle, is loaded unloaded or (7) With the volume varying by no without being removed from the motor more than 5 percent (due to a change in vehicle; and length only); and (3) Is not fabricated under a speci (8) For the purposes of 178.338 fication for cylinders, intermediate § only, with the same insulation system. bulk containers, multi-unit tank car External tanks, portable tanks, or tank cars. self-closing stop valve means a self-closing stop valve designed Cargo tank motor vehicle means a so that the self-stored motor vehicle with one or more cargo energy source is located outside the cargo tank tanks permanently attached to or and the welded flange. forming an integral part of the motor vehicle. Extreme dynamic loading means the maximum Cargo tank wall means those parts of loading a cargo tank motor the cargo tank that make up the pri vehicle may experience during its ex mary lading retention structure, in pected life, excluding accident loadings cluding shell, bulkheads, and fittings resulting from an accident, such as and, when closed, yield the minimum overturn or collision. volume of the cargo tank assembly. Flange means the structural ring for Charging line means a hose, tube, guiding or attachment of a pipe or fit pipe, or a similar device used to pres ting with another flange (companion surize a tank with material other than flange), pipe, fitting or other attach the lading. ment. Companion flange means one of two Inspection pressure means the pres mating flanges where the flange faces sure used to determine leak tightness are in contact or separated only by a of the cargo tank when testing with thin leak-sealing gasket and are se pneumatic pressure. cured to one another by bolts or Internal self-closing stop valve means a clamps. self-closing stop valve designed so that Connecting structure means the struc the self-stored energy source is located ture joining two cargo tanks. inside the cargo tank or cargo tank Constructed and certified in accordance sump, or within the welded flange, and with the ASME Code means a cargo the valve seat is located within the tank is constructed and stamped in ac cargo tank or within one inch of the cordance with Section VIII of the external face of the welded flange or ASME Code (IBR, see §171.7 of this sub sump of the cargo tank. chapter), and is inspected and certified Lading means the hazardous material by an Authorized Inspector. contained in a cargo tank. Constructed in accordance with the Loading/unloading connection means ASME Code means a cargo tank is con the fitting in the loading/unloading structed in accordance with Section line farthest from the loading/unload VIII of the ASME Code with authorized ing outlet to which the loading/unload exceptions (see § 178.346 through ing hose, pipe, or device is attached. 178.348) and is inspected and certified Loading/unloading outlet means a by a Registered Inspector. cargo tank outlet used for normal load Design type means one or more cargo ing/unloading operations. tanks that are made— Loading/unloading stop valve means (1) To the same specification; the stop valve farthest from the cargo (2) By the same manufacturer: tank loading/unloading outlet to which (3) To the same engineering drawings the loading/unloading connection is at and calculations, except for minor tached.

941 § 178.320 49 CFR Ch. I (10—1—10 Edition) Manufacturer means any person en fabricated to more than one cargo tank gaged in the manufacture of a DOT specification. specification cargo tank, cargo tank Normal operating loading means the motor vehicle, or cargo tank equip loading a cargo tank motor vehicle ment that forms part of the cargo tank may be expected to experience rou wall. This term includes attaching a tinely in operation. cargo tank to a motor vehicle or to a Nozzle means a subassembly con motor vehicle suspension component sisting of a pipe or tubular section with that involves welding on the cargo or without a welded or forged flange on tank wall. A manufacturer must reg one end. ister with the Department in accord Outlet means any opening in the shell ance with subpart F of part 107 in sub or head of a cargo tank, (including the part A of this chapter. means for attaching a closure), except Maximum allowable working pressure that the following are not outlets: a or MAWP means the maximum pres threaded opening securely closed dur sure allowed at the top of the tank in ing transportation with a threaded its normal operating position. The plug or a threaded cap, a flanged open MAWP must be calculated as pre ing securely closed during transpor scribed in Section VIII of the ASME tation with a bolted or welded blank Code. In use, the MAWP must be great flange, a manhole, a gauging device, a er than or equal to the maximum lad thermometer well, or a pressure relief ing pressure conditions prescribed in device. § 173.33 of this subchapter for each ma Outlet stop valve means the stop valve terial transported. at a cargo tank loading or unloading Maximum lading pressure. See outlet. § 173.33(c). Pipe coupling means a fitting with in Minimum thickness means the min ternal threads on both ends. imum required shell and head (and baf Rear bumper means the structure de fle and bulkhead when used as tank re signed to prevent a vehicle or object inforcement) thickness needed to meet from under-riding the rear of another the specification. The minimum thick motor vehicle. See §393.86 of this title. ness is the greatest of the following val Rear-end tank protection device means ues: (1)(i) For MC 330, MC 331, and MC the structure designed to protect a 338 cargo tanks, the specified minimum cargo tank and any lading retention thickness found the applicable speci piping or devices in case of a rear end fication(s); or collision. (ii) For DOT 406, DOT 407 and DOT Self-closing stop valve means a stop 412 cargo tanks, the specified minimum valve held in the closed position by thickness found in Tables I and II of means of self-stored energy, that opens the applicable specification(s); or only by application of an external force (iii) For MC 300, MC 301, MC 302, MC and that closes when the external force 303, MC 304, MC 305, MC 306, MC 307, MC is removed. 310, MC 311, and MC 312 cargo tanks, Shell means the circumferential por the in-service minimum thickness pre tion of a cargo tank defined by the scribed in Tables I and II of basic design radius or radii excluding § l80.407(i)(5) of this subchapter, for the the bulkheads. minimum thickness specified by Tables Stop valve means a valve that stops I and II of the applicable specifica the flow of lading. tion(s); or Sump means a protrusion from the (2) The thickness necessary to meet bottom of a cargo tank shell designed with the structural integrity and acci to facilitate complete loading and un dent damage requirements of the appli loading of lading. cable specification(s); or Tank means a container, consisting (3) The thickness as computed per of a shell and heads, that forms a pres the ASME Code requirements (if appli sure tight vessel having openings de cable). signed to accept pressure tight fittings Multi-specification cargo tank motor ve or closures, but excludes any appur hicle means a cargo tank motor vehicle tenances, reinforcements, fittings, or equipped with two or more cargo tanks closures. 942 Pipeline and Hazardous Materials Safety Admin., DOT § 178.337—1

Test pressure means the pressure to compliance with certain paragraphs of which a tank is subjected to determine the ASME Code, compliance with those structural integrity. paragraphs is not prohibited. Toughness of material means the capa [Amdt. 178—89, 55 FR bility of a material to absorb energy 37055, Sept. 7, 1990, as amended by Amdt. 178-98, 58 FR 33306, June represented by the area under a stress 16, 1993; Amdt. 178—118, 61 FR 51339, Oct. 1, strain curve (indicating the energy ab 1996; 68 FR 19277, Apr. 18, 2003; 68 FR 52370, sorbed per unit volume of the material) Sept. 3, 2003; 68 FR 75752, Dec. 31, 20031 up to the point of rupture. Vacuum cargo tank means a cargo § 178.337 Specification MC 331; cargo tank that is loaded by reducing the tank motor vehicle primarily for pressure in the cargo tank to below at transportation of compressed gases mospheric pressure. as defined in subpart G of part 173 of this subchapter. Variable specification cargo tank means a cargo tank that is constructed § 178.337—1 General requirements. in accordance with one specification, (a) ASME Code construction. Tanks but that may be altered to meet an must be— other specification by changing relief (I) Seamless or welded construction, device, closures, lading discharge de or a combination of vices, and other both; lading retention de (2) Designed, vices. constructed, certified, and stamped in accordance with Sec Void means the space between tank tion VIII of the ASME Code (IBR, see heads or bulkheads and a connecting 171.7 this structure. § of subchapter); (3) Made of steel or aluminum; how Welded flange means a flange at ever, if aluminum is used, the cargo tached to the tank by a weld joining tank must be insulated and the haz the tank shell to the cylindrical outer ardous material to be transported must surface of the flange, or by a fillet weld be compatible with the aluminum (see joining the tank shell to a flange §l78.337—l(e)(2), 173.315(a) table, shaped to fit the shell contour. and 178.337—2(a) (1) of this subchapter); and (b) Design certification. (1) Each cargo (4) Covered with a steel jacket if the tank or cargo tank motor vehicle de cargo tank is insulated and used to sign type, including its required acci transport a flammable gas (see dent damage protection device, must §173.315(a) table Note 11 of this sub be certified to conform to the specifica chapter). tion requirements by a Design Certi (b) Design pressure. The design pres fying Engineer who is registered in ac sure of a cargo tank authorized under cordance with subpart F of part 107 of this specification shall be not less than this title. An accident damage protec the vapor pressure of the commodity tion device is a rear-end protection, contained therein at 115 CF. or as pre overturn protection, or piping protec scribed for a particular commodity in tion device. § 173.315(a) of this subchapter, except (2) The Design Certifying Engineer that in no case shall the design pres shall furnish to the manufacturer a sure of any cargo tank be less than 100 certificate to indicate compliance with p.5.1g. nor more than 500 p.s.i.g. the specification requirements. The certificate must include the sketches, NOTE 1: The term design pressure as used in drawings, and calculations used for cer this specification, is identical to the term tification. Each certificate, including MA WP as used in the ASME Code. sketches, drawings, and calculations, (c) Openings. (1) Excess pressure relief shall be signed by the Design Certi valves shall be located in the top of the fying Engineer. cargo tank or heads. (3) The manufacturer shall retain the (2) A chlorine cargo tank shall have design certificate at his principal place only one opening. That opening shall of business for as long as he manufac be in the top of the cargo tank and tures DOT specification cargo tanks. shall be fitted with a nozzle that meets (c) Exceptions to the ASME Code. Un the following requirements: less otherwise specified, when excep (i) On a cargo tank manufactured on tions are provided in this subpart from or before December 31, 1974, the nozzle 943 § 178.337—1 49 CFR Ch. 1(10—1—10 Edition)

shall be protected by a dome cover as a unit after completion of all the plate which conforms to either the welds in and/or to the shells and heads. standard of The Chlorine Institute, The method must be as prescribed in Inc., Dwg. 103-3, dated January 23, 1958, Section VIII of the ASME Code. Welded or to the standard specified in 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. 103—4, 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 § 178.337—1 through attached to a cargo tank motor vehicle 178.337—18: shall, unless covered with a jacket Emergency discharge control means the made of aluminum, stainless steel, or ability to stop a cargo tank unloading other bright nontarnishing metal, be operation in the event of an 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. (I) 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 §l73.315(a) table the need for human intervention with and 178.337—1 (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 tank’s 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 ASME Code must be postweld heat self-stored energy. treated. Each chlorine cargo tank must Primary discharge control system be fully radiographed and postweld means a primary shut-off installed at a heat treated in accordance with the product discharge outlet of a cargo provisions in Section VIII of the ASME tank consisting of an internal self-clos Code under which it is constructed. ing stop valve that may include an in Where postweld heat treatment is re tegral excess flow valve or an excess quired, the cargo tank must be treated flow feature, together with linkages 944 Pipeline and Hazardous Materials Safety Admin., DOT § 178.337—3

that must be installed between the ferential orientation of the cargo tank valve and remote actuator to provide shell. manual and thermal on-truck remote (b) For a chlorine cargo tank. Plates, means of closure. the manway nozzle, and anchorage [Order 59—B. 30 FR 579, Jan. 16, 1965. Redesig shall be made of carbon steel which nated at 32 FR 5606, Apr. 5, 19671 meets the following requirements: (1) For a cargo tank manufactured on EDITORIAL NOTE: For FEDERAL REGISTER ci or before December 31, 1974— tations affecting § 178.337—1, see the List of CFR Sections Affected which appears in the (i) Material shall conform to ASTM A Finding Aids section of the printed volume 300, “Steel Plates for Pressure Vessels and on GPO Access. for Service at Low Temperatures” (IBR, see §171.7 of this subchapter); § 178.337—2 Material. (ii) Material shall be Class I, Grade (a) General. (1) All material used for A, flange or firebox quality; construction of the cargo tank and ap (iii) Plate impact test specimens, as purtenances must be suitable for use required under paragraph (a) of this with the commodities to be trans section, shall be of the Charpy keyhole ported therein and must conform to notch type; and the requirements in Section II of the (iv) Plate impact test specimens ASME Code (IBR, see §171.7 of this sub shall meet the impact test require chapter) and/or requirements of the ments in paragraph (a) of this section American Society for Testing and Ma in both the longitudinal and transverse terials in all respects. directions of rolling at a temperature (2) Impact tests are required on steel of minus 45.5 C. (—50 °F.). used in the fabrication of each cargo (2) For a cargo tank manufactured on tank constructed in accordance with or after January 1, 1975— part UHT in Section VIII of the ASME (i) Material shall conform to ASTM A Code. The tests must be made on a lot 612 (IBR, see §171.7 of this subchapter), basis. A lot is defined as 100 tons or less Grade B or A 516/A 5l6M (IBR, see § 171.7 of the same heat treatment processing of this subchapter), Grade 65 or 70; lot having a thickness variation no (ii) Material shall meet the Charpy greater than plus or minus 25 percent. V-notch test requirements of ASTM A The minimum impact required for full 20/A 20M (IBR, see § 171.7 of this sub size specimens must be 20 foot-pounds chapter); and in the longitudinal direction at —30 (iii) Plate impact test specimens °F., Charpy V-Notch and 15 foot-pounds shall meet the impact test require in the transverse direction at —30 °F., ments in paragraph (a) of this section Charpy V-Notch. The required values in both the longitudinal and transverse for subsize specimens must be reduced directions of rolling at a temperature in direct proportion to the cross-sec of minus 40°C. (—40 °F.). tional area of the specimen beneath the (c) A cargo tank in anhydrous ammo notch. If a lot does not meet this re nia service must be constructed of quirement, individual plates may be steel. The use of copper, silver, zinc or accepted if they individually meet this their alloys is prohibited. Baffles made requirement. from aluminum may be used only if (3) The fabricator shall record the joined to the cargo tank by a process heat, and slab numbers, and the cer not requiring postweld heat treatment tified Charpy impact values, where re of the cargo tank. quired, of each plate used in each cargo [Order 59—B, 30 FR 579, Jan. 16, 1965. Redesig tank on a sketch showing the location nated at 32 FR 5606. Apr. 5, 1967] of each plate in the shell and heads of EDITORIAL NOTE: For FEDERAL REGISTER the cargo tank. Copies of each sketch ci tations affecting § 178.337—2, see the List of shall be provided to the owner and re CFR Sections Affected which appears in the tained for at least five years by the Finding Aids section of the printed volume fabricator and made available to duly and on GPO Access. identified representatives of the De partment of Transportation. i 178.337—3 Structural integrity. (4) The direction of final rolling of (a) General requirements and accept the shell material shall be the circum ance criteria. (1) Except as provided in 945 § 1 7&337—3 49 CFR Ch. I (10—1—10 Edition)

paragraph (d) of this section, the max throughout the cargo tank motor vehi imum calculated design stress at any cle. The vertical, longitudinal, and lat point in the cargo tank may not exceed eral normal operating loadings can the maximum allowable stress value occur simultaneously and must be prescribed in Section VIII of the ASME combined. The vertical, longitudinal Code (IBR, see §171.7 of this sub and lateral extreme dynamic loadings chapter), or 25 percent of the tensile occur separately and need not be com strength of the material used. bined. (2) The relevant physical properties (1) Normal operating loadings. The fol of the materials used in each cargo lowing procedure addresses stress in tank may be established either by a the tank shell resulting from normal certified test report from the material operating loadings. The effective stress manufacturer or by testing in conform (the maximum principal stress at any ance with a recognized national stand point) must be determined by the fol ard. In either case, the ultimate tensile lowing formula:

strength of the material used in the de —. S)2 ± S = O.5(S, ± S) ±[O.25(S S2]O.5 sign may not exceed 120 percent of the ultimate tensile strength specified in Where: either the ASME Code or the ASTM (i) S = effective stress at any given standard to which the material is man point under the combination of static ufactured. and normal operating loadings that can (3) The maximum design stress at occur at the same time, in psi. any point in the cargo tank must be (ii) S = circumferential stress gen calculated separately for the loading erated by the MAWP and external pres conditions described in paragraphs (b), sure, when applicable, plus static head, (c), and (d) of this section. Alternate in psi. test or analytical methods, or a com (iii) S, = The following net longitu bination thereof, may be used in place dinal stress generated by the following of the procedures described in para static and normal operating loading graphs (b), (c), and (d) of this section, if conditions, in psi: the methods are accurate and (A) The longitudinal stresses result verifiable. ing from the MAWP and external pres (4) Corrosion allowance material may sure, when applicable, plus static head, not be included to satisfy any of the in combination with the bending stress design calculation requirements of this generated by the static weight of the section. fully loaded cargo tank motor vehicle, (b) Static design and construction. (1) all structural elements, equipment and The static design and construction of appurtenances supported by the cargo each cargo tank must be in accordance tank wall; with Section VIII of the ASME Code. (B) The tensile or compressive stress The cargo tank design must include resulting from normal operating longi calculation of stresses generated by de tudinal acceleration or deceleration. In sign pressure, the weight of lading, the each case, the forces applied must be weight of structure supported by the 0.35 times the vertical reaction at the cargo tank wall, and the effect of tem suspension assembly, applied at the perature gradients resulting from lad road surface, and as transmitted to the ing and ambient temperature extremes. cargo tank wall through the suspension When dissimilar materials are used, assembly of a trailer during decelera their thermal coefficients must be used tion; or the horizontal pivot of the in calculation of thermal stresses. truck tractor or converter dolly fifth (2) Stress concentrations in tension, wheel, or the drawbar hinge on the bending and torsion which occur at fixed dolly during acceleration; or an pads, cradles, or other supports must choring and support members of a be considered in accordance with ap truck during acceleration and decelera pendix G in Section VIII of the ASME tion, as applicable. The vertical reac Code. tion must be calculated based on the (c) Shell design. Shell stresses 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 946 Pipeline and Hazardous Materials Safety Admin., DOT § 178.337—3

supported by the cargo tank wall. The sembly of a trailer, applied at the road following loadings must be included: surface, and as transmitted to the (1) The axial load generated by a cargo tank wall through the suspension decelerative force; assembly of a trailer, and the hori ( The bending moment generated by zontal pivot of the upper coupler (fifth a decelerative force; wheel) or turntable; or anchoring and (3) The axial load generated by an ac 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(S ± S) ±L0.25(S — S)2 ± S21° (iv) S = The following shear stresses generated by the following static and Where: normal operating loading conditions, (i) S = effective stress at any given in psi: point under a combination of static (A) The static shear stress resulting and extreme dynamic loadings that can from the vertical reaction at the sus occur at the same time, in psi. pension assembly of a trailer, and the (ii) S = 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) S = 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 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 (C) The lateral shear stress generated cargo tank wall through the suspension by a normal operating lateral accelera assembly of a trailer during decelera tive force equal to 0.2 times the tion; or the horizontal pivot of the vertical reaction at each suspension as- truck tractor or converter dolly fifth 947 § 178.337—3 49 CFR Cli. I (10—1—10 Edition)

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 ( 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 ( 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) (d) In order to account for stresses or turntable; or the anchoring and sup due to impact in an accident, the de port members of a truck, as applicable. sign calculations for the cargo tank The vertical reaction must be cal shell and heads must include the load culated based on the static weight of resulting from the design pressure in the fully loaded cargo tank motor vehi combination with the dynamic pres cle, all structural elements, equipment sure resulting from a longitudinal de and appurtenances supported by the celeration of “2g. For this loading cargo tank wall. condition the stress value used may (iv) S = The following shear stresses not exceed the lesser of the yield generated by static and extreme dy strength or 75 percent of the ultimate namic loading conditions, in psi: tensile strength of the material of con (A) The static shear stress resulting struction. For cargo tanks constructed from the vertical reaction at the sus of stainless steel the maximum design pension assembly of a trailer, and the stress may not exceed 75 percent of the horizontal pivot of the upper coupler ultimate tensile strength of the type (fifth wheel) or turntable; or anchoring steel used. and support members of a truck, as ap (e) The minimum metal thickness for plicable. The vertical reaction must be the shell and heads on tanks with a de calculated based on the static weight sign pressure of 100 psig or more must of the fully loaded cargo tank motor be 4.75 mm (0.187 inch) for steel and 6.86 vehicle, all structural elements, equip mm (0.270 inch) for aluminum, except ment and appurtenances supported by for chlorine and sulfur dioxide tanks. the cargo tank wall; In all cases, the minimum thickness of (B) The vertical shear stress gen the tank shell and head shall be deter erated by an extreme vertical accelera mined using structural design require tive force equal to 0.7 times the ments in Section VIII of the ASME vertical reaction at the suspension as Code or 25% of the tensile strength of sembly of a trailer, and the horizontal the material used. For a cargo tank pivot of the upper coupler (fifth wheel) used in chlorine or sulfur dioxide serv or turntable; or anchoring and support ice, the cargo tank must be made of members of a truck, as applicable. The steel. A corrosion allowance of 20 per vertical reaction must be calculated cent or 2.54 mm (0.10 inch), whichever based on the static weight of the fully is less, must be added to the thickness 948 Pipeline and Hazardous Materials Safety Admin., DOT § 178.337—4

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 tale holes are used, the pad must be in paragraph (a) of this section. drilled or punched at the lowest point (g) The design, construction, and in before it is welded to the tank. Each stallation of an attachment, appur pad must— tenance to the cargo tank, structural (i) Be fabricated from material deter support member between the cargo mined to be suitable for welding to tank and the vehicle or suspension both the cargo tank material and the component, or accident protection de material of the appurtenance or struc vice must conform to the following re tural support member; a Design Certi quirements: fying Engineer must make this deter (1) Structural members, the suspen mination considering chemical and sion sub-frame, accident protection physical properties of the materials structures, and external circumferen and must specify filler material con tial reinforcement devices must be forming to the requirements in Section used as sites for attachment of appur VIII of the ASME Code (IBR, tenances and see §171.7 other accessories to the of this subchapter). cargo tank, when practicable. (ii) Be preformed to an inside (2) A lightweight attachment to the radius no greater than the outside radius cargo tank wall such as a conduit clip, of the cargo tank at brake line clip, skirting structure, the attachment loca tion. lamp mounting bracket, or placard holder must be of a construction hav (iii) Extend at least 2 inches in each ing lesser strength than the cargo tank direction from any point of attachment wall materials and may not be more of an appurtenance or structural sup than 72 percent of the thickness of the port member. This dimension may be material to which it is attached. The measured from the center of the at lightweight attachment may be se tached structural member. cured directly to the cargo tank wall if (iv) Have rounded corners, or other the device is designed and installed in wise be shaped in a manner to mini such a manner that, if damaged, it will mize stress concentrations on the shell not affect the lading retention integ or head. rity of the tank. A lightweight attach (v) Be attached by continuous fillet ment must be secured to the cargo welding. Any fillet weld discontinuity tank shell or head by a continuous may only be for the purpose of pre weld or in such a manner as to preclude venting an intersection between the fil formation of pockets which may be let weld and a tank or jacket seam come sites for corrosion. Attachments weld. meeting the requirements of this para lAmdt. 178—89, 55 FR 37056, Sept. 1990, graph are not authorized for 7, as cargo amended by Amdt. 178—104, 59 FR 49135, Sept. tanks constructed under part UHT in 26, 1994; Amdt. 178—105, 60 FR 17401, Apr. 5, Section VIII of the ASME Code. 1995; Amdt. 178—118, 61 FR 51340, Oct. 1, 1996; (3) Except as prescribed in para 65 FR 58631, Sept. 29, 2000; 68 FR 19279, Apr. graphs (g)(l) and (g)(2) of this section, 18, 2003; 68 FR 52370, Sept. 3, 2003; 68 FR 75753, the welding of any appurtenance to the Dec. 31, 20031 cargo tank wall must be made by at tachment of a mounting pad so that § 178.337—4 Joints. there will be no adverse effect upon the.. (a) Joints shall be as required in Sec lading retention integrity of the cargo tion VIII of the ASME Code (IBR, see tank if any force less than that pre § 171.7 of this subchapter), with all un scribed in paragraph (b) (1) of this sec dercutting in shell and head material tion is applied from any direction. The repaired as specified therein. 949 § 1 7&337—5 49 CFR Ch. I (10—1—10 Edition)

(b) Welding procedure and welder per § 178.337—6 Closure for manhole. formance must be in accordance with (a) Each cargo tank marked or cer Section IX of the ASME Code. In addi tified after April 21, 1994, must be pro tion to the essential variables named vided with a manhole conforming to therein, the following must be consid paragraph UG-46(g)(l) and other appli ered as essential variables: Number of cable requirements in Section VIII of passes; thickness of plate; heat input the ASME Code (IBR, see 171.7 of this per pass; and manufacturer’s identi § subchapter), except that a cargo tank fication of rod and flux. When fabrica constructed of NQT steel having a ca tion is done in accordance with part pacity of 3,500 water gallons or less UHT in Section VIII of the ASME Code, may be provided with an inspection filler material containing more than opening conforming to paragraph UG 0.08 percent vanadium must not be 46 and other applicable requirements of used. The number of passes, thickness the ASME Code instead of a manhole. of plate, and heat input per pass may The manhole assembly not vary more than 25 percent from the (b) of cargo tanks constructed after June procedure or welder qualifications. 30, 1979, may not be located on the front head of Records of the qualifications must be the cargo tank. retained for at least 5 years by the cargo tank manufacturer and must be [Amdt. 178—7, 34 FR 18250, Nov. 14, 1969, as made available to duly identified rep amended by Amdt. 178—52, 43 FR 58820, Dec. resentatives of the Department and the 18, 1978; Amdt. 178—89, 54 FR 25017, June 12, owner of the cargo tank. 1989; 55 FR 21038, May 22, 1990: 56 FR 27876, June 17, 58 FR 12905, March longitudinal shell welds shall 1991: 8, 1993: (c) All Amdt. 178—118, 61 FR 51340, Oct. 1, 1996: 68 FR be located in the upper half of the 75753, Dec. 31, 20031 cargo tank. (d) Edge preparation of shell and § 178.337—7 Overturn protection. head components may be by machine (a) See § 178.337—10. provided such surfaces heat processes, (b) [Reserved] are remelted in the subsequent welding process. Where there will be no subse [Order 59—B, 30 FR 580, Jan. 16, 1965. Redesig quent remelting of the prepared surface nated at 32 FR 5606, Apr. 5, 19671 as in a tapered section, the final 0.050 shall be removed by § 178.337—8 Openings, inlets, and out inch of material lets. mechanical means. (e) The maximum tolerance for mis (a) General. The requirements in this alignment and butting up shall be in paragraph (a) apply to MC 331 cargo accordance with the requirement in tanks except for those used to trans Section VIII of the ASME Code. port chlorine. The requirements for in (f) Substructures shall be properly lets and outlets on chlorine cargo fitted before attachment, and the weld tanks are in paragraph (b) of this sec ing sequence shall be such as to mini tion. mize stresses due to shrinkage of (1) An opening must be provided on welds. each cargo tank used for the transpor tation of liquefied materials to permit [Order 59-B, 30 FR 580, Jan. 16, 1965. Redesig complete drainage. nated at 32 FR 5606, Apr. 5, 19671 (2) Except for gauging devices, ther EDITORIAL NOTE: For FEDERAL REGISTER ci mometer wells, pressure relief valves, tations affecting § 178.337—4, see the List of manhole openings, product inlet open CFR Sections Affected which appears in the ings, and product discharge openings, Finding Aids section of the printed volume each opening in a cargo tank must be and on GPO Access. closed with a plug, cap, or bolted flange. § 178.337-5 Bulkheads, baffles and ring stiffeners. (3) Except as provided in paragraph (b) of this section, each product inlet (a) Not a specification requirement. opening, including vapor return lines, (b) [Reserved] must be fitted with a back flow check [Order 59—B, 30 FR 580, Jan. 16, 1965. Redesig valve or an internal self-closing stop nated at 32 FR 5606, Apr. 5, 1967] valve located inside the cargo tank or 950 Pipeline and Hazardous Materials Safety Admin., DOT § 178.337—8

inside a welded nozzle that is an inte ditions incident to discharge of prod gral part of the cargo tank. The valve uct. seat must be located inside the cargo (iii) All parts of a valve inside a tank or within 2.54 cm (one inch) of the cargo tank or within a welded flange external face of the welded flange. must be made of material that will not Damage to parts exterior to the cargo corrode or deteriorate in the presence tank or mating flange must not pre of the lading. 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 §178.337—1(g). valve, or excess flow feature. Thermal remote operators must acti (v) An integral excess flow valve or vate at a temperature of l2l.l1C (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) (1), ad tem is not required on the following: ditional means of thermal remote clo (1) A vapor or liquid discharge open sure must be installed so that heat ing of less than 1¼ NPT equipped with from a fire in the loading/unloading an excess flow valve together with a connection area or the discharge pump manually operated external stop valve will activate the primary discharge in place of an internal self-closing stop control system. The loading/unloading valve. connection area is where hoses or hose (ii) An engine fuel line on a truck- reels are connected to the permanent mounted cargo tank of not more than metal piping. ¾ NPT equipped with a valve having an (ii) On a cargo tank of 13,247.5 L (3,500 integral excess flow valve or excess gallons) water capacity or less, a ther flow feature. mal means of remote closure must be (iii) A cargo tank motor vehicle used installed at or near the internal self- to transport refrigerated liquids such closing stop valve. A mechanical as argon, carbon dioxide, helium, kryp means of remote closure must be in ton, neon, nitrogen, and xenon, or mix stalled on the end of the cargo tank tures thereof. furthest away from the loading/unload (6) In addition to the internal self- ing connection area. The loading/un closing stop valve, each filling and dis loading connection area is where hoses charge line must be fitted with a stop or hose reels are connected to the per valve located in the line between the manent metal piping. Linkages be internal self-closing stop valve and the tween closures and remote operators hose connection. A back flow check must be corrosion resistant and effec valve or excess flow valve may not be tive in all types of environmental con- used to satisfy this requirement. 951 § 178.337—9 49 CR? Ch. 1(10—1—10 Edition)

(7) An excess flow valve may be de service, see paragraph (b)(7) of this sec signed with a bypass, not to exceed a tion. 0.1016 centimeter (0.040 inch) diameter (2) Pipe joints must be threaded, opening, to allow equalization of pres welded, or flanged. If threaded pipe is sure. used, the pipe and fittings must be (b) Inlets and discharge outlets on chlo Schedule 80 weight or heavier, except rine tanks. The inlet and discharge out for sacrificial devices. Malleable metal, lets on a cargo tank used to transport stainless steel, or ductile iron must be chlorine must meet the requirements used in the construction of primary of § l78.337—1(c)(2) and must be fitted valve body parts and fittings used in with an internal excess flow valve. In liquid filling or vapor equalization. addition to the internal excess flow Stainless steel may be used for internal valve, the inlet and discharge outlets components such as shutoff discs and must be equipped with an external stop springs except where incompatible with valve (angle valve). Excess flow valves the lading to be transported. Where must conform to the standards of The copper tubing is permitted, joints must Chlorine Institute, Inc., as follows: be brazed or be of equally strong metal (1) A valve conforming to The Chlo union type. The melting point of the rine Institute, Inc., Dwg. 101—7 (IBR, brazing material may not be lower see §171.7 of this subchapter), must be than 538 °C (1,000 SF). 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. 106—6 (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 purpose. [64 FR 28049, May 24, 1999, as amended at 66 (5) [Reservedj FR 45387. Aug. 28, 2001; 68 FR 19279, Apr. 18, (6) Cargo tank manufacturers and 2003: 68 FR 75753, Dec. 31, 2003] fabricators must demonstrate that all piping, valves, and fittings on a cargo § 178.337—9 Pressure relief devices, piping, valves, hoses, and fittings. tank are free from leaks. To meet this requirement, the piping, valves, and (a) Pressure relief devices. (1) See fittings must be tested after installa § 173.315(i) of this subchapter. tion at not less than 80 percent of the (2) On cargo tanks for carbon dioxide design pressure marked on the cargo or nitrous oxide see §173.315 (i) (9) and tank. (10) of this subchapter. (7) A hose assembler must: (3) Each valve must be designed, con (i) Permanently mark each hose as structed, and marked for a rated pres sembly with a unique identification sure not less than the cargo tank de number. sign pressure at the temperature ex (ii) Demonstrate that each hose as pected to be encountered. sembly is free from leaks by per (b) Piping, valves, hose, and fittings. (1) forming the tests and inspections in The burst pressure of all piping, pipe § 180.416(f) of this subchapter. fittings, hose and other pressure parts, (iii) Mark each hose assembly with except for pump seals and pressure re the month and year of its original pres lief devices, must be at least 4 times sure test. the design pressure of the cargo tank. (8) Chlorine cargo tanks. Angle valves Additionally, the burst pressure may on cargo tanks intended for chlorine not be less than 4 times any higher service must conform to the standards pressure to which each pipe, pipe fit of the Chlorine Institute, Inc.. Dwg. ting, hose or other pressure part may 104—8 or “Section 3, Pamphlet 166, be subjected to in service. For chlorine Angle Valve Guidelines for Chlorine 952 Pipeline and Hazardous Materials Safety Admin., DOT § 178.337—10

Bulk Transportation.” (IBR, see §171.7 valves shall be so protected that in the of this subchapter). Before installation, event of overturn of the vehicle onto a each angle valve must be tested for hard surface, their opening will not be leakage at not less than 225 psig using prevented and their discharge will not dry air or inert gas. be restricted. (c) Marking inlets and outlets. Except (b) The protective devices or housing for gauging devices, thermometer must be designed to withstand static wells, and pressure relief valves, each loading in any direction equal to twice cargo tank inlet and outlet must be the weight of the tank and attach marked “liquid” or “vapor” to des ments when filled with the lading, ignate whether it communicates with using a safety factor of not less than liquid or vapor when the cargo tank is four, based on the ultimate strength of filled to the maximum permitted fill the material to be used, without dam ing density. A filling line that commu age to the fittings protected, nicates with vapor and must may be marked be made of “spray-fill” metal at least 3/is—inch instead of “vapor.” thick. (d) Refrigeration and heating coils. (1) (c) Rear-end protection. Refrigeration and heating coils must tank Rear-end tank be securely anchored with provisions 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 be mounted on the motor vehicle. the materials used, with such load (2) Where any liquid susceptible to being applied horizontally and parallel freezing, or the vapor of any such liq to the major axis of the cargo tank. uid, is used for heating or refrigera The rear bumper dimensions must also tion, the heating or refrigeration sys meet the requirements of § 393.86 of this tem shall be arranged to permit com title: or plete drainage. (2) Conform to the requirements of 178.345—8(d). [Order 59—B, 30 FR 580. Jan. 16, 1965. Redesig § nated at 32 FR 5606, Apr. 5, 19671 (d) Chlorine tanks. A chlorine tank must be equipped with a protective EDITORIAL NOTE: For FEDERAL REGISTER ci housing and a manway tations affecting 178.337—9, see cover to permit § the List of the use CFR Sections Affected which appears in the of standard emergency kits for Finding Aids section of the printed volume controlling leaks in fittings on the and on GPO Access. dome cover plate. For tanks manufac tured on or after October 1, 2009, the § 178.337—10 Accident damage protec housing and manway cover must con tion. form to the Chlorine Institute, Inc., (a) All valves, fittings, pressure relief Dwg. 137—5 (IBR, see §171.7 of this sub devices, and other accessories to the chapter). tank proper shall be protected in ac (e) Piping and fittings. Piping and fit cordance with paragraph (b) of this sec tings must be grouped in the smallest tion against such damage as could be practicable space and protected from caused by collision with other vehicles damage as required in this section. or objects, jack-knifing and over (f) Shear section. A shear section or turning. In addition, pressure relief sacrificial device is required for the 953 § 178.337—11 49 CFR Ch. 1(10—1—10 Edition) valves specified in the following loca cargo tank and the vehicle chassis tions: when the vehicle is in operation. Such (1) A section that will break under restraining devices must be readily ac strain must be provided adjacent to or cessible for inspection and mainte outboard of each valve specified in nance. §l78.337—8(a)(3) and (4). (b) On a cargo tank motor vehicle de (2) Each internal self-closing stop signed and constructed so that the valve, excess flow valve, and check cargo tank constitutes in whole or in sec valve must be protected by a shear part the structural member used in tion other sacrificial device. The or place of a motor vehicle frame, the sacrificial device must be located in cargo tank must be supported by exter the piping system outboard of the stop nal cradles. A cargo tank mounted on a valve and within the accident damage protection to prevent any accidental motor vehicle frame must be supported loss of lading. The failure of the sac by external cradles or longitudinal rificial device must leave the protected members. Where used, the cradles must lading protection device and its attach subtend at least 120 degrees of the shell ment to the cargo tank wall intact and circumference. capable of retaining product. (c) The design calculations of the support elements must satisfy the re [Order 59-B, 30 FR 581. Jan. 16, 1965. Redesig nated at 32 FR 5606, Apr. 5, 1967] quirements of §178.337—3, (a), (b), (c), and (d). FEDERAL REGISTER ci EDITORIAL NOTE: For (d) Where any cargo tank support is tations affecting § 178.337—10. see the List of CFR Sections Affected which appears in the attached to any part of a cargo tank Finding Aids section of the printed volume head, the stresses imposed upon the and on GPO Access. head must be provided for as required in paragraph (c) of this section. § 178.337—11 Emergency discharge con trol. [68 FR 19280, Apr. 18, 2003] (a) Emergency discharge control equip § 178.337—14 Gauging devices. ment. Emergency discharge control equipment must be installed in a liquid (a) Liquid level gauging devices. See discharge line as specified by product §173.315(h) of this subchapter. and service in §173.315(n) of this sub (b) Pressure gauges. (1) See §173.315(h) chapter. The performance and certifi of this subchapter. cation requirements for emergency dis (2) Each cargo tank used in carbon charge control equipment are specified dioxide, refrigerated liquid or nitrous in § 173.315(n) of this subchapter and are oxide, refrigerated liquid service must not a part of the cargo tank motor ve be provided with a suitable pressure hicle certification made under this gauge. A shut-off valve must be in specification. stalled between the pressure gauge and (b) Engine fuel lines. On a truck- the cargo tank. emergency dis mounted cargo tank, (c) Orifices. See § 173.315(h) (3) and (4) equipment is not re charge control of this subchapter. quired on an engine fuel line of not more than 3/4 NPT equipped with a [Amdt. 178—29, 38 FR 27599, Oct. 5, 1973, as valve having an integral excess flow amended by Amdt. 178-89, 54 FR 25018, June valve or excess flow feature. 12, 1989; Amdt. 178—118, 61 FR 51340, Oct. 1, 1996] [64 FR 28050, May 24, 1999] § 178.337—15 Pumps and compressors. § 178.337—12 [Reserved] (a) Liquid pumps or gas compressors, § 178.337-13 Supporting and anchor if used, must be of suitable design, ade ing. quately protected against breakage by (a) A cargo tank that is not perma collision, and kept in good condition. nently attached to or integral with a They may be driven by motor vehicle vehicle chassis must be secured by the power take-off or other mechanical, use of restraining devices designed to electrical, or hydraulic means. Unless prevent relative motion between the they are of the centrifugal type, they 954 Pipeline and Hazardous Materials Safety Admin., DOT § 178.337—17 shall be equipped with suitable pres formed, and the repaired areas shall sure actuated by-pass valves permit again be tested. ting flow from discharge to suction or LOrder to the cargo tank. 59—B, 30 FR 582, Jan. 16, 1965. Redesig nated at 32 FR 5606, Apr. 5, 1967, and amended (b) A liquid chlorine pump may not by Amdt. 178—7, 34 FR 18250, Nov. 14, 1969; be installed on a cargo tank intended Arndt. 178—99, 58 FR 51534, Oct. 1, 1993; Amdt. for the transportation of chlorine. 178—118, 61 FR 51340, Oct. 1, 1996; 68 FR 75753, Dec. 31, 2003] lAmdt. 178—89, 54 FR 25018, June 12, 1989, as amended by Amdt. 178-118. 61 FR 51340, Oct. § 178.337—17 Marking. 1, 1996] (a) General. Each cargo tank certified § 178.337—16 Testing. after October 1, 2004 must have a corro sion-resistant metal name plate (a) Inspection arid tests. Inspection of (ASME Plate) and specification plate materials of construction of the cargo permanently attached to the cargo tank and its appurtenances and origi tank by brazing, welding, or other suit nal test and inspection of finished the able means on the left side near the cargo tank and its appurtenances must front, in a place accessible for inspec be as required by Section VIII of the tion. If the specification plate is at ASME Code (IBR, see §171.7 of this sub tached directly to the cargo tank wall chapter) and as further required by this by welding, it must be welded to specification, the except that for cargo tank before the cargo tank is postweld tanks constructed in accordance with heat treated. part UHT in Section VIII of the ASME (1) The plates must be legibly marked Code the original test pressure must be by stamping, embossing, or other at least twice the cargo tank design means of forming letters into pressure. the metal of the plate, with the informa (b) Weld testing and inspection. (1) tion required in paragraphs (b) and (c) Each cargo tank constructed in accord of this section, in addition to that re ance with part UHT in Section VIII of quired by the ASME Code, in char the ASME Code must be subjected, acters at least 3/16 inch high (par after postweld heat treatment and hy enthetical abbreviations may be used). drostatic tests, to a wet fluorescent All plates must be maintained in a leg magnetic particle inspection to be ible condition. made on all welds in or on the cargo (2) Each insulated cargo tank must tank shell and heads both inside and have additional plates, as described, at out. The method of inspection must tached to the jacket in the location conform to appendix 6 in Section VIII specified unless the specification plate of the ASME Code except that perma is attached to the chassis and has the nent magnets shall not be used. information required in paragraphs (b) (2) On cargo tanks of over 3,500 gal- and (c) of this section. ions water capacity other than those (3) The information required for both described in paragraph (b)(I) of this the name and specification plate may section unless fully radiographed, a be displayed on a single plate. If the in test must be made of all welds in or on formation required by this section is the shell and heads both inside and displayed on a plate required by the outside by either the wet fluorescent ASME, the information need not be re magnetic particle method conforming peated on the name and specification to appendix U in Section VIII of the plates. ASME Code, liquid dye penetrant (4) The specification plate may be at method, or ultrasonic testing in ac tached to the cargo tank motor vehicle cordance with appendix 12 in Section chassis rail by brazing, welding, or VIII of the ASME Code. Permanent other suitable means on the left side magnets must not be used to perform near the front head, in a place acces the magnetic particle inspection. sible for inspection. If the specification (c) All defects found shall be re plate is attached to the chassis rail, paired, the cargo tanks shall then then the cargo tank serial number as again be postweld heat treated, if such signed by the cargo tank manufacturer heat treatment was previously per- must be included on the plate.

955 ______

§ 178.337—18 49 CR? Ch. I (10—1—10 Edition)

(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) °F to plicable. °F. (9) Cargo tank serial number, as (5) Nominal capacity (Water Cap.), in signed by cargo tank manufacturer (CT pounds. serial), if applicable. (6) Maximum design density of lading NOTE 1 TO PARAGRAPH (c): See §173.315(a) of (Max. Lading density), in pounds per this chapter regarding water capacity. gallon. NOTE 2 TO PARAGRAPH (c): When the shell (7) Material specification number— and head materials are the same thickness, yyy***), they may be combined (Shell & head matl, shell (Shell matl, where “yyy” yyy***). is replaced by the alloy designation and “***“ is replaced by the alloy type. (d) The design weight of lading used (8) Material specification number— in determining the loading in § 178.337— heads (Head matl. yyy***), where 3(b), 178.337—10(b) and (c), and 178.337— ‘yyy” is replaced by the alloy designa 13(a) and (b), must be shown as the tion and “***“ by the alloy type. maximum weight of lading marking re (9) Minimum Thickness—shell (Mm. quired by paragraph (c) of this section. Shell-thick), in inches. When minimum [68 FR 19280, Apr. 18, 2003; 68 FR 52370, Sept. shell thicknesses are not the same for 3, 2003, as amended at 68 FR 57633, Oct. 6, different areas, show (top, side, 2003] bottom, in inches). (10) Minimum thickness—heads (Mm. § 178.337—18 Certification. heads thick.), in inches. (a) At or before the time of delivery, (11) Manufactured thickness—shell the cargo tank motor vehicle manufac (Mfd. Shell thick.), top, side, turer must supply and the owner must bottom, in inches. (Required when obtain, a cargo tank motor vehicle additional thickness is provided for manufacturer’s data report as required corrosion allowance.) by Section VIII of the ASME Code (12) Manufactured thickness—heads (IBR, see § 171.7 of this subchapter), and (Mfd. Heads thick.), in inches. (Re a certificate stating that the com quired when additional thickness is pleted cargo tank motor vehicle con provided for corrosion allowance.) forms in all respects to Specification (13) Exposed surface area, in square MC 331 and the ASME Code. The reg feet. istration numbers of the manufacturer, the Design Certifying Engineer, and NOTE TO PARAGRAPH (b): When the shell and the Registered Inspector, as appro head materials are the same thickness, they priate, must appear on the certificates may be combined, (Shell&head matl, yyy$**). (see subpart F, part 107 in subchapter A of this chapter). (c) Specification plate. The following (1) For each design type, the certifi information must be marked on the cate must be signed by a responsible of specification plate in accordance with ficial of the manufacturer and a Design this section: Certifying Engineer; and (1) Cargo tank motor vehicle manu (2) For each cargo tank motor vehi facturer (CTMV mfr.). cle, the certificate must be signed by a (2) Cargo tank motor vehicle certifi responsible official of the manufac cation date (CTMV cert. date). turer and a Registered Inspector. (3) Cargo tank manufacturer (CT (3) When a cargo tank motor vehicle mfr.). is manufactured in two or more stages, (4) Cargo tank date of manufacture each manufacturer who performs a (CT date of mfr.), month and year. manufacturing function or portion 956 Pipeline and Hazardous Materials Safety Admin., DOT § 178.338—1

thereof on the incomplete cargo tank (b) The owner shall retain the copy of motor vehicle must provide to the suc the data report and certificates and re ceeding manufacturer, at or before the lated papers in his files throughout his time of delivery, a certificate that ownership of the cargo tank motor ve states the function performed by the hicle and for at least one year there manufacturer, including any certifi after; and in the event of change in cates received from previous manufac ownership, retention by the prior turers, Registered Inspectors, and De owner of nonfading photographically sign Certifying Engineers. reproduced copies will be deemed to (4) Specification shortages. When a satisfy this requirement. Each motor cargo tank motor vehicle is manufac carrier using the cargo tank motor ve tured in two or more stages, the manu hicle, if not the owner thereof, shall facturer of the cargo tank must attach obtain a copy of the data report and the name plate and specification plate certificate and retain them in his files as required by § 178.337—17(a) and (b) during the time he uses the cargo tank without the original date of certifi motor vehicle and for at least one year cation stamped on the specification thereafter. plate. Prior manufacturers must list [Order 59—B, 30 FR 583, Jan. 16, 1965. Redesig the specification requirements that are nated at 32 FR 5606, Apr. 5, 1967] not completed on the Certificate of EDITORIAL NOTE: For FEDERAL REGISTER ci Compliance. When the cargo tank tations affecting § 178.337-18, see the List of motor vehicle is brought into full com CFR Sections Affected which appears in the pliance with the applicable specifica Finding Aids section of the printed volume tion, the cargo tank motor vehicle and on GPO Access. manufacturer must have a Registered Inspector stamp the date of certifi § 178.338 Specification MC-.338; insu lated cargo tank motor vehicle. cation on the specification plate and issue a Certificate of Compliance to the § 178.338—1 General requirements. owner of the cargo tank motor vehicle. (a) For purposes The Certificate of Compliance must the of this section— (1) Design list the actions taken to bring the pressure means the ‘MAWP” as used in Section cargo tank motor vehicle into full VIII of the ASME Code (IBR, see compliance. In addition, the certificate §171.7 of this sub chapter), and is the must include the date of certification gauge pressure at the top of the tank. and the person (manufacturer, carrier (2) Design service temperature or repair organization) accomplishing means the coldest compliance. temperature for which the tank is suitable (see §l73.3l8 (a)(l) 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 piping, or device shall supply and the having piping, valves, supports and owner shall obtain a certificate assert other appurtenances as specified in this complete ing compliance with these subchapter. For the purpose of this specifications for such devices. The specification, tank means inner vessel certificate, or certificates, will include and jacket means either the outer shell sufficient sketches, drawings, and or insulation cover. other information to indicate the loca (c) Each tank must be designed, con tion, make, model, and size of each structed, certified, and stamped in ac valve and the arrangement of all piping cordance with Section VIII of the associated with the cargo tank. ASME Code. (6) The certificate must contain a (d) The exterior surface of the tank statement indicating whether or not must be insulated with a material com the cargo tank was postweld heat patible with the lading. treated for anhydrous ammonia as (1) Each cargo tank must have an in specified in § 178.337—1(f). sulation system that will prevent the 957 § 178.338—2 49 CFR Ch. I (10—1—10 Edition)

tank pressure from exceeding the pres § 178.338—2 Material. sure relief valve set pressure within the (a) All material used in the construc specified holding time when the tank is tion of a tank and its appurtenances loaded with the specific cryogenic liq that may come in contact with the lad uid at the design conditions of— ing must be compatible with the lading (i) The specified temperature and to be transported. All material used for pressure of the cryogenic liquid, and tank pressure parts must conform to (ii) The exposure of the filled cargo the requirements in Section II of the tank to an average ambient tempera ASME Code (IBR, see §171.7 of this sub ture of 85 °F. chapter). All material used for evacu (2) For a cargo tank transport used to ated jacket pressure parts must con oxygen, the insulation may not sustain form to the chemistry and steelmaking combustion in a 99.5 percent oxygen at practices of one of the material speci mosphere at atmospheric pressure fications of Section II of the ASME when contacted with a continuously Code or the following ASTM Specifica heated glowing platinum wire. The tions (IBR, see §171.7 of this sub cargo tank must be marked in accord chapter): A 242, A 441, A 514, A 572, A ance with l78.338—18(b)(7). § 588, A 606, A 633, A 715, A 1008/A lOO8M, (3) Each vacuum-insulated cargo A 1011/A lOllM. tank must provided be with a connec (b) All tie-rods, mountings, and other tion for a vacuum gauge to indicate the appurtenances within the jacket and absolute pressure within the insulation all piping, fittings and valves must be space. of material suitable for use at the low (e) The insulation must be com est temperature to be encountered. pletely covered by a metal jacket. The (c) Impact tests are required on all jacket or the insulation must be so tank materials, except materials that constructed and sealed prevent as to are excepted from impact testing by moisture from coming into contact the ASME Code, and must be per with the insulation (see §173.3l8(a)(3) of formed using the procedure prescribed this subchapter). Minimum metal in Section VIII of the ASME Code. thicknesses are as follows: (d) The direction of final rolling of Jacket evacu- Jacket not the shell material must be the circum Type metal ated evacuated ferential orientation of the tank shell. Gauge Inches Gauge Inches (e) Each tank constructed in accord ance with part UHT in Section VIII of Stainless steel 18 0.0428 22 0.0269 the ASME Low carbon mild steel 12 0.0946 14 0.0677 Code must be postweld heat Aluminum 0.125 0.1000 treated as a unit after completion of all welds to the shell and heads. Other (f) An evacuated jacket must be in tanks must be postweld heat treated as compliance with the following require required in Section VIII of the ASME ments: Code. For all tanks the method must (I) The jacket must be designed to be as prescribed in the ASME Code. sustain a minimum critical collapsing Welded attachments to pads may be pressure of 30 psig. made after postweld heat treatment. (2) If the jacket also supports addi (f) The fabricator shall record the tional loads, such as the weight of the heat and slab numbers and the certified tank and lading, the combined stress, Charpy impact values of each plate computed according to the formula in used in the tank on a sketch showing § 178.338—3(b), may not exceed 25 percent the location of each plate in the shell of the minimum specified tensile and heads of the tank. A copy of the strength. sketch must be provided to the owner of the cargo tank and a copy must be [Amdt. 178—77, 48 FR 27703, June 16, 1983, as retained by the fabricator for at least amended at 49 FR 24316, June 12, 1984: Amdt. 178—104, 59 FR 49135, Sept. 26, 1994; 66 FR 45387, Aug. 28, 2001; 68 FR 75754, Dec. 31, 2003]

958 Pipeline and Hazardous Materials Safety Admin., DOT § 178.338—3

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 2137-0017) bending, and torsion which occur at IAmdt. 178—77. 48 FR 27703 and 27713, June i6, pads, cradles, or other supports must 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, 20051 Code. § 178.338—3 Structural integrity. (c) Stresses resulting from static and 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 imum calculated design stress at any for cal culating the effective point in the tank may not exceed the stress in the tank resulting lesser of the maximum allowable stress from static and dynamic value prescribed in section VIII of the loadings. The effective stress (the max ASME Code, or 25 percent of the tensile imum principal stress at any point) strength of the material used. must be determined by the following (2) The relevant physical properties formula; of the materials used in each tank may S = 0.5 (S + S) ±(0.25(S — S)2 + S2) D.5 be established either by a certified test report from the material manufacturer Where: or by testing in conformance with a (1) S effective stress recognized national standard. In either at any given point under the most case, the ultimate tensile strength of severe combina tion the material used in the design may of static and dynamic loadings not exceed 120 percent of the minimum that can occur at the same time, in psi. ultimate tensile strength specified in (2) S = circumferential stress gen either the ASME Code or the ASTM erated by internal and external pres standard to which the material is man sure when applicable, in psi. ufactured. (3) S, the net longitudinal stress, in (3) The maximum design stress at psi, generated by the following loading any point in the tank must be cal conditions: culated separately for the loading con (i) The longitudinal tensile stress ditions described in paragraphs (b), (c), generated by internal pressure; and (d) of this section. Alternate test (ii) The tensile or compressive stress analytical or methods, or a combina generated by the axial load resulting tion thereof, may be used in lieu of the from a decelerative force applied inde procedures described in paragraphs (b), pendently to each suspension assembly (c), and (d) of this section, if the meth at the road surface using applicable ods are accurate and verifiable. static loadings specified in 178.338—13 (4) Corrosion allowance material § may (b); not be included to satisfy any of the (iii) The tensile or design calculation requirements of this compressive stress section. generated by the bending moment re (b) Static design and construction. (1) sulting from a decelerative force ap The static design and construction of plied independently to each suspension each tank must be in accordance with assembly at the road surface using ap appendix G in Section VIII of the plicable static loadings specified in ASME Code (IBR, see §171.7 of this sub §178.338—13 (b); chapter). The tank design must include (iv) The tensile or compressive stress calculation of stress due to the design generated by the axial load resulting pressure, the weight of lading. the from an accelerative force applied to weight of structures supported by the the horizontal pivot of the fifth wheel tank wall, and the effect of tempera supporting the vehicle using applicable ture gradients resulting from lading static loadings specified in § 178.338—13 and ambient temperature extremes. (b); 959 § 178.338—3 49 CFR Ch. I (10—1—10 Edition) (v) The tensile or compressive stress component or accident protection de generated by the bending moment re vice must conform to the following re sulting from an accelerative force ap quirements: plied to the horizontal pivot of the (1) Structural members, the suspen fifth wheel supporting the vehicle sion subframe, accident protection using applicable static loadings speci structures and external circumferen fied in §178.338—13 (b); and tial reinforcement devices must be (vi) The tensile or compressive stress used as sites for attachment of appur generated by a bending moment pro tenances and other accessories to the duced by a vertical force using applica cargo tank, when practicable. ble static loadings specified in § 178.338— (2) A lightweight attachment to the 13 (b). cargo tank wall such as a conduit clip, (4) S = The following shear stresses brakeline clip, skirting structure, lamp that apply, in psi,: The vectorial sum mounting bracket, or placard holder of the applicable shear stresses in the must be of a construction having lesser plane under consideration, including strength than the cargo tank wall ma direct shear generated by the static terials and may not be more than 72 vertical loading; direct lateral and tor percent of the thickness of the mate sional shear generated by a lateral ac rial to which it is attached. The light celerative force applied at the road sur weight attachment may be secured di face, using applicable static loads spec rectly to the cargo tank wall if the de ified in § 178.338—13 (b) vice is designed and installed in such a (d) In order to account for stresses manner that, if damaged, it will not af due to impact in an accident, the de fect the lading retention integrity of sign calculations for the tank shell and the tank. A lightweight attachment heads must include the load resulting must be secured to the cargo tank shell from the design pressure in combina or head by a continuous weld or in such tion with the dynamic pressure result a manner as to preclude formation of ing from a longitudinal deceleration of pockets that may become sites for cor ‘2g”. For this loading condition the rosion. Attachments meeting the re stress value used may not exceed the quirements of this paragraph are not lesser of the yield strength or 75 per authorized for cargo tanks constructed cent of the ultimate tensile strength of under part UHT in Section VIII of the the material of construction. For a ASME Code. cargo tank constructed of stainless (3) Except as prescribed in para steel, the maximum design stress may graphs (g)(l) and (g)(2) of this section, not exceed 75 percent of the ultimate the welding of any appurtenance the tensile strength of the type steel used. cargo tank wall must be made by at (e) The minimum thickness of the tachment of a mounting pad so that shell or heads of the tank must be 0.187 there will be no adverse effect upon the inch for steel and 0.270 inch for alu lading retention integrity of the cargo minum. However, the minimum thick tank if any force less than that pre ness for steel may be 0.110 inches pro scribed in paragraph (b) (1) of this sec vided the cargo tank is: tion is applied from any direction. The (I) Vacuum insulated, or thickness of the mounting pad may not (2) Double walled with a load bearing be less than that of the shell or head to jacket designed to carry a propor which it is attached, and not more tionate amount of structural loads pre than 1.5 times the shell or head thick scribed in this section. ness. However, a pad with a minimum (f) Where a tank support is attached thickness of 0.187 inch may be used to any part of the tank wall, the when the shell or head thickness is stresses imposed on the tank wall must over 0.187 inch. If weep holes or tell meet the requirements in paragraph (a) tale holes are used, the pad must be of this section. drilled or punched at the lowest point (g) The design, construction and in before it is welded to the tank. Each stallation of an attachment, appur pad must: tenance to the cargo tank or structural (i) Be fabricated from material deter support member between the cargo mined to be suitable for welding to tank and the vehicle or suspension both the cargo tank material and the 960 Pipeline and Hazardous Materials Safety Admin., DOT § 178.338—7

material of the appurtenance or struc ing sequence must minimize stresses tural support member; a Design Certi due to shrinkage of welds. fying Engineer must make this deter (e) Filler material containing more mination considering chemical and than 0.05 percent vanadium may not be physical properties of the materials used with quenched and tempered steel. and must specify filler material con (I) All tank nozzle-to-shell and noz forming to the requirements in Section zle-to-head welds must be full penetra IX of the ASME Code (IBR, see §171.7 of tion welds. this subchapter). (ii) Be preformed to an inside radius (Approved by the Office of Management and no greater than the outside radius of Budget under control number 2 137-0017) the cargo tank at the attachment loca [Amdt. 178—77, 48 FR 27704 and 27713. June 16, tion. 1983, as amended at 49 FR 24316, June 12, 1984; (iii) Extend at least 2 inches in each 68 FR 75754, Dec. 31, 2003] direction from any point of attachment of an appurtenance or structural sup § 178.338—5 Stiffening rings. port member. This dimension may be (a) A tank is not required to be pro measured from the center of the at vided with stiffening rings, except as tached structural member. prescribed in Section VIII of the ASME (iv) Have rounded corners, or other Code (IBR, see §171.7 of this sub wise be shaped in a manner to mini chapter). mize stress concentrations the on shell (b) If a jacket is evacuated, or head. it must be constructed in compliance with (v) Be attached by continuous fillet 178.338-1 (f). Stiffening rings welding. Any fillet weld discontinuity § may be used to meet these requirements. may only be for the purpose of pre venting an intersection between the fil [Amdt. 178—77, 48 FR 27704, June 16. 1983, as let weld and a tank or jacket seam amended at 68 FR 75754, Dec. 31, 2003] weld. § 178.338—6 Manholes. lAmdt. 178—89, 55 FR 37057, Sept. 7, 1990, as amended by Amdt. 178-89, 56 FR 27876. June (a) Each tank in oxygen service must 17, 1991; 56 FR 46354, Sept. 11, 1991; 68 FR be provided with a manhole as pre 19281, Apr. 18, 2003; 68 FR 57633, Oct. 6, 2003; 68 scribed in Section VIII of the ASME FR 75754, Dec. 31, 2003] Code (IBR, see §171.7 of this sub chapter). § 178.338—4 Joints. (b) Each tank having a manhole must (a) All joints in the tank, and in the be provided with a means of entrance jacket if evacuated, must be as pre and exit through the jacket, or the scribed in Section VIII of the ASME jacket must be marked to indicate the Code (IBR, see §171.7 of this sub manway location on the tank. chapter), except that a butt weld with (c) A manhole with a bolted closure one plate edge offset not authorized. is may not be located on the front head of (b) Welding procedure and welder per the tank. formance tests must be made in ac cordance with Section IX of the ASME [Amdt. 178—77, 48 FR 27704, June 16, 1983, as Code. Records of the qualification must amended at 49 FR 24316, June 12, 1984; 68 FR be retained by the tank manufacturer 75754, Dec. 31, 2003] for at least five years and must be § 178.338—7 Openings. made available, upon request, to any duly identified representative of the (a) The inlet to the liquid product Department, or the owner of the cargo discharge opening of each tank in tank. tended for flammable ladings must be (c) All longitudinal welds in tanks at the bottom centerline of the tank. and load bearing jackets must be lo (b) If the leakage of a single valve, cated so as not to intersect nozzles or except a pressure relief valve, pressure 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 961 § 178.338—8 49 CFR Ch. I (10—1—10 Edition) design pressure must be provided out (7) All fittings must be rated for the board of such valve. maximum tank pressure and suitable for the coldest temperature to which [Amdt. 178—77, 48 FR 27704, June 16, 1983] they will be subjected in actual serv § 178.338—8 Pressure relief devices, ice. piping, valves, and fittings. (8) All piping, valves, and fittings must be grouped in the smallest prac (a) Pressure relief devices. Each tank ticable space and protected from dam pressure relief device must be designed, age as required by 178.338—10. constructed, and marked in accordance § (9) When a pressure-building coil is with 173.318(b) of this subchapter. § used on a tank designed to handle oxy (b) Piping, valves, and fittings. (I) The gen or flammable ladings, the vapor burst pressure of all piping, pipe fit connection to that coil must be pro tings, hoses and other pressure parts, vided with a valve or check valve except for pump seals and pressure re as close to the tank shell practicable to lief devices, must be at least 4 times as prevent the loss of vapor from the tank the design pressure of the tank. Addi in case of damage to the coil. The liq tionally, the burst pressure may not be uid connection to that coil must also less than 4 times any higher pressure be provided with a valve. to which each pipe, pipe fitting, hose or other pressure part may be subjected [Amdt. 178—77, 48 FR 27704, June 16, 1983, as to in service. amended by Amdt. 178-89, 54 FR 25019, June (2) Pipe joints must be threaded, 12, 19891 welded or flanged. If threaded pipe is Holding time. used, the pipe and fittings must be §178.338-9 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 5iip 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 or after installation on the tank. temperature. This measured holding (6) Each valve must be suitable for time for the test cryogenic liquid must the tank design pressure at the tank be adjusted to an equivalent holding design service temperature. time for each cryogenic liquid that is 962 Pipeline and Hazardous Materials Safety Admin., DOT § 178.338—10 to be identified on or adjacent to the (ii) The rated holding time (RHT) specification plate, at an average ambi must be calculated as follows: ent temperature of 85 F. This is the RHT = [(U2 — U1) Wi / rated holding time (RHT). The marked q rated holding time (MRHT) displayed Where: on or adjacent to the specification RHT = rated holding time, in hours plate (see §178.338—18(c)(10)) may not ex U1 and U2 = internal energy for the combined ceed this RHT. liquid and vapor lading at the pressure of (c) Optional test regimen. (1) If more fered for transportation, and the set pres than one cargo tank is made to the sure of the applicable pressure control or same design, only valve pressure relief valve, respectively, one cargo tank must Btu]lb. be subjected to the full holding time W = total weight of the combined liquid and test at the time of manufacture. How vapor lading in the cargo tank, pounds. ever, each subsequent cargo tank made q = calculated heat transfer rate to cargo to the same design must be perform tank with lading, Btu/hr. ance tested during its first trip. The (iii) The MRHT (see §178.338—18(b)(9) holding time determined in this test of this subchapter) may not exceed the may not be less than 90 percent of the RHT. marked rated holding time. This test must be performed in accordance with [Amdt. 178—77. 48 FR 27704, June 16, 1983; 48 §l73.3l8(g)(3) and 177.840(h) of this sub FR 50442, Nov. 1, 1983, as amended at 49 FR chapter, regardless of the classification 24316, June 12, 1984: 49 FR 43965, Nov. 1, 1984; 59 FR 55173, of the cryogenic liquid. Nov. 3, 1994: Amdt. 178—118, 61 FR 51340, Oct. 1, 1996: 68 FR 57634, Oct. 6, 2003; 71 (2) Same design. The term “same de FR 54397, Sept. 14. 2006] sign” as used in this section means cargo tanks made to the same design § 178.338—10 Accident damage protec type. See §178.320(a) for definition of tion. “design type”. (a) All valves, fittings, pressure relief For (3) a cargo tank used in nonflam devices and other accessories to the mable cryogenic liquid service, in place tank proper, which are not isolated of the holding time tests prescribed in from the tank by closed intervening paragraph (b) of this section, the shut-off valves or check valves, must marked rated holding time (MRHT) be installed within the motor vehicle may be determined as follows: framework or within a suitable colli While (i) the cargo tank is sta sion resistant guard or housing, and tionary, heat the transfer rate must be appropriate ventilation must be pro determined by measuring the normal vided. Each pressure relief device must evaporation rate (NER) of the test be protected so that in the event of the cryogenic liquid (preferably the lading, upset of the vehicle onto a hard sur where feasible) maintained at approxi face, the device’s opening will not be mately one atmosphere. The calculated prevented and its discharge will not be heat transfer rate must be determined restricted. from: (b) Each protective device or housing,

= q [n(A h)(85—ti)] I [t — tf] and its attachment to the vehicle structure, Where: must be designed to with stand static loading in any direction = calculated q heat transfer rate to cargo that it may loaded tank with lading, Btu/hr. be as a result of front, rear, side, or sideswipe collision, o = normal evaporation rate (NER), which is the rate of evaporation, determined by the or the overturn of the vehicle. The test of a test cryogenic liquid in a cargo static loading shall equal twice the tank maintained at a pressure of approxi loaded weight of the tank and attach mately one atmosphere, absolute, lb/hr. ments. A safety factor of four, based on z h = latent heat of vaporization of test fluid the tensile strength of the material, at test pressure, BtuIlb. shall be used. The protective device or = average temperature of outer shell dur ing test, F. the housing must be made of steel at least 3/is-inch thick, = equilibrium temperature of lading at or other material maximum loading pressure, °F. of equivalent strength. tf = equilibrium temperature of test fluid at (c) Rear-end tank protection. Rear-end one atmosphere, °F. tank protections devices must:

963 § 178.338—11 49 CFR Ch. 1(10—1—10 Edition) (I) 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. suit in loss of lading; or The loading/unloading connection area (2) Conform to the requirements of is where hoses are connected to the § 178.345—8(b). permanent metal piping. The number (d) Every part of the loaded cargo and location of remote operators and tank, and any associated valve, pipe, thermal devices shall be as follows: enclosure, or protective device or (1) 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 FR 27705, June 16, 1983, as [Amdt. 178—77, 48 site locations. If the loading/unloading amended at 49 FR 24316, June 12, 1984; Amdt. 178—99, 58 FR 51534, Oct. 1, 1993; 68 FR 19282, connection at the cargo tank is not in Apr. 18, 2003; 68 FR 52371, Sept. 3, 2003] the general vicinity of one of these lo cations, at least one additional ther § 178.338—11 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. 178—77, 48 FR 27705, June 16, 1983, as motely controlled self-closing shutoff amended by Amdt. 178-105, 59 FR 55173, Nov. valve. 3, 1994; 60 FR 17402, Apr. 5, 1995; 68 FR 19282, (1) If pressure from a reservoir or Apr. 18, 20031 from an engine-driven pump or com pressor is used to open this valve, the § 178.338—12 Shear section. control must be of fail-safe design and Unless the valve is located in a rear spring-biased to stop the admission of cabinet forward of and protected by the 964 Pipeline and Hazardous Materials Safety Admin., DOT § 178.338—14 bumper (see § 178.338-10(c)), the design (iv) Laterally of 2. and installation of each valve, damage (b) When a loaded tank is supported to which could result in loss of liquid within the vacuum jacket by struc or vapor, must incorporate a shear sec tural members, the design calculations tion or breakage groove adjacent to, for the tank and its structural mem and outboard of, the valve. The shear bers must be based on a safety factor of section or breakage groove must yield four and the tensile strength of the ma or break under strain without damage terial at ambient temperature. The en to the valve that would allow the loss hanced tensile strength of the material of liquid or vapor. The protection spec at actual operating temperature may ified in § 178.338—10 is not a substitute be substituted for the tensile strength for a shear section or breakage groove. at ambient temperature to the extent recognized in IAmdt. 178—77, 49 FR 24316, June 12, 19841 the ASME Code for static loadings. Static loadings must take § 178.338—13 Supporting and anchor. into consideration the weight of the ing. tank and the structural members when (a) On a cargo tank motor vehicle de the tank is filled to the design weight signed and constructed so that the of lading (see Appendix C of Section cargo tank constitutes in whole or in VIII, Division I of the ASME Code), part the structural member used in multiplied by the following factors. place of a motor vehicle frame, the Static loadings must take into consid eration cargo tank or the jacket must be sup the weight of the tank and the ported by external cradles or by load structural members when the tank is rings. For a cargo tank mounted on a filled to the design weight of lading motor vehicle frame, the tank or jack (see appendix C in Section VIII of the ASME et must be supported by external cra Code), multiplied by the fol lowing dles, load rings, or longitudinal mem factors. When load rings in the jacket are used bers. If cradles are used, they must for supporting the tank, they must subtend at least 120 degrees of the be designed to carry the fully cargo tank circumference. The design loaded tank at the specified static loadings, calculations for the supports and load- plus external pressure. Minimum loadings bearing tank or jacket, and the support static must be as follows: attachments must include beam stress, (1) Vertically shear stress, torsion stress, bending downward of 2; (2) Vertically upward of l’/2; moment, and acceleration stress for (3) Longitudinally of 11/2; and, the loaded vehicle as a unit, a (4) Lat using erally of 1’/z. safety factor of four, based on the ten sile strength of the material, and static [68 FR 19282. Apr. 18, 2003, as amended at 68 loading that uses the weight of the FR 75754, Dec. 31, 2003] cargo tank and its attachments when §178.338-14 filled to the design weight of the lading Gauging devices. (see appendix G in Section VIII of the (a) Liquid level gauging devices. (1) Un ASME Code) (IBR, see §171.7 of this. less a cargo tank is intended to be subchapter), multiplied by the fol filled by weight, it must be equipped lowing factors. The effects of fatigue with one or more gauging devices, must also be considered in the calcula which accurately indicate the max tions. Minimum static loadings must imum permitted liquid level at the be as follows; loading pressure, in order to provide a (1) For a vacuum-insulated cargo minimum of two percent outage below tank— the inlet of the pressure control valve (1) Vertically downward of 2; or pressure relief valve at the condition (ii) Vertically upward of 2; of incipient opening of that valve. A (iii) Longitudinally of 2; and fixed-length dip tube, a fixed trycock (iv) Laterally of 2. line, or a differential pressure liquid (2) For any other insulated cargo level gauge must be used as the pri tank— mary control for filling. Other gauging (1) Vertically downward of 3; devices, except gauge , may be (ii) Vertically upward of 2; used, but not as the primary control (iii) Longitudinally of 2; and for filling. 965 § 178.338—15 49 CFR Ch. I (10—1—10 Edition)

(2) The design pressure of each liquid §178.338-16 Inspection and testing. level gauging device must be at least (a) General. The material of construc that the tank. of 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- sure control valve, whichever is lowest. tenth of the test pressure until the re 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 ½-inch head welds subject to pressure shall be nominal pipe size. radiographed in accordance with Sec [Amdt. 178—77, 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 § 178.338—15 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 or ance with CGA G—4.l (IBR, see 171.7 of bing equally effective means, and all § such residue this subchapter). All loose particles and cleaning solution from fabrication, such as weld beads, must be removed from the tank prior to final dirt, grinding wheel debris, and other closure of the tank. (d) Defect cracks loose materials, must be removed prior repair. All and other defects must repaired as prescribed to the final closure of the manhole of be in Section VIII ASME the tank. Chemical or solvent cleaning of the Code. The welder and with a material compatible with the the welding procedure must be qualified in accordance intending lading must be performed to with Section of remove any contaminants likely to IX the ASME Code (IBR, see §171.7 of this subchapter). react with the lading. After repair, the tank must again be postweld heat-treated, if [68 FR 75755, Dec. 31, 20031 such heat treatment was previously 966 Pipeline and Hazardous Materials Safety Admin., DOT § 178.338—18

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. 178—77, 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. 178.338—17 Pumps compressors. § and (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. 178—89, 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). §178.338—18 Marking. (3) MAWP in psig. (4) Cargo tank test pressure (a) General. Each cargo tank certified (Test P), 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) °F to 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 mat!, 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. means of forming letters into the (9) Material specification number— metal of the plate, with the informa heads (Head mati. yyy * * *), where tion required in paragraphs (b) and (c) ‘yyy” is replaced by the alloy designa of this section, in addition to that re tion and •* * “ by the alloy type. 967 § 178.338—19 49 CFR Ch. I (10—1—10 Edition)

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 mati, yyy they may be combined (Shell & head mati, yyy**). (10) Weld material (Weld mati.). (11) Minimum Thickness-shell (Mm. (d) The design weight of lading used Shell-thick), in inches. When minimum in determining the loading in § 178.338— shell thicknesses are not the same for 3 (b), 178.338—10 (b) and (c), and 178.338— 13 (b), must be shown as the maximum different areas, show (top , side weight of lading marking required bottom , in inches). by (12) Minimum thickness-heads (Mm paragraph (c) of this section. heads thick.), in inches. 168 FR 19283, Apr. 18, 2003, as amended at 68 (13) Manufactured thickness-shell FR 57634, Oct. 6. 2003: 68 FR 75755, Dec. 31,

(Mfd. Shell thick.), top , side 20031 bottom , in inches. (Required when additional thickness is provided for § 178.338—19 Certification. corrosion allowance.) (a) At or before the time of delivery, (14) Manufactured thickness-heads the manufacturer of a cargo tank (Mfd. Heads thick.), in inches. (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 manufacturer’s 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 er’s 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 effect (3) Cargo tank manufacturer (CT on the date (month, year) of cer mfr.). tification. The registration numbers of the (4) Cargo tank date of manufacture manufacturer, the Design Certi fying Engineer, (CT date of mfr.), month and year. 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. minute (Max Unload rate). lons per (b) In the case of a cargo tank vehicle Lining materials (Lining), if ap (8) manufactured in two or more stages, plicable. each manufacturer who performs a service” or (9) “Insulated for oxygen manufacturing operation on the incom “Not insulated for oxygen service” as plete vehicle or portion thereof shall appropriate. furnish to the succeeding manufac rated holding (10) Marked time for at turer, at or before the time of delivery, least one cryogenic liquid, in hours, a certificate covering the particular and the name of that cryogenic liquid operation performed by that manufac (MRHT hrs, name of cryogenic 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 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 I 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 968 Pipeline and Hazardous Materials Safety Admin., DOT § 178.345—1

the manufacturing firm responsible for Baffle means a non-liquid-tight trans the portion of the complete cargo tank verse partition device that deflects, vehicle represented thereby, such as checks or regulates fluid motion in a basic tank fabrication, insulation, tank. jacket, or piping. The final manufac Bulkhead means a liquid-tight trans turer shall furnish the owner with all verse closure at the ends of or between certificates, as well as the documents cargo tanks. required by paragraph (a) of this sec Charging line means a hose, tube. tion. pipe, or similar device used to pres The owner retain (c) shall the data surize a tank with material other than report, certificates, and related papers the lading. throughout his ownership of the cargo Companion flange means tank. In the event of change of owner one of two mating flanges where the flange ship, the prior owner shall retain non- faces are in contact or separated fading photographically reproduced only by a thin leak sealing gasket and are copies of these documents for at least se cured to one one year. Each operator another by bolts or using the clamps. cargo tank vehicle, if not the owner Connecting thereof, shall obtain a copy of the data structure means the struc ture report and the certificate or certifi joining two cargo tanks. cates and retain them during the time Constructed and certified in conform he uses the cargo tank and for at least ance with the ASME Code means the one year thereafter. cargo tank is constructed and stamped in accordance with the ASME Code, (Approved by the Office of Management and and is inspected and certified by an Au Budget under control number 2137-0017) thorized Inspector. lAmdt. 178—77, 48 FR 27707 and 27713, June 16, Constructed in accordance with the 1983, as amended by Amdt. 178-89, 55 FR ASME Code means the cargo tank is 37058, Sept. 7, 1990; Amdt. 178—99, 58 FR 51534, constructed in accordance with the Oct. 1, 1993; 62 FR 51561, Oct. 1, 68 FR 1997; ASME Code 75755, Dec. 31, 2003] with the authorized excep tions (see §5178.346, 178.347, and 178.348) § 178.340—178.343 [Reserved] and is inspected and certified by a Reg istered Inspector. § 178.345 General design and construc External self-closing stop-valve means tion requirements applicable to a self-closing stop-valve designed so Specification DOT 406 ( 178.346), that the DOT 407 self-stored energy source is lo (178.347), and DOT 412 cated (5178.348) cargo tank motor vehi outside the cargo tank and the cles. welded flange. Extreme dynamic loading means the § 178.345—1 General requirements. maximum single-acting loading a cargo (a) Specification DOT 406, DOT 407 tank motor vehicle may experience and DOT 412 cargo tank motor vehicles during its expected life, excluding acci must conform to the requirements of dent loadings. this section in addition to the require Flange means the structural ring for ments of the applicable specification guiding or attachment of a pipe or fit contained in §5178.346, 178.347 or 178.348. ting with another flange (companion (b) All specification requirements are flange), pipe, fitting or other attach minimum requirements. ment. (c) Definitions. See § 178.320(a) for the Inspection pressure means the pres definition of certain terms used in sure used to determine leak tightness §5178.345, 178.346, 178.347, and 178.348. In of the cargo tank when testing with addition, the following definitions pneumatic pressure. apply to §5178.345, 178.346, 178.347, and Internal self-closing stop-valve means a 178.348: self-closing stop-valve designed so that Appurtenance means any cargo tank the self-stored energy source is located accessory attachment that has no 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 969 § 178.345—1 49 CFR Ch. I (10—1—10 Edition)

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. operations. ing/unloading 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 tached. ex 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 Swap 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. manhole, or gauging devices, flange, a 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 at the cargo tank loading/unloading Toughness of material means the capa 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 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

970 Pipeline and Hazardous Materials Safety Admin., DOT § 178.345—2

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 §178.345-3. Any void within structure. the connecting structure must be vent Welded flange means a flange at ed to the atmosphere and have a drain tached to the tank by a weld joining located on the bottom centerline. Each the tank shell to the cylindrical outer drain must be accessible and must be surface of the flange, or by a fillet weld kept open at all times. The drain in joining the tank shell to a flange any void within the connecting struc shaped to fit the shell contour. ture of a carbon steel, self-supporting (d) A manufacturer of a cargo tank cargo tank may be either a single drain must hold a current ASME certificate of at least 1.0 inch diameter, or two or of authorization and must be registered more drains of at least 0.5 inch diame with the Department in accordance ter, 6.0 inches apart, one of which is lo with part 107, subpart F of this chapter. cated on the bottom centerline. (e) All construction must be certified (j) Variable specification cargo tank. A by an Authorized Inspector or by a cargo tank that may be physically al Registered Inspector as applicable to tered to conform to another cargo tank the cargo tank. specification must have the required (f) Each cargo tank must be designed physical alterations to convert from and constructed in conformance with one specification to another clearly in the requirements of the applicable dicated on the variable specification cargo tank specification. Each DOT 412 plate. cargo tank with a MAWP” greater [Amdt. 178—89, 54 FR 25020, than 15 psig, and each DOT 407 June 12, 1989, as cargo amended at 55 FR 37058, Sept. 7, 1990; tank with Amdt. a maximum allowable work 178—105, 59 FR 55173, Nov. 3, 1994; Amdt. 178— ing pressure greater than 35 psig must 118, 61 FR 51340, Oct. 1, 1996: 66 FR 45387, be “constructed and certified in con 45389, Aug. 28, 2001: 68 FR 19283, Apr. 18, 2003; formance with Section VIII of the 68 FR 52371, Sept. 3, 2003; 68 FR 75755, Dec. 31, ASME Code” (IBR, see §171.7 of this 2003; 70 FR 56099, Sept. 23, 2005] subchapter) except as limited or modi fied by the applicable cargo § 178.345—2 Material and material tank speci thickness. fication. Other cargo tanks must be “constructed in accordance with Sec (a) All material for shell, heads, tion VIII of the ASME Code,” except as bulkheads, and baffles must conform to limited or modified by the applicable Section II of the ASME Code (IBR, see cargo tank specification. § 171.7 of this subchapter) except as fol (g) Requirements relating to parts lows; and accessories on motor vehicles, (1) The following steels are also au which are contained in part 393 of the thorized for cargo tanks “constructed Federal Motor Carrier Safety Regula in accordance with the ASME Code”, tions of this title, are incorporated Section VIII. into these specifications. ASTM A 569 (h) Any additional requirements pre ASTM A 570 scribed in part 173 of this subchapter ASTM A 572 that pertain to the transportation of a ASTM A 622 specific lading are incorporated into ASTM A 656 ASTM these specifications. A 715 ASTM A 1008/ A 1008M, ASTM A 1011/A 1OI1M (1) Cargo tank motor vehicle composed of multiple cargo tanks. (1) A cargo tank (2) Aluminum alloys suitable for fu motor vehicle composed of more than sion welding and conforming with the one cargo tank may be constructed 0, H32 or H34 tempers of one of the fol with the cargo tanks made to the same lowing ASTM specifications may be specification or to different specifica used for cargo tanks “constructed in tions. Each cargo tank must conform accordance with the ASME Code”; in all respects with the specification ASTM B-209 Alloy 5052 for which it is certified. ASTM B-209 Alloy 5086 971 § 178.345—3 49 CFR Ch. I (10—1—10 Edition)

ASTM B-209 Alloy 5154 the cargo tank wall may not exceed the ASTM B-209 Alloy 5254 maximum allowable stress value pre ASTM B-209 Alloy 5454 scribed in Section VIII of the ASTM B-209 Alloy 5652 ASME Code (IBR, see §171.7 of this sub All heads, bulkheads and baffles must chapter), or 25 percent of the tensile be of 0 temper (annealed) or stronger strength of the material used at design tempers. All shell materials shall be of conditions. H 32 or H 34 tempers except that the (2) The relevant physical properties lower ultimate strength tempers may of the materials used in each cargo be used if the minimum shell tank may be established either by a thicknesses in the tables are increased certified test report from the material in inverse proportion to the lesser ulti manufacturer or by testing in conform mate strength. ance with a recognized national stand (b) Minimum thickness. The minimum ard. In either case, the ultimate tensile thickness for the shell and heads (or strength of the material used in the de baffles and bulkheads when used as sign may not exceed 120 percent of the tank reinforcement) must be no less minimum ultimate tensile strength than that determined under criteria for specified in either the ASME Code or minimum thickness specified in the ASTM standard to which the mate § 178.320(a). rial is manufactured. (c) Corrosion or abrasion protection. (3) The maximum design stress at When required by 49 CFR part 173 for a any point in the cargo tank must be particular lading, a cargo tank or a calculated separately for the loading part thereof, subject to thinning by conditions described in paragraphs (b) corrosion or mechanical abrasion due and (c) of this section. Alternate test to the lading, must be protected by or analytical methods, or a combina providing the tank or part of the tank tion thereof, may be used in place of with a suitable increase in thickness of the procedures described in paragraphs material, a lining or some other suit (b) and (c) of this section, if the meth able method of protection. ods are accurate and verifiable. TTMA (1) Corrosion allowance. Material RP 96-01, Structural Integrity of DOT added for corrosion allowance need not 406, DOT 407, and DOT 412 Cylindrical be of uniform thickness if different Cargo Tanks, may be used as guidance rates of attack can reasonably be ex in performing the calculations. pected for various areas of the cargo (4) Corrosion allowance material may tank. not be included to satisfy any of the (2) Lining. Lining material must con design calculation requirements of this sist of a nonporous, homogeneous ma section. terial not less elastic than the parent (b) ASME Code design and construc metal and substantially immune to at tion. The static design and construc tack by the lading. The lining material tion of each cargo tank must be in ac must be bonded or attached by other cordance with Section VIII of the appropriate means to the cargo tank ASME Code. The cargo tank design wall and must be imperforate when ap must include calculation of stresses plied. Any joint or seam in the lining generated by the MAWP, the weight of must be made by fusing the materials the lading, the weight of structures together, or by other satisfactory supported by the cargo tank wall and means. the effect of temperature gradients re sulting from lading and ambient tem [Amdt. 178—89, 54 FR 25021, June 12, 1989, as amended at 55 FR 37059, Sept. 7. 1990; 56 FR perature extremes. When dissimilar 27876, June 17, 1991; Amdt. 178—97, 57 FR 45465, materials are used, their thermal coef Oct. 1, 1992; Amdt. 178—118, 61 FR 51341, Oct. ficients must be used in the calculation 1, 1996; 68 FR 19283, Apr. 18, 2003; 68 FR 75755, of thermal stresses. Dec. 31, 2003; 70 FR 34076, June 13. 20051 (I) Stress concentrations in tension, bending and torsion which occur at § 178.345—3 Structural integrity. pads, cradles, or other supports must (a) General requirements and accept be considered in accordance with ap ance criteria. (1) The maximum cal pendix G in Section VIII of the ASME culated design stress at any point in Code. 972 Pipeline and Hazardous Materials Safety Admin., DOT § 178.345—3

(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 UG-23(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 tank’s 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 decelerative force; combined. The vertical, longitudinal ( The bending moment generated by and lateral extreme dynamic loadings a decelerative force; occur separately and need not be com ( The axial load generated by an ac bined. celerative force; and (I) IVormal operating loadings. The fol ( The bending moment generated by lowing procedure addresses stress in an accelerative force; and the cargo tank shell resulting from (C) The tensile or compressive stress normal operating loadings. The effec generated by the bending moment re tive stress (the maximum principal sulting from normal operating vertical stress at any point) must be deter accelerative force equal to 0.35 times mined by the following formula: the vertical reaction at the suspension assembly of a trailer; or the horizontal S = 0.5(S ± S) ±[0.25(S_S,J2 ± Ss2]°5 pivot of the upper coupler (fifth wheel) Where: or turntable; or anchoring and support (i) S = effective stress at any given members of a truck, as applicable. The point under the combination of static vertical reaction must be calculated and normal operating loadings that can based on the static weight of the fully occur at the same time, in psi. loaded cargo tank motor vehicle, all (ii) S = circumferential stress gen structural elements, equipment and ap erated by the MAWP and external pres purtenances supported by the cargo sure, when applicable, plus static head, tank wall. in psi. (iv) Ss = The following shear stresses (iii) S, = The following net longitu generated by the following static and dinal stress generated by the following normal operating loading conditions, static and normal operating loading in psi: conditions, in psi: (A) The static shear stress resulting (A) The longitudinal stresses result from the vertical reaction at the sus ing from the MAWP and external pres pension assembly of a trailer, and the sure, when applicable, plus static head, horizontal pivot of the upper coupler in combination with the bending stress (fifth wheel) or turntable; or anchoring 973 § 178.345—3 49 CFR Ch. I (10—1—10 Edition)

and support members of a truck, as ap when applicable, plus static head, in plicable. The vertical reaction must be psi.

calculated based on the static weight (iii) S = the following net longitu of the fully loaded cargo tank motor dinal stress generated by the following vehicle, all structural elements, equip static and extreme dynamic loading ment and appurtenances supported by conditions, in psi: the cargo tank wall; (A) The longitudinal stresses result (B) The vertical shear stress gen ing from the MAWP and external pres erated by a normal operating accelera sure, when applicable, plus static head, tive force equal to 0.35 times the in combination with the bending stress 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 and surface, as transmitted to the wheel, or the drawbar hinge on the tank wall through cargo 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 coupler (fifth upper truck during acceleration and decelera or turntable; wheel) or anchoring and tion, as applicable. The vertical reac support members of truck, as applica a tion must be calculated based on the The vertical reaction be ble. must 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 supported and appurtenances 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 The bending moment scribed in paragraph (c) (I) (iv) (C) of this ( generated by a decelerative force; section. The axial load generated by (2) Extreme dynamic loadings. The fol ( an ac celerative force; and lowing procedure addresses stress in the cargo tank shell resulting from ex ( The bending moment generated by treme dynamic loadings. The effective an accelerative force; and stress (the maximum principal stress (C) The tensile or compressive stress at any point) must be determined by generated by the bending moment re the following formula: sulting from an extreme vertical accel erative force equal to 0.7 times the

S 0.5(S ± S) ±[0.25(S — S)2 ÷ Ss2]°5 vertical reaction at the suspension as sembly of a trailer, and the horizontal Where: pivot of the upper coupler (fifth wheel) (i) S = effective stress at any given or turntable; or the anchoring and sup point under a combination of static port members of a truck, as applicable. and extreme dynamic loadings that can The vertical reaction must be cal occur at the same time, in psi. culated based on the static weight of (ii) S = circumferential stress gen the fully loaded cargo tank motor vehi erated by MAWP and external pressure, cle, all structural elements, equipment 974 Pipeline and Hazardous Materials Safety Admin., DOT § 178.345—3

and appurtenances supported by the supports, the calculation of effective cargo tank wall. stresses for the loading conditions in (iv) Ss = The following shear stresses paragraph (c) of this section may in generated by static and extreme dy clude the structural contribution of namic loading conditions, in psi: the frame or the integral structural (A) The static shear stress resulting supports. from the vertical reaction at the sus (f) The design, construction, and in pension assembly of a trailer, and the stallation of an attachment, appur horizontal pivot of the upper coupler tenance to a cargo tank, structural (fifth wheel) or turntable; or anchoring support member between the cargo and support members of a truck, as ap tank and the vehicle or suspension plicable. The vertical reaction must be component must conform to the fol calculated based on the static weight lowing requirements: of the fully loaded cargo tank motor (1) Structural members, the suspen vehicle, all structural elements, equip sion sub-frame, accident protection ment and appurtenances supported by structures and external circumferen the cargo tank wall; tial reinforcement devices must be (B) The vertical shear stress gen used as sites for attachment of appur erated by an extreme vertical accelera tenances and other accessories to the tive force equal to 0.7 times the cargo tank, when practicable. vertical reaction at the suspension as (2) A lightweight attachment to a sembly of a trailer, and the horizontal cargo tank wall such as a conduit clip, pivot of the upper coupler (fifth wheel) brake line clip, skirting structure, or turntable; or anchoring and support lamp mounting bracket, or placard members of a truck, as applicable. The holder must be of a construction hav vertical reaction must be calculated ing lesser strength than the cargo tank based on the static weight of the fully wall materials and may not be more loaded cargo tank motor vehicle, all than 72 percent of the thickness of the structural elements, equipment and ap material to which it is attached. The purtenances supported by the cargo lightweight attachment may be se tank wall; cured directly to the cargo tank wall if (C) The lateral shear stress generated the device is designed and installed in by an extreme lateral accelerative such a manner that, if damaged, it will force equal to 0.4 times the vertical re not affect the lading retention integ action at the suspension assembly of a rity of the tank. A lightweight attach trailer, applied at the road surface, and ment must be secured to the cargo as transmitted to the cargo tank wall tank shell or head by continuous weld through the suspension assembly of a or in such a manner as to preclude for trailer, and the horizontal pivot of the mation of pockets which may become upper coupler (fifth wheel) or turn sites for corrosion. table; or anchoring and support mem (3) Except as prescribed in para bers of a truck, as applicable. The graphs (f)(l) and (f)(2) of this section, vertical reaction must be calculated the welding of any appurtenance to the based on the static weight of the fully cargo tank wall must be made by at loaded cargo tank motor vehicle, all tachment of a mounting pad so that structural elements, equipment and ap there will be no adverse effect upon the purtenances supported by the cargo lading retention integrity of the cargo tank wall; and tank if any force less than that pre (D) The torsional shear stress gen scribed in paragraph (b) (1) of this sec erated by the same lateral forces as de tion is applied from any direction. The scribed in paragraph (c) (2) (iv) (C) of this thickness of the mounting pad may not section. be less than that of the shell or head to (d) In no case may the minimum which it is attached, and not more thickness of the cargo tank shells and than 1.5 times the shell or head thick heads be less than that prescribed in ness. However, a pad with a minimum § 178.346—2, § 178.347—2, or § 178.348—2, as thickness of 0.187 inch may be used applicable. when the shell or head thickness is (e) For a cargo tank mounted on a over 0.187 inch. If weep holes or tell frame or built with integral structural tale holes are used, the pad must be 975 § 178.345—4 49 CFR Ch. I (10—1—10 Edition)

drilled or punched at the lowest point § 178.345—5 Manhole assemblies. before it is welded tank. Each to the (a) Each cargo tank with capacity pad must: greater than 400 gallons must be acces (i) Be fabricated from material deter sible through a manhole at least 15 mined to be suitable for welding to inches in diameter. both the cargo tank material and the (b) Each manhole, fill opening and material of the appurtenance or struc washout assembly must be structurally tural support member; a Design Certi capable of withstanding, without leak fying Engineer must make this deter age or permanent deformation that mination considering chemical and would affect its structural integrity, a physical properties of the materials static internal fluid pressure of at least and must specify filler material con 36 psig, or cargo tank test pressure, forming to the requirements of the whichever is greater. The manhole as ASME Code (incorporated by reference; sembly manufacturer shall verify com see §171.7 of this subchapter). pliance with this requirement by (ii) Be preformed to an inside radius hydrostatically testing at least one no greater than the outside radius of percent (or one manhole closure, the cargo tank at the attachment loca whichever is greater) of all manhole tion. closures of each type produced each 3 months, as follows: (iii) Extend in at least 2 inches each (1) The manhole, fill opening, or direction from any point of attachment washout assembly must be tested with of an appurtenance or structural sup the venting devices blocked. Any leak port member. This dimension may be age or deformation that would affect measured from the center of the struc the product retention capability of the tural member attached. assembly shall constitute a failure. (iv) Have rounded corners, or other (2) If the manhole, fill opening, or wise be shaped in a manner to mini washout assembly tested fails, then mize stress concentrations on the shell five more covers from the same lot or head. must be tested. If one of these five cov (v) Be attached by continuous fillet ers fails, then all covers in the lot from welding. Any fillet weld discontinuity which the tested covers were selected may only be for the purpose of pre are to be 100% tested or rejected for venting an intersection between the fil service. let weld and the tank or jacket seam (c) Each manhole, filler and washout weld. cover must be fitted with a safety de vice that prevents the cover from open [Amdt. 178—89, 55 FR 37059, Sept. 7, 1990, as ing fully when internal pressure is amended by Amdt. 178-89, 56 FR 27876, June present. 59 FR 49135, Sept. 17, 1991; Amdt. 178—104, 26, (d) Each manhole and fill cover must Amdt. 178—105, 59 FR 55173, 55174 and 1994; be 55175, Nov. 3, 1994; 60 FR 17402, Apr. 5, 1995: secured with fastenings that will Amdt. 178—118, 61 FR 51341, Oct. 1, 1996; 65 FR prevent opening of the covers as a re 58631, Sept. 29, 2000; 68 FR 19283, Apr. 18, 2003: sult of vibration under normal trans 68 FR 75755, Dec. 31, 2003; 74 FR 16143, Apr. 9, portation conditions or shock impact 2009] due to a rollover accident on the road way or shoulder where the fill cover is § 178.345—4 Joints. not struck by a substantial obstacle. (a) All joints between the cargo tank Ce) On cargo tank motor vehicles shell, heads, baffles, baffle attaching manufactured after October 1, 2004, rings, and bulkheads must be welded in each manhole assembly must be per conformance with Section VIII of the manently marked on the outside by stamping ASME Code (IBR, see §171.7 of this sub or other means in a location chapter). visible without opening the manhole assembly or fill opening, with: all must (b) Where practical welds be (1) Manufacturer’s name; easily accessible for inspection. (2) Test pressure psig; [Amdt. 178—89, 54 FR 25022, June 12, 1989, as (3) A statement certifying that the amended by Amdt. 178-118, 61 FR 51341, Oct. manhole cover meets the requirements 1, 1996; 68 FR 75756, Dec. 31, 2003] in §178.345—5. 976 Pipeline and Hazardous Materials Safety Admin., DOT § 178.345—7

(f) All components mounted on a and tensile strength of the shell mate manhole cover that form part of the rial in combination with the frame and lading retention structure of the cargo reinforcement produces structural in tank wall must withstand the same tegrity at least equal to that pre static internal fluid pressure as that scribed in § 178.345—3 and in such a man required for the manhole cover. The ner that the maximum unreinforced component manufacturer shall verify portion of the shell does not exceed 60 compliance using the same test proce inches. For cargo tanks designed to be dure and frequency of testing as speci loaded by vacuum, spacing of circum fied in §178.345—5(b). ferential reinforcement may exceed 60 [Amdt. 178—89, 54 FR 25022, June 12, 1989, as inches provided the maximum amended by Amdt. 178—105, 59 FR 55175, Nov. unreinforced portion of the shell con 3, 1994; 68 FR 19284, Apr. 18, 2003; 74 FR 16144, forms with the requirements in Section Apr. 9, 20091 VIII of the ASME Code (IBR, see § 171.7 of this subchapter). § 178.345-6 Supports and anchoring. (2) Where circumferential joints are (a) A cargo tank with a frame not in made between conical shell sections, or tegral to the cargo tank must have the between conical and cylindrical shell tank secured by restraining devices to sections, and the angle between adja eliminate any motion between the cent sections is less than 160 degrees, tank and frame that may abrade the circumferential reinforcement must be tank shell due to the stopping, start located within one inch of the shell ing, or turning of the cargo tank motor joint, unless otherwise reinforced with vehicle. The design calculations of the structural members capable of main support elements must include the taining shell stress levels authorized in stresses indicated in § 178.345—3(b) and § 178.345—3. When the joint is formed by as generated by the loads described in the large ends of adjacent conical shell §178.345—3(c). Such restraining devices sections, or by the large end of a con must be readily accessible for inspec ical shell and a cylindrical shell sec tion and maintenance, except that in tion, this angle is measured inside the sulation and jacketing are permitted to shell; when the joint is formed by the cover the restraining devices. small end of a conical shell section and (b) A cargo tank designed and con a cylindrical shell section, it is meas structed so that it constitutes, in ured outside the shell. whole or in part, the structural mem (b) Except for doubler plates and ber used in lieu of a frame must be sup knuckle pads, no reinforcement may ported in such a manner that the re cover any circumferential joint. sulting stress levels in the cargo tank (c) When a baffle or baffle attach do not exceed those specified in ment ring is used as a circumferential § 178.345—3(a). The design calculations of reinforcement member, it must the support elements must include the produce structural integrity at least stresses indicated in § 178.345—3(b) and equal to that prescribed in § 178.345—3 as generated by the loads described in and must be circumferentially welded § 178.345—3(c). to the cargo tank shell. The welded lAmdt. 178—89, 54 FR 25023, June 12, 1989, as portion may not be less than 50 percent amended by Amdt. 178-105, 59 FR 55175, Nov. of the total circumference of the cargo 3, 1994; Amdt. 178—118, 61 FR 51341, Oct 1, tank and the length of any unwelded 19961 space on the joint may not exceed 40 times the shell thickness unless rein § 178.345—7 Circumferential reinforce forced external to the cargo tank. ments. (d) When a ring stiffener is used as a (a) A cargo tank with a shell thick circumferential reinforcement mem ness of less than /8 inch must be cir ber, whether internal or external, rein cumferentially reinforced with bulk forcement must be continuous around heads, baffles, ring stiffeners, or any the circumference of the cargo tank combination thereof, in addition to the shell and must be in accordance with cargo tank heads. the following: (1) Circumferential reinforcement (1) The section modulus about the must be located so that the thickness neutral axis of the ring section parallel 977 § 178.345—8 49 CFR Ch. 1(10—1—10 Edition) to the shell must be at least equal to § 178.345—8 Accident damage protec that derived from the applicable for tion. mula (a) General. Each cargo tank motor

I/C = 0.00027WL, for MS, HSLA and SS; vehicle must be designed and con or structed in accordance with the re I/C 0.000467WL, for aluminum alloys; quirements of this section and the ap plicable individual specification to Where; minimize the potential for the loss of I/C Section modulus in inches lading due to an accident. W = Tank width, or diameter, inches (1) Any dome, sump, or washout L Spacing of ring stiffener, inches; i.e., the maximum longitudinal distance from the cover plate projecting from the cargo midpoint of the unsupported shell on one tank wall that retains lading in any side of the ring stiffener to the midpoint of tank orientation, must be as strong the unsupported shell on the opposite side and tough as the cargo tank wall and of the ring stiffener. have a thickness at least equal to that specified by the appropriate cargo tank (2) If a ring stiffener is welded to the specification. Any such projection lo cargo tank shell, a portion of the shell cated in the lower ‘/3 of the tank cir may be considered as part of the ring cumference (or cross section perimeter section for purposes of computing the for non-circular cargo tanks) that ex ring section modulus. This portion of tends more than half its diameter at the shell may be used provided at least the point of attachment to the tank or 50 percent of the total circumference of more than 4 inches from the cargo tank the cargo tank is welded and the length wall, or located in the upper 2/3 of the of any unwelded space on the joint does tank circumference (or cross section not exceed 40 times the shell thickness. perimeter for non-circular cargo tanks) The maximum portion of the shell to that extends more than ‘/4 its diameter be used in these calculations is as fol or more than 2 inches from the point of lows: attachment to the tank must have ac Number of circum Shell sec cident damage protection devices that ferential ring stiffener- lion are: to-shell welds (i) As specified in this section; 1 201 (ii) 125 percent as strong as the other 2 Less than 20t 201+J wise required accident damage protec 2 201 or more 401 tion device; or 1 where: t=ShelI thickness, inches; (iii) Attached to the cargo tank in JLongitudinal distance belween parallel circumferential accordance with the requirements of ring stiffener-to-shell welds. paragraph (a) (3) of this section. (3) When used to meet the vacuum re (2) Outlets, valves, closures, piping, quirements of this section, ring stiff or any devices that if damaged in an eners must be as prescribed in Section accident could result in a loss of lading VIII of the ASME Code. from the cargo tank must be protected (4) If configuration of internal or ex by accident damage protection devices ternal ring stiffener encloses an air as specified in this section. space, this air space must be arranged (3) Accident damage protection de for venting and be equipped with drain vices attached to the wall of a cargo age facilities which must be kept oper tank must be able to withstand or de ative at all times. flect away from the cargo tank the (5) Hat shaped or open channel ring loads specified in this section. They stiffeners which prevent visual inspec must be designed, constructed and in tion of the cargo tank shell are prohib stalled so as to maximize the distribu ited on cargo tank motor vehicles con tion of loads to the cargo tank wall and structed of carbon steel. to minimize the possibility of ad versely affecting the lading retention [Amdt. 178—89, 55 FR 37060, Sept. 7, 1990, as integrity of the cargo tank. Accident amended by Amdt. 178-89, 56 FR 27876, June 17, 1991; 56 FR 46354, Sept. 11, 1991; Amdt. 178— induced stresses resulting from the ap 104, 59 FR 49135, Sept. 26, 1994; Amdt. 178—118, propriate accident damage protection 61 FR 51341, Oct. 1, 1996; 68 FR 75756, Dec. 31, device requirements in combination 2003] with the stresses from the cargo tank 978 Pipeline and Hazardous Materials Safety Admin., DOT § 178.345—8

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 2/3 be calculated at the gross vehicle of a cargo tank circumference (or cross weight rating of the cargo tank motor section perimeter for non-circular vehicle. tanks) must be protected by being lo (b) Each outlet, projection or piping cated within or between adjacent roll located in the lower ½ of the cargo over damage protection devices, or by tank circumference (or cross section being 125 percent of the strength that perimeter for non-circular cargo tanks) would be provided by the otherwise re that could be damaged in an accident quired damage protection device. that may result in the loss of lading (1) A rollover damage protection de must be protected by a bottom damage vice on a cargo tank motor vehicle protection device, except as provided must be designed and installed to with by paragraph (a) (1) of this section and stand loads equal to twice the weight § 173.33(e) of this subchapter. Outlets, of the loaded cargo tank motor vehicle projections and piping may be grouped applied as follows: normal to the cargo or clustered together and protected by tank shell (perpendicular to the cargo a single protection device. tank surface); and tangential (perpen (1) Any bottom damage protection dicular to the normal load) from any device must be able to withstand a direction. The stresses shall not exceed 979 § 178.345—9 49 CFR Ch. 1(10—1—10 Edition) the ultimate strength of the material tion device may not exceed 24 inches. A of construction. These design loads notched, indented, or separated rear- may be considered to be uniformly dis end protection device may be used only tributed and independently applied. If when the piping at the rear of the more than one rollover protection de cargo tank is equipped with a sacrifi vice is used, each device must be capa cial device outboard of a shut-off valve. ble of carrying its proportionate share (iii) The widest part of the motor ve of the required loads and in each case hicle at the rear may not extend more at least one-fourth the total tangential than 18 inches beyond the outermost load. The design must be proven capa ends of the device or (if separated) de ble of carrying the required loads by vices on either side of the vehicle. calculations, tests or a combination of (3) The structure of the rear-end pro tests and calculations. tection device and its attachment to (2) A rollover damage protection de the vehicle must be designed to satisfy vice that would otherwise allow the ac the conditions specified in paragraph cumulation of liquid on the top of the (d)(l) of this section when subjected to cargo tank, must be provided with a an impact of the cargo tank motor ve drain that directs the liquid to a safe hicle at rated payload, at a decelera point of discharge away from any tion of 2 ‘g”. Such impact must be structural component of the cargo considered as being uniformly applied tank motor vehicle. in the horizontal plane at an angle of (d) Rear-end tank protection. Each 10 degrees or less to the longitudinal cargo tank motor vehicle must be pro axis of the vehicle. vided with a rear-end tank protection (e) Longitudinal deceleration protec device to protect the cargo tank and tion. In order to account for stresses piping in the event of a rear-end colli due to longitudinal impact in an acci sion and reduce the likelihood of dam dent, the cargo tank shell and heads age that could result in the loss of lad must be able to withstand the load re ing. Nothing in this paragraph relieves sulting from the design pressure in the manufacturer of responsibility for combination with the dynamic pres complying with the requirements of sure resulting from a longitudinal de §393.86 of this title and, if applicable, celeration of 2 “g”. For this loading paragraph (b) of this section. The rear- condition, the allowable stress value end tank protection device must con used may not exceed the ultimate form to the following requirements: strength of the material of construc (1) The rear-end cargo tank protec tion using a safety factor of 1.3. Per tion device must be designed so that it formance testing, analytical methods, can deflect at least 6 inches hori or a combination thereof, may be used zontally forward with no contact be to prove this capability provided the tween any part of the cargo tank methods are accurate and verifiable. motor vehicle which contains lading For cargo tanks with internal baffles, during transit and with any part of the the decelerative force may be reduced rear-end protection device, or with a by 0.25 “g” for each baffle assembly, vertical plane passing through the out but in no case may the total reduction board surface of the protection device. in decelerative force exceed 1.0 “g”. (2) The dimensions of the rear-end [Amdt. 178—89, 54 FR 25023, June 12, 1989, as cargo tank protection device shall con amended at 55 FR 37061, Sept. 7. 1990: Amdt. form to the following: 178—105, 59 FR 55175, Nov. 3, 1994: Amdt. 178— (i) The bottom surface of the rear-end 118, 61 FR 51341, Oct. 1, 1996; 68 FR 19284, Apr. protection device must be at least 4 18, 2003] inches below the lower surface of any part at the rear of the cargo tank § 178.345—9 Pumps, piping, hoses and motor vehicle which contains lading connections. during transit and not more than 60 (a) Suitable means must be provided inches from the ground when the vehi during loading or unloading operations cle is empty. to ensure that pressure within a cargo (ii) The maximum width of a notch, tank does not exceed test pressure. indentation, or separation between sec (b) Each hose, piping, stop-valve, lad tions of a rear-end cargo tank protec ing retention fitting and closure must 980 Pipeline and Hazardous Materials Safety Admin., DOT § 178.345—10 be designed for a bursting pressure of (b) Type and construction of relief sys the greater of 100 psig or four times the tems and devices. (1) Each cargo tank MAWP. must be provided with a primary pres (c) Each hose coupling must be de sure relief system consisting of one or signed for a bursting pressure of the more reclosing pressure relief valves. A greater of 120 psig or 4.8 times the secondary pressure relief system con MAW? of the cargo tank, and must be sisting of another pressure relief valve designed so that there will be no leak in parallel with the primary pressure age when connected. relief system may be used to augment (d) Suitable provision must be made the total venting capacity of the cargo to allow for and prevent damage due to tank. Non-reclosing pressure relief de expansion, contraction, jarring, and vi vices are not authorized in any cargo bration. Slip joints may not be used for tank except when in series with a re this purpose in the lading retention closing pressure relief device. Gravity system. actuated reclosing valves are not au (e) Any heating device, when in thorized on any cargo tank. stalled, must be so constructed that (2) When provided by §l73.33(c)(l)(iii) the breaking of its external connec of this subchapter, cargo tanks may be tions will not cause leakage of the equipped with a normal vent. Such cargo tank lading. vents must be set to open at not less (f) Any gauging, loading or charging than 1 psig and must be designed to device, including associated valves, prevent loss of lading through the de must be provided with an adequate vice in case of vehicle overturn. means of secure closure to prevent (3) Each pressure relief system must leakage. be designed to withstand dynamic pres (g) The attachment and construction sure surges in excess of the design set of each loading/unloading or charging pressure as specified in paragraphs line must be of sufficient strength, or (b)(3) (i) and (ii) of this section. Set be protected by a sacrificial device, pressure is a function of MAW? as set such that any load applied by loading! forth in paragraph (d) of this section. unloading or charging lines connected (i) Each pressure relief device must to the cargo tank cannot cause damage be able to withstand dynamic pressure resulting in loss of lading from the surge reaching 30 psig above the design cargo tank. set pressure and sustained above the (Ii) Use of a nonmetallic pipe, valve set pressure for at least 60 milliseconds or connection that is not as strong and with a total volume of liquid released heat resistant as the cargo tank mate not exceeding one gallon before the re rial is authorized only if such attach lief device recloses to a leak-tight con ment is located outboard of the lading dition. This requirement must be met retention system. regardless of vehicle orientation. This [Amdt. 178—89, 54 FR 25025, June 12, 1989, as capability must be demonstrated by amended at 55 FR 37061. Sept. 7, 1990, Amdt. testing. An acceptable method is out 178—89, 56 FR 27877, June 17, 1991; Amdt. 178— lined in TTMA RP No. 81-97 “Perform 118, 61 FR 51341, Oct. 1, 19961 ance of Spring Loaded Pressure Relief Valves on MC 306, MC 307, MC 312, DOT 178.345—10 Pressure relief. § 406, DOT 407, and DOT 412 Tanks” (in (a) Each cargo tank must be equipped corporated by reference; see §171.7 of to relieve pressure and vacuum condi this subchapter). tions in conformance with this section (ii) After August 31, 1995, each pres and the applicable individual specifica sure relief device must be able to with tion. The pressure and vacuum relief stand a dynamic pressure surge reach system must be designed to operate ing 30 psig above the design set pres and have sufficient capacity to prevent sure and sustained above the design set cargo tank rupture or collapse due to pressure for at least 60 milliseconds over-pressurization or vacuum result with a total volume of liquid released ing from loading, unloading, or from not exceeding 1 L before the relief heating and cooling of lading. Pressure valve recloses to a leak-tight condi relief systems are not required to con tion. This requirement must be met re form to the ASME Code. gardless of vehicle orientation. This 981 § 178.345—10 49 CFR Ch. 1(10—1—10 Edition) capability must be demonstrated by sure to not more than the cargo tank testing. TTMA RP No. 81, cited in para test pressure. The total venting capac graph (b) (3) (i) of this section, is an ac 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 § 178.348—4. stalled in such a manner as to prevent unauthorized adjustment of the relief TABLE I—MINIMUM EMERGENCY VENT CAPACITY valve setting. [In cubic feel free air/hour at 60 F and I 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 40 31,600 be mounted, shielded and drainable so 50 39,500 as to minimize the accumulation of 60 47,400 material that could impair the oper 70 55,300 80 63,300 ation or discharge capability of the 90 71,200 system by freezing, corrosion or block 100 79,100 age. 120 94,900 140 110,700 (c) Location of relief devices. Each 160 126,500 pressure relief device must commu 180 142,300 nicate with the vapor space above the 200 158,100 225 191,300 lading as near as practicable to the 250 203,100 center of the vapor space. For example, 275 214,300 on a cargo tank designed to operate in 300 225,100 device should be 350 245,700 a level attitude, the 400 265,000 positioned at the horizontal and trans 450 283,200 verse center of the cargo tank; on 500 300,600 sloped to the rear, the de 550 317,300 cargo tanks 600 333,300 vice should be located in the forward 650 348,800 half of the cargo tank. The discharge 700 363,700 from any device must be unrestricted. 750 378,200 800 392,200 Protective devices which deflect the 850 405,900 flow of vapor are permissible provided 900 419,300 the required vent capacity is main 950 432,300 1,000 445,000 tained. (d) Settings of pressure relief system. NoTe 1: Interpolate for intermediate sizes. The set pressure of the pressure relief (1) Primary pressure relief system. Un system is the pressure at which it less otherwise specified in the applica starts to open, allowing discharge. ble individual specification, the pri (1) Primary pressure relief system. The mary relief system must have a min set pressure of each primary relief imum venting capacity of 12,000 SCFH valve must be no less than 120 percent per 350 square feet of exposed cargo of the MAWP, and no more than 132 tank area, but in any case at least one percent of the MAWP. The valve must fourth the required total venting ca reclose at not less than 108 percent of pacity for the cargo tank. the MAWP and remain closed at lower (2) Secondary pressure relief system. If pressures. the primary pressure relief system does (2) Secondary pressure relief system. not provide the required total venting The set pressure of each pressure relief capacity, additional capacity must be valve used as a secondary relief device provided by a secondary pressure relief must be not less than 120 percent of the system. MAWP. (f) Certification of pressure relief de (e) Venting capacity of pressure relief vices. The manufacturer of any pressure systems. The pressure relief system (pri relief device, including valves, fran mary and secondary, including piping) gible (rupture) disks, vacuum vents and must have sufficient venting capacity combination devices must certify that to limit the cargo tank internal pres the device model was designed and 982 Pipeline and Hazardous Materials Safety Admin., DOT § 17&345—1 1

tested in accordance with this section must be protected in accordance with and the appropriate cargo tank speci § 178.345—8. fication. The certificate must contain (b) Each cargo tank loading/unload sufficient information to describe the ing outlet must be equipped with an in device and its performance. The certifi ternal self-closing stop-valve, or alter cate must be signed by a responsible of natively, with an external stop-valve ficial of the manufacturer who ap located as close as practicable to the proved the flow capacity certification. cargo tank wall. Each cargo tank load (g) Rated flow capacity certification ing/unloading outlet must be in accord test. Each pressure relief device model ance with the following provisions: must be successfully flow capacity cer (1) Each loading/unloading outlet tification tested prior to first use. De must be fitted with a self-closing sys vices having one design, size and set tem capable of closing all such outlets pressure are considered to be one in an emergency within 30 seconds of model. The testing requirements are as actuation. During normal operations follows: the outlets may be closed manually. (1) At least 3 devices of each specific The self-closing system must be de model must be tested for flow capacity signed according to the following: at a pressure not greater than the test (1) Each self-closing system must in pressure of the cargo tank. For a de clude a remotely actuated means of vice model to be certified, the capac closure located more than 10 feet from ities of the devices tested must fall the loading/unloading outlet where ve within a range of plus or minus 5 per hicle length allows, or on the end of cent of the average for the devices test the cargo tank farthest away from the ed. loading/unloading outlet. The actu (2) The rated flow capacity of a de ating mechanism must be corrosion-re vice model may not be greater than 90 sistant and effective in all types of en percent of the average value for the de vironment and weather. vices tested. (ii) If the actuating system is acci (3) The rated flow capacity derived dentally damaged or sheared off during for each device model must be certified transportation, each loading/unloading by a responsible official of the device outlet must remain securely closed and manufacturer. capable of retaining lading. (h) Marking of pressure relief devices. (iii) When required by part 173 of this Each pressure relief device must be subchapter for materials which are permanently marked with the fol flammable, pyrophoric, oxidizing, or lowing: Division 6.1 (poisonous liquid) mate (1) Manufacturer’s name; rials, the remote means of closure (2) Model number; must be capable of thermal activation. (3) Set pressure, in psig; and The means by which the self-closing (4) Rated flow capacity, in SCFH at system is thermally activated must be the rating pressure, in psig. located as close as practicable to the primary loading/unloading connection [Amdt. 178—89, 54 FR 25025, June 12, 1989, as and must amended at 55 FR 21038. May 22, 1990; 55 FR actuate the system at a tem 37062, Sept. 7, 1990: Amdt. 178—89, 56 FR 27877, perature not over 250 °F. In addition, June 17, 1991; Amdt. 178—105, 59 FR 55175, Nov. outlets on these cargo tanks must be 3, 1994; Amdt. 178—118, 61 FR 51341, Oct. 1, capable of being remotely closed manu 1996; 65 FR 58631, Sept. 29. 2000; 66 FR 45389, ally or mechanically. Aug. 28, 2001; 68 FR 19284, Apr. 18, 20031 (2) Bottom loading outlets which dis charge lading into the cargo tank 178.345—11 Tank outlets. § through fixed internal piping above the (a) General. As used in this section, maximum liquid level of the cargo ‘loading/unloading outlet” means any tank need not be equipped with a self opening in the cargo tank wall used for closing system. loading or unloading of lading, as dis (c) Any loading/unloading outlet ex tinguished from outlets such as man tending beyond an internal self-closing hole covers, vents, vapor recovery de stop-valve, or beyond the innermost ex vices, and similar closures. Cargo tank ternal stop-valve which is part of a outlets, closures and associated piping self-closing system, must be fitted with 983 § 17&345—12 49 CFR Ch. I (10—1—10 Edition) another stop-valve or other leak-tight scribed in the applicable specification. closure at the end of such connection. The pressure must be gauged at the top (d) Each cargo tank outlet that is not of the cargo tank. The prescribed test a loading/unloading outlet must be pressure must be maintained for at equipped with a stop-valve or other least 10 minutes during which time the leak-tight closure located as close as cargo tank must be inspected for leak practicable to the cargo tank outlet. age, bulging, or other defect. Any connection extending beyond this (2) Pneumatic method. A pneumatic closure must be fitted with another test may be used in place of the hydro stop-valve or other leak-tight closure static test. However, pneumatic pres at the end of such connection. sure testing may involve higher risk [Amdt. 178—89, 56 FR 27877, June 17, 1991, as than hydrostatic testing. Therefore, amended by Amdt. 178—97, 57 FR 45465, Oct. 1, suitable safeguards must be provided to 1992; Amdt. 178—118, 61 FR 51341, Oct. 1, 1996] protect personnel and facilities should failure occur during the test. The cargo § 178.345-12 Gauging devices. tank must be pressurized with air or an Each cargo tank, except a cargo tank inert gas. Test pressure must be intended to be filled by weight, must be reached gradually by increasing the equipped with a gauging device that 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 liquid level. Gauge glasses are not per pressure is reached. Test pressure must mitted. be held for at least 5 minutes. The pres sure must then be reduced to the in [Amdt. 178—89, 55 FR 37062, Sept. 7, 1990, as spection pressure which must be main amended by Amdt. 178-118, 61 FR 51342, Oct. 1, 1996] tained while the entire cargo tank sur face is inspected for leakage and other § 178.345—13 Pressure and leakage sign of defects. The inspection method tests. must consist of coating all joints and (a) Each cargo tank must be pressure fittings with a solution of soap and and leakage tested in accordance with water or other equally sensitive meth this section and § 178.346—5, 178.347—5, or od. 178.348—5. (c) Leakage test. The cargo tank with (b) Pressure test. Each cargo tank or all its accessories in place and operable cargo tank compartment must be test must be leak tested at not less than 80 ed hydrostatically or pneumatically. percent of tank’s MAWP with the pres Each cargo tank of a multi-cargo tank sure maintained for at least 5 minutes. motor vehicle must be tested with the (d) Any cargo tank that leaks, bulges adjacent cargo tanks empty and at at or shows any other sign of defect must mospheric pressure. Each closure, ex be rejected. Rejected cargo tanks must cept pressure relief devices and load be suitably repaired and retested suc ing/unloading venting devices rated at cessfully prior to being returned to less than the prescribed test pressure, service. The retest after any repair must be in place during the test. If the must use the same method of test venting device is not removed during under which the cargo tank was origi the test, such device must be rendered nally rejected. inoperative by a clamp, plug or other [Amdt. 178—89, 54 FR 25026, June 12, 1989, as equally effective restraining device, amended at 55 FR 37063, Sept. 7, 1990; Amdt. which may not prevent the detection of 178—105, 59 FR 55176, Nov. 3, 1994; Amdt. 178— leaks, or damage the device. Restrain 118, 61 FR 51342, Oct. 1, 1996; 65 FR 58631, ing devices must be removed imme Sept. 29, 2000; 68 FR 19284, Apr. 18, 2003] diately after the test is completed. (1) Hydrostatic method. Each cargo § 178.345—14 Marking. tank, including its domes, must be (a) General. The manufacturer shall filled with water or other liquid having certify that each cargo tank motor ve similar viscosity, the temperature of hicle has been designed, constructed which may not exceed 100 °F. The cargo and tested in accordance with the ap tank must then be pressurized as pre plicable Specification DOT 406, DOT 407 984 Pipeline and Hazardous Materials Safety Admin., DOT § 178.345—14 or DOT 412 (5 178.345, 178.346, 178.347, is replaced by the alloy designation 178.348) cargo tank requirements and, and “***“ by the alloy type. when applicable, with Section VIII of (9) Material specification number— the ASME Code (IBR, see §171.7 of this heads (Head matl, yyy***), where subchapter). The certification shall be “yyy” is replaced by the alloy designa accomplished by marking the cargo tion and “**“ by the alloy type. tank as prescribed in paragraphs (b) NOTE: When the shell and heads materials and (c) of this section, and by pre are the same thickness, they may be com paring the certificate prescribed in bined, (Shell&head matl, yyy**). § 178.345—15. Metal plates prescribed by (10) Weld material (Weld paragraphs (b), (c), (d) and (e) of this matl.). (11) Minimum thickness—shell section, must be permanently attached (Mm. 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 —, side or other suitable means. These plates bottom —, in inches). must be affixed on the left side of the (12) Minimum thickness—heads (Mm. vehicle near the front of the cargo tank heads thick.), in inches. (or the frontmost cargo tank of a (13) Manufactured thickness—shell multi-cargo tank motor vehicle), in a (Mfd. shell thick.), top —, side —, bot place readily accessible for inspection. tom —, 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.) ing. embossing or other means in char (14) Manufactured thickness—heads 3/ acters at least inch high. The infor (Mfd. heads thick.), in inches. (Re mation required by paragraphs (b) and quired when additional thickness is (c) of this section may be combined on provided for corrosion allowance.) one specification plate. (15) Exposed surface area, in square (b) Nameplate. Each cargo tank must feet. have a corrosion resistant nameplate (c) Specification plate. Each cargo permanently attached to it. The fol tank motor vehicle must have an addi lowing information, in addition to any tional corrosion resistant metal speci applicable information required by the fication plate attached to it. The speci ASME Code, must be marked on the fication plate must contain the fol tank nameplate (parenthetical abbre lowing information (parenthetical ab viations may be used): breviations may be used): (1) DOT-specification number DOT (1) Cargo tank motor vehicle manu XXX (DOT XXX) where ‘XXX” is re facturer (CTMV mfr.). placed with the applicable specification (2) Cargo tank motor vehicle certifi number. For cargo tanks having a vari cation date (CTMV cert. date), if dif able specification plate, the DOT-speci ferent from the cargo tank certifi fication number is replaced with the cation date. words “See variable specification (3) Cargo tank manufacturer (CT plate.” mfr.). (2) Original test date, month and (4) Cargo tank date of manufacture year (Orig. Test Date). (CT date of mfr.), month and year. (3) Tank MAWP in psig. (5) Maximum weight of lading (Max. Payload), in pounds. (4) Cargo tank test pressure (Test P), (6) Maximum in psig. loading rate in gallons per minute (Max. Load rate, GPM). (5) Cargo tank design temperature (7) Maximum unloading rate in gal range (Design temp. range),_ — °F to lons per minute (Max. Unload rate). °F. (8) Lining material (Lining), if appli (6) Nominal capacity (Water cap.), in cable. gallons. (9) Heating system design pressure (7) Maximum design density of lading (Heating sys. press.), in psig, if applica (Max. lading density), in pounds per ble: gallon. (10) Heating system design tempera (8) Material specification number— ture (Heating sys. temp.), in °F, if ap shell (Shell matl, yyy***), where “yyy” plicable. 985 ______

§ 178.345—15 49 CFR Ch. 1(10—1—10 Edition) (d) Multi-cargo tank motor vehicle. For equipped, the word “None” must be in a multi-cargo tank motor vehicle hav serted. ing all its cargo tanks not separated by (3) Those parts to be changed or any void, the information required by added must be stamped with the appro paragraphs (b) and (c) of this section priate MC or DOT Specification mark may be combined on one specification ings. plate. When separated by a void, each (4) The alterations that must be cargo tank must have an individual made in order for the tank to be modi nameplate as required in paragraph (b) fied from one specification to another of this section, unless all cargo tanks must be clearly indicated on the manu are made by the same manufacturer facturer’s certificate and on the vari with the same materials, manufactured able specification plate. thickness, minimum thickness and to [Amdt. 178—89, 54 FR 25027, June 12, 1989, as the same specification. The cargo tank amended at 55 FR 37063. Sept. 7, 1990; Amdt. motor vehicle may have a combined 178—99, 58 FR 51534, Oct. 1, 1993; Amdt. 178—104, nameplate and specification plate. 59 FR 49135, Sept. 26, 1994; Amdt. 178—105, 59 When only one plate is used, the plate FR 55176, Nov. 3, 1994; 60 FR 17402, Apr. 5, must be visible and not covered by in 1995; Amdt. 178-118, 61 FR 51342, Oct. 1, 1996; 66 FR 45389, Aug. 28, 18, The required information 2001; 68 FR 19284, Apr. sulation. 2003; 68 FR 52371, Sept. 3, 2003; 68 FR 75756, must be listed on the plate from front Dec. 31, 2003] to rear in the order of the cor responding cargo tank location. § 178.345—15 Certification. (e) Variable specification cargo tank. (a) At or before the time of delivery, Each variable specification cargo tank the manufacturer of a cargo tank must have a corrosion resistant metal motor vehicle must provide certifi variable specification plate attached to cation documents to the owner of the it. The mounting of this variable speci cargo tank motor vehicle. The registra fication plate must be such that only tion numbers of the manufacturer, the the plate identifying the applicable Design Certifying Engineer, and the specification under which the tank is Registered Inspector, as appropriate, being operated is legible. must appear on the certificates (see (1) The following information must subpart F, part 107 in subchapter A of be included (parenthetical abbrevia this chapter). tions are authorized): (b) The manufacturer of a cargo tank Specification DOT XXX (DOT XXX). where motor vehicle made to any of these ‘XXX” is replaced with the applicable speci specifications must provide: fication number. (I) For each design type, a certificate signed by a responsible official of the Required manufacturer and a Design Certifying Equipment required rating Engineer certifying that the cargo Pressure relief devices: tank motor vehicle design meets the Pressure actuated applicable specification; and type. (2) For each ASME cargo tank, a Frangible type cargo tank manufacturer’s data report Lading discharge de as required by Section VIII of the vices. ASME Code (IBR, see §171.7 of this sub Top chapter). For each cargo tank motor Bottom Pressure unloading vehicle, a certificate signed by a re fitting. sponsible official of the manufacturer Closures: and a Registered Inspector certifying

Manhole that the cargo tank motor vehicle is Fill openings constructed, tested and completed in Discharge openings conformance with the applicable speci 1 Required rating—to meet the applicable fication. specification. (c) The manufacturer of a variable (2) If no change of information in the specification cargo tank motor vehicle specification plate is required, the let must provide: ters “NC” must follow the rating re (1) For each design type, a certificate quired. If the cargo tank is not so signed by a responsible official of the

986 Pipeline and Hazardous Materials Safety Admin., DOT § 178.346—1

manufacturer and a Design Certifying date and person (manufacturer, carrier, Engineer certifying that the cargo or repair organization) accomplishing tank motor vehicle design meets the the compliance. applicable specifications; and lAmdt. 178—89, 55 FR 37063, Sept. 7, 1990, as (2) For each variable specification amended by Arndt. 178-98, 58 FR 33306, June cargo tank motor vehicle, a certificate 16, 1993; Amdt. 178—105, 59 FR 55176, Nov. 3, signed by a responsible official of the 1994; Amdt. 178-118, 61 FR 51342, Oct. 1, 1996; manufacturer and a Registered Inspec 68 FR 75756, Dec. 31, 20031 tor certifying that the cargo tank motor vehicle is constructed, tested § 178.346 Specification DOT 406; cargo and completed in conformance with the tank motor vehicle. applicable specifications. The certifi § 178.346—1 General requirements. cate must include all the information required and marked on the variable (a) Each Specification DOT 406 cargo specification plate. tank motor vehicle must meet the gen (d) In the case of a cargo tank motor eral design and construction require vehicle manufactured in two or more ments in §178.345, in addition to the stages, each manufacturer who per specific requirements contained in this forms a manufacturing operation on section. the incomplete vehicle or portion (b) MAWP: The MAWP of each cargo tank must thereof shall provide to the succeeding be no lower than 2.65 psig and no higher manufacturer, at or before the time of than 4 psig. (c) Vacuum loaded cargo delivery, a certificate covering the par tanks must not be constructed to this ticular operation performed by that specifica tion. manufacturer, including any certifi (d) Each cargo tank must cates received from previous manufac be “con structed in accordance with Section turers, Registered Inspectors, and De VIII of the ASME Code” (IBR, sign Certifying Engineers. Each certifi see 171.7 of this subchapter) except must portion § as cate indicate the of the modified herein: complete cargo tank motor vehicle rep (1) The record-keeping requirements resented thereby, such as basic cargo contained in the ASME Code Section fabrication, tank insulation, jacket, VIII do not apply. Parts UG-90 through lining, or final piping. The manufac 94 in Section VIII do not apply. Inspec shall provide turer all applicable cer tion and certification must be made by tificates to the owner. an inspector registered in accordance (e) Specification shortages. If a cargo with subpart F of part 107. tank is manufactured which does not (2) Loadings must be as prescribed in meet all applicable specification re § 178.345—3. quirements, thereby requiring subse (3) The knuckle radius of flanged quent manufacturing involving the in heads must be at least three times the stallation of additional components, material thickness, and in no case less parts, appurtenances or accessories, than 0.5 inch. Stuffed (inserted) heads the cargo tank manufacturer may affix may be attached to the shell by a fillet the name plate and specification plate, weld. The knuckle radius and dish ra as required by §178.345-14 (b) and (c), dius versus diameter limitations of without the original date of certifi UG-32 do not apply. Shell sections of cation stamped on the specification cargo tanks designed with a non-cir plate. The manufacturer shall state the cular cross section need not be given a specification requirements not com preliminary curvature, as prescribed in plied with on the manufacturer’s Cer UG-79(b). tificate of Compliance. When the cargo (4) Marking, certification, data re tank is brought into full compliance ports, and nameplates must be as pre with the applicable specification, the scribed in § 178.345—14 and 178.345—15. Registered Inspector shall stamp the (5) Manhole closure assemblies must date of compliance on the specification conform to § 178.345—5 and 178.346—5. plate. The Registered Inspector shall (6) Pressure relief devices must be as issue a Certificate of Compliance stat prescribed in § 178.34 6—3. ing details of the particular operations (7) The hydrostatic or pneumatic test performed on the cargo tank, and the must be as prescribed in § 178.346—5. 987 § 178.346—2 49 CFR Ch. I (10—1—10 Edition)

(8) The following paragraphs in parts tests are completed. Before welding, UG and UW in Section VIII of the the fit-up of the joints on the test ASME Code do not apply: UG-il, UG specimens must represent production 12, UG—22(g), UG—32(e), UG—34, UG—35, conditions that would result in the UG-44, UG-76, UG—77, UG-80, UG-81, least joint strength. Evidence of joint UG—96, UG—97, UW—l3(b)(2), UW—l3.l(f) fit-up and test results must be retained and the dimensional requirements at the manufacturers’ facility. found in Figure UW-l3.l. (iv) Weld joint efficiency. The lower (9) Single full fillet lap joints with value of stress at failure attained in out plug welds may be used for arc or the two tensile test specimens shall be gas welded longitudinal seams without used to compute the efficiency of the radiographic examination under the joint as follows: Determine the failure following conditions: ratio by dividing the stress at failure (i) For a truck-mounted cargo tank, by the mechanical properties of the ad no more than two such joints may be jacent metal; this value, when multi used on the top half of the tank and no plied by 0.75, is the design weld joint ef more than two joints may be used on ficiency. the bottom half. They may not be lo (10) The requirements paragraph cated farther from the top and bottom of centerline than 16 percent of the shell’s UW-9(d) in Section VIII of the ASME circumference. Code do not apply. (ii) For a self-supporting cargo tank, [Amdt. 178—89, 54 FR 25028, June 12, 1989, as no more than two such joints may be amended at 55 FR 37063, Sept. 7, 1990; Amdt. used on the top of the tank. They may 178—89, 56 FR 27877, June 17, 1991; Amdt. 178— not be located farther from the top 105, 59 FR 55176, Nov. 3, 1994; 65 FR 58631, centerline than 12.5 percent of the Sept. 29, 2000; 66 FR 45387, Aug. 28, 2001: 68 FR shell’s circumference. 19285, Apr. 18. 2003; 68 FR 75756, Dec. 31, 20031 (iii) Compliance test. Two test speci material to be used in the § 178.346—2 Material and thickness of mens of the material. manufacture of a cargo tank must be tested to failure in tension. The test The type and thickness of material specimens must be of the same for DOT 406 specification cargo tanks thicknesses and joint configuration as must conform to §178.345—2, but in no the cargo tank, and joined by the same case may the thickness be less than welding procedures. The test specimens that determined by the minimum may represent all the tanks that are thickness requirements in § 178.320(a). made of the same materials and weld The following Tables I and II identify ing procedures, have the same joint the specified minimum thickness val configuration, and are made in the ues to be employed in that determina same facility within 6 months after the tion. TABLE I—SPECIFIED MINIMUM THIcKNEss OF HEADS (OR BULKHEADS AND BAFFLES WHEN USED AS TANK REINFORCEMENT) USING MILD STEEL (MS), HIGH STRENGTH Low ALLOY STEEL (HSLA), AUSTENITIC STAINLESS STEEL (SS), OR ALUMINUM (AL)—ExPRESSED IN DECIMALS OF AN INCH AFTER FORMING

Over 23 HSLA I MS AL

.129 .129 .187

TABLE Il—SPECIFIED MINIMUM THICKNESS OF SHELL USING MILD STEEL (MS), HIGH STRENGTH Low ALLOY STEEL (HSLA), AUSTENITIC STAINLESS STEEL (SS), OR ALUMINUM (AL)—ExPRESSED IN DECIMALS OF AN INCH AFTER FORMING1

Cargo tank motor vehicle rated capacity (gallons) MS SS/HSLA AL

More than 0 to at least 4,500 0.100 0.100 0.151 More than 4,500 to at least 8,000 0.115 0.100 0.160

988 Pipeline and Hazardous Materials Safety Admin., DOT § 178.346—4

TABLE Il—SPECIFIED MINIMUM THIcKNEss OF SHELL USING MILD STEEL (MS), HIGH STRENGTH Low ALLOY STEEL (HSLA), Au5TENITIc STAINLESS STEEL (SS), OR ALUMINUM (AL)—ExPRESSED IN DECIMALS OF AN INCH AFTER FORMING 1—Continued

Cargo tank motor vehicle rated capacity (gallons) MS SS/HSLA AL More than 8,000 to at least 14,000 0.129 0.129 0.173 More than 14000 0.143 0.143 0.187 Maximum distance between bulkheads, baffles, or ring stiffeners shall not exceed 60 inches.

[Amdt. 178—89, 54 FR 25028, June 12, 1989, as amended at 55 FR 37064, Sept. 7, 1990; Amdt. 178— 105, 59 FR 55176, Nov. 3, 1994; 68 FR 19285, Apr. 18, 2003]

§ 178.346—3 Pressure relief. (2) Each vacuum relief device must (a) Each cargo tank must be equipped be set to open at no more than 6 ounces with a pressure relief system in accord vacuum. ance with § 178.345—10 and this section. (d) Venting capacities. (1) Notwith (b) Type and construction. In addition standing the requirements in § 178.345— to the pressure relief devices required 10 (e) and (g), the primary pressure re in § 178.345—10; lief valve must have a venting capacity (1) Each cargo tank must be equipped of at least 6,000 SCFH, rated at not with one or more vacuum relief de greater than 125 percent of the tank vices; test pressure and not greater than 3 (2) When intended for use only for psig above the MAWP. The venting ca lading meeting the requirements of pacity required in § 178.345—10(e) may be §173.33(c)(1)(iii) of this subchapter, the rated at these same pressures. cargo tank may be equipped with a (2) Each vacuum relief system must normal vent. must Such vents be set to have sufficient capacity to limit the 1 open at not less than psig and must vacuum to 1 psig. be designed to prevent loss of lading (3) If pressure loading through the device in case of vehicle or unloading upset; and devices are provided, the relief system (3) Notwithstanding the requirements must have adequate vapor and liquid in § 178.345—10(b), after August 31, 1996, capacity to limit the tank pressure to each pressure relief valve must be able the cargo tank test pressure at max to withstand a dynamic pressure surge imum loading or unloading rate. The reaching 30 psig above the design set maximum loading and unloading rates pressure and sustained above the set must be included on the metal speci pressure for at least 60 milliseconds fication plate. with a total volume of liquid released [Amdt. 178—89, 54 FR 25029, June 12, 1989, as not exceeding before the I L relief amended at 55 FR 37064, Sept. 7, 1990; Amdt. valve recloses to a leak-tight condi 178—105, 59 FR 55176, Nov. 3, 1994. Redesig tion. This requirement must be met re nated by Amdt. 178—112, 61 FR 18934. Apr. 29, gardless of vehicle orientation. This 1996; 66 FR 45389, Aug. 28, 2001; 68 FR 75756. capability must be demonstrated by Dec. 31, 2003] testing. TTMA RP No. 81 (IBR, see §171.7 of this subchapter), cited at § 178.346—4 Outlets. 178.345—10(b) (3) acceptable § (i), is an test (a) All outlets on each tank must procedure. conform to 178.345—11 and this section. (c) Pressure settings of relief valves. (1) § (b) External self-closing stop-valves Notwithstanding the requirements in are not authorized § 178.345—10(d), the set pressure of each as an alternative to primary relief valve must be not less internal self-closing stop-valves on than 110 percent of the MAWP or 3.3 loading/unloading outlets. psig, whichever is greater, and not [Amdt. 178—89, 54 FR 25029, June 12, 1989. Re more than 138 percent of the MAWP. designated by Amdt. 178-112, 61 FR 18934, The valve must close at not less than Apr. 29, 19961 the MAWP and remain closed at lower pressures.

989 § 178.346—5 49 CFR Ch. I (10—1—10 Edition)

§ 178.346—5 Pressure and leakage tests. of this subchapter). The external de (a) Each cargo tank must be tested in sign pressure for a cargo tank loaded accordance with §178.345-13 and this by vacuum must be at least 15 psi. section. (d) Each cargo tank built to this (b) Pressure test. Test pressure must specification with MAWP of 35 psig or be as follows: less must be “constructed in accord (1) Using the hydrostatic test meth ance with Section VIII of the ASME od, the test pressure must be the great Code” except as modified. er of 5.0 psig or 1.5 times the cargo (1) The record-keeping requirements tank MAWP. contained in Section VIII of the ASME (2) Using the pneumatic test method, Code do not apply. The inspection re the test pressure must be the greater of quirements of parts UG—90 through 94 5.0 psig or 1.5 times the cargo tank do not apply. Inspection and certifi MAWP, and the inspection pressure cation must be made by an inspector must be the cargo tank MAWP. registered in accordance with subpart (c) Leakage test. A cargo tank used to F of part 107. transport a petroleum distillate fuel (2) Loadings must be as prescribed in that is equipped with vapor recovery § 178.345—3. equipment may be leakage tested in (3) The knuckle radius of flanged accordance with 40 CFR 63.425(e). To heads must be at least three times the satisfy the leakage test requirements material thickness, and in no case less of this paragraph, the test specified in than 0.5 inch. Stuffed (inserted) heads 40 CFR 63.425(e)(l) must be conducted may be attached to the shell by a fillet using air. The hydrostatic test alter weld. The knuckle radius and dish ra native permitted under Appendix A to dius versus diameter limitations of 40 CFR Part 60 (“Method 27—Deter UG-32 do not apply for cargo tank mination of Vapor Tightness of Gaso motor vehicles with a MAWP of 35 psig line Delivery Tank Using Pressure- or less. Vacuum Test”) may not be used to sat (4) Marking, certification, data re isfy the leakage test requirements of ports and nameplates must be as pre this paragraph. A cargo tank tested in scribed in § 178.345—14 and 178.345—15. accordance with 40 CFR 63.425(e) may (5) Manhole closure assemblies must be marked as specified in §180.415 of conform to § 178.347—3. this subchapter. (6) Pressure relief devices must be as prescribed in § 178.347—4. [Amdt. 178—89, 54 FR 25029, June 12, 1989, as (7) The hydrostatic or pneumatic test amended at 55 FR 37064, Sept. 7. 1990: Amdt. must be as prescribed in § 178.347—5. 178—105, 59 FR 55176, Nov. 3, 1994. Redesig (8) The following nated by Amdt. 178—112, 61 FR 18934, Apr. 29, paragraphs in parts 1996: 68 FR 19285, Apr. 18, 2003] UG and UW in Section VIII the ASME Code do not apply: UG-Il, UG-l2, UG § 178.347 Specification DOT 407; cargo 22(g), UG—32(e), UG—34, UG—35, UG—44, tank motor vehicle. UG-76, UG-77, UG-80, UG-8l, UG-96, UG—97, UW—l2, UW—13(b)(2), UW—13.l(f), § 178.347—1 General requirements. and the dimensional requirements (a) Each specification DOT 407 cargo found in Figure UW-13.l. tank motor vehicle must conform to (9) The strength of a weld seam in a the general design and construction re bulkhead that has not been radio- quirements in § 178.345 in addition to graphically examined shall be 0.85 of the specific requirements contained in the strength of the bulkhead under the this section. following conditions: (b) Each tank must be of a circular (i) The welded seam must be a full cross-section and have an MAWP of at penetration butt weld. least 25 psig. (ii) No more than one seam may be (c) Any cargo tank built to this spec used per bulkhead. ification with a MAWP greater than 35 (iii) The welded seam must be com psig and each tank designed to be load pleted before forming the dish radius ed by vacuum must be constructed and and knuckle radius. certified in conformance with Section (iv) Compliance test: Two test speci VIII of the ASME Code (IBR, see §171.7 mens of materials representative of 990 Pipeline and Hazardous Materials Safety Admin., DOT § 178.347—3 those to be used in the manufacture of cent material of all samples of a test a cargo tank bulkhead must be tested lot must be greater than 0.85. to failure in tension. The test specimen [Amdt. 178—89. 54 FR 25029, June 12, 1989, must be of the same thickness and as amended at 55 FR 37064, Sept. 7, 1990; Amdt. joined by the same welding procedure. 178—89, 56 FR 27877, June 17, 1991; 65 FR 58632, The test specimens may represent all Sept. 29, 2000: 66 FR 45387, Aug. 28, 2001: 68 FR the tanks that are made in the same 19285, Apr. 18, 2003; 68 FR 75756, Dec. 31, 2003] facility within 6 months after the tests are completed. Before welding, the fit § 178.347—2 Material and thickness of up of the joints on the test specimens material. must represent production conditions (a) The type and thickness of mate that would result in the least joint rial for DOT 407 specification cargo strength. Evidence of joint fit-up and tanks must conform to § 178.345—2, but test results must be retained at the in no case may the thickness be less manufacturers’ facility for at least 5 than that determined by the minimum years. thickness requirements in §178.320(a). (v) Acceptance criteria: The ratio of Tables I and II identify the specified the actual tensile stress at failure to minimum thickness values to be em the actual tensile strength of the adja ployed in that the determination:

TABLE I—SPECIFIED MINIMUM THICKNESS OF HEADs (OR BULKHEADS AND BAFFLES WHEN USED AS TANK REINFORCEMENT) USING MILD STEEL (MS), HIGH STRENGTH Low ALLOY STEEL (HSLA), AUsTENITIC STAINLESS STEEL (SS), OR ALUMINUM (AL)—ExPREsSED IN DECIMALS OF AN INCH AFTER FORMING

1Oor O1ve0 O,e4 Ove2 Volume capacity in gallons per inch Ove8 Ove026 Over 30

Thickness (M5) 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 (S5) 0.100 0.100 0.115 0.129 0.129 0.143 0.156 Thickness (AL) 0.160 0.160 0.173 0.187 0.194 0.216 0.237

TABLE Il—SPECIFIED MINIMUM THICKNESS OF SHELL USING MILD STEEL (MS), HIGH STRENGTH Low ALLOY STEEL (HSLA), AuSTENITIC STAINLESS STEEL (SS), OR ALUMINUM (AL)—ExPRESSED IN DECIMALS OF AN INCH AFTER FORMING

O1ve;,0 O1ve;4 Ove8 ove622jveo26 Volume capacity in gallons per inch Over 30

Thickness (MS) 0.100 0.100 0.115 0.129 0.129 0.143 0.156 Thickness (HSLA) 0.100 0.100 0.115 0.129 0.129 0.143 0.156 Thickness (SS) 0.100 0.100 0.115 0.129 0.129 0.143 0.156 Thickness (AL) 0.151 0.151 0.160 0.173 0.194 0.216 0.237

(b) [Reserved]

[Amdt. 178—89, 54 FR 25030, June 12, 1989, as amended at 55 FR 37064, Sept. 7. 1990; Amdt. 178— 104. 59 FR 49135, Sept. 26, 1994; 68 FR 19285, Apr. 18, 2003]

§ 178.347—3 Manhole assemblies. 40 psig or test pressure of the tank, whichever Each manhole assembly must con is greater. form to § 178.345—5, except that each [Amdt. 178—89, 54 FR 25030, June 12, 1989. Re manhole assembly must be capable of designated by Amdt. 178-112. 61 FR 18934, withstanding internal fluid pressures of Apr. 29, 1996]

991 § 178.347—4 49 CFR Ch. 1(10—1—10 Edition)

§ 178.347—4 Pressure relief. the specific requirements of this sec tion. (a) Each cargo tank must be equipped (b) The MAWP of each cargo tank with a pressure and vacuum relief sys must be at least 5 psig. tem in accordance with §178.345-10 and (c) The MAWP for each cargo tank this section. designed to be loaded by vacuum must (b) Type and Construction. Vacuum re be at least 25 psig internal and 15 psig lief devices are not required for cargo external. tanks designed to be loaded by vacuum (d) Each cargo tank having a MAWP or built to withstand full vacuum. greater than 15 psig must be of circular settings relief valves. (c) Pressure of cross-section. setting of pressure relief valves The (e) Each cargo tank having a— must be in accordance with 178.345— § (1) MAWP greater than 15 psig must 10(d). be “constructed and certified in con capacities. (1) The vacuum (d) Venting formance with Section VIII of the relief system must limit the vacuum to ASME Code” (IBR, see §171.7 of this less than 80 percent of the design vacu subchapter): or of the cargo tank. um capability (2) MAWP of 15 psig or less must be (2) If pressure loading or unloading “constructed in accordance with Sec devices are provided, the relief system tion VIII of the ASME Code,” except as must have adequate vapor and liquid modified herein: capacity to limit the tank pressure to (i) The recordkeeping requirements the cargo tank test pressure at max contained in Section VIII of the ASME imum loading or unloading rate. The Code do not apply. Parts UG-90 maximum loading or unloading rate through 94 in Section VIII do not must be included on the metal speci apply. Inspection and certification fication plate. must be made by an inspector reg [Amdt. 178—89, 54 FR 25030, June 12, 1989, as istered in accordance with subpart F of amended at 55 FR 37064, Sept. 7, 1990. Redes part 107. ignated by Amdt. 178-112, 61 FR 18934. Apr. (ii) Loadings must be as prescribed in 29, 1996] § 178.345—3. (iii) The knuckle radius of flanged 178.347—5 Pressure and leakage test. § heads must be at least three times the (a) Each cargo tank must be tested in material thickness, and in no case less accordance with § 178.345—13 and this than 0.5 inch. Stuffed (inserted) heads section. may be attached to the shell by a fillet (b) Pressure test. Test pressure must weld. The knuckle radius and dish ra be as follows: dius versus diameter limitations of (1) Using the hydrostatic test meth UG-32 do not apply for cargo tank od, the test pressure must be at least 40 motor vehicles with a MAWP of 15 psig psig or 1.5 times tank MAWP, which or less. Shell sections of cargo tanks ever is greater. designed with a non-circular cross sec (2) Using the pneumatic test method, tion need not be given a preliminary the test pressure must be 40 psig or 1.5 curvature, as prescribed in UG—79(b). times tank MAWP, whichever is great (iv) Marking, certification, data re er, and the inspection pressure is tank ports, and nameplates must be as pre MAWP. scribed in § 178.345—14 and 178.345—15. (v) Manhole closure assemblies must [Amdt. 178—89, 54 FR 25030, June 12, 1989. Re designated by Amdt. 178—112, 61 FR 18934, conform to § 178.345—5. Apr. 29, 1996] (vi) Pressure relief devices must be as prescribed in § 178.348—4. § 178.348 Specification DOT 412; cargo (vii) The hydrostatic or pneumatic tank motor vehicle. test must be as prescribed in § 178.348—5. (viii) The following paragraphs in § 178.348—1 General requirements. parts UG and UW in Section VIII of the (a) Each specification DOT 412 cargo ASME Code do not apply: UG-ll, UG tank motor vehicle must conform to 12, UG—22(g), UG—32(e), UG—34, UG—35, the general design and construction re UG-44, UG-76, UG-77, UG-80, UG-8l, quirements in §178.345 in addition to UG—96, UG—97, UW—13(b)(2), UW—13.1(f), 992 Pipeline and Hazardous Materials Safety Admin., DOT § 178.348-2

and the dimensional requirements tanks must conform to §178.345-2, but found in Figure UW-13.l. in no case may the thickness be less [Amdt. 178-89, 54 FR 25031, June 12, 1989, as than that determined by the minimum amended at 55 FR 37065, Sept. 7, 1990; Amdt. thickness requirements in § 178.320(a). 178-89, 56 FR 27877, June 17, 1991; 65 FR 58632, The following Tables I and II identify Sept. 29, 2000; 68 FR 19285, Apr. 18, 2003; 68 fR the “Specified Minimum Thickness” 75756, Dec. 31, 2003] values to be employed in that deter § 178.348—2 Material and thickness of mination. material. (a) The type and thickness of mate rial for DOT 412 specification cargo

993 C0 TABLE I—SPECIFIED MINIMUMTHICKNESS OF HEADS (OR BULKHEADSAND BAFFLEs WHEN USED AS TANK REINFORCEMENT)USING MILD STEEL (MS), HIGH STRENGTH Low ALLOYSTEEL (HSLA), AUSTENITICSTAINLESS STEEL (SS), OR ALUMINUM(AL)—ExpREssED IN DECIMALSOF AN NCH AFTER FORMING

Volume capacity (gallons per inch) 10 or less Over 10 to 14 Over 14 to 18 18 and over cr F’.)

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 lOto l3to l6lbs and lOto l3to l6lbs and lOto l3to and lOto l3to less 13 lbs 16 lbs less 13 lbs 16 lbs less 13 lbs 16 lbs less 13 lbs 16 lbs Thickness (inch), steel 100 .129 .157 .187 .129 .157 .187 .250 .157 .250 .250 .157 .250 .312 Thickness (inch), aluminum 144 .187 .227 .270 .187 .227 .270 .360 .227 .360 .360 .227 .360 .450

TABLE Il—SPECIFIED MINIMUMTHICKNESSOF SHELL USING MILDSTEEL (MS), HIGH STRENGTH Low ALLOYSTEEL (HSLA), AusTENITIc STAINLESS STEEL (SS), OR ALUMINUM(AL)—ExPRESSED IN DECIMALS OFAN INCHAFTER FORMING

Volume capacity in gallons per inch 10 or less Over 10 to 14 Over 14 to 18 18 and over

Lading density at 60 F in pounds per gallon 10 lbs Over Over Over 10 lbs Over Over Over 10 lbs Over Over 10 lbs Over Over and 10 to 13 to 16 lbs and 10 to 13 to 16 lbs and 10 to 13 to and 10 to 13 to less 13 lbs 16 lbs less 13 lbs 16 lbs less 13 lbs 16 lbs less 13 lbs 16 lbs Thickness (steel): Distances between heads (and bulkheads baffles and ring stiffeners when used as tank reinforcement): 36in.orless 100 .129 .157 .187 .100 .129 .157 .187 .100 .129 .157 .129 .157 .187 Over36in.to54inches 100 .129 .157 .187 .100 .129 .157 .187 .129 .157 .187 .157 .250 .250 Over 54 in. to 60 inches 100 .129 .157 .187 .129 .157 .187 .250 .157 .250 .250 .187 .250 .312 Thickness (aluminum): Distances between heads (and bulkheads baffles and ring 0-F’ stiffeners when used as tank reinforcement): 36 in. or less 144 .187 .227 .270 .144 .187 .227 .270 .144 .187 .227 .187 .227 .270 0 Over 36 in. to 54 inches 144 .187 .227 .270 .144 .187 .227 .270 .187 .227 .270 .157 .360 .360 Over 54 in. to 60 inches 144 .187 .227 .270 .187 .227 .270 .360 .227 .360 .360 .270 .360 .450

C m 0. z0 Pipeline and Hazardous Materials Safety Admin., DOT § 178.348—5 (b) [Reserved]

[Amdt. 178—89, 54 FR 25031, June 12, 1989; 54 FR 28750, July 7, 1989, as amended at 55 FR 37065, Sept. 7, 1990; 68 FR 19285, Apr. 18, 2003]

§ 178.348—3 Pumps, piping, hoses and Formula in Nonmetric Units connections. Q = 37,980,000 A0.82 (ZT)°•5 / (LC)(M05) Each pump and all piping, hoses and connections on each cargo tank motor Where: vehicle must conform to § 178.345—9, ex Q The total required venting capacity, in cept that the use of nonmetallic pipes, cubic meters of air per hour at standard conditions of 15.6 °C and 1 valves, or connections are authorized atm (cubic feet of air per hour at standard conditions of 60 on DOT 412 cargo tanks. °F and 14.7 psia); T = The [Amdt. 178—89. 55 FR 37065, Sept. 7, 1990. Re absolute temperature of the vapor at the venting designated by Amdt. 178-112. 61 FR 18934, conditions—degrees Kelvin Apr. 29, 1996] °C±273) [degrees Rankine (F÷460)]; A The exposed surface area of tank shell— square meters (square § 178.348—4 Pressure relief. feet); L The latent heat of vaporization of the (a) Each cargo tank must be equipped lading—calories per gram (BTUI1b); with a pressure and vacuum relief sys Z = The compressibility factor for the vapor (if this factor tem in accordance with §178.345—10 and is unknown, let Z equal 1.0); M = The molecular this section. weight of vapor; C A constant derived from (K), the ratio of (b) Type and construction. Vacuum re specific heats of the vapor. If (K) is un lief devices are not required for cargo known, let C = 315. tanks designed to be loaded by vacuum C = 5201K(2/(K±1))L(K l)f(K— or built to withstand full vacuum. Where: (c) Pressure settings of relief valves. K = C, I C The setting of the pressure relief de C, = The specific heat at constant pressure, vices must be in accordance with in -calories per gram degree centigrade §178.345—10(d), except as provided in (BTU/lb °F.); and paragraph (d) (3) of this section. C = The specific heat at constant volume. in (d) Venting capacities. (I) The vacuum -calories per gram degree centigrade (BTU/ lb CF.). relief system must limit the vacuum to less than 80 percent of the design vacu [Amdt. 178—89, 54 FR 25032, June 12, 1989, as um capability of the cargo tank. amended at 55 FR 37065, Sept. 7, 1990; Amdt. 178—104, 59 FR 49135, Sept. 26, (2) If pressure loading or unloading 1994. Redesig nated by Amdt. 178—112, 61 FR 18934, Apr. devices 29, are provided, the pressure relief 1996; 72 FR 55696, Oct. 1, 2007; 72 FR 59146, system must have adequate vapor and Oct. 18, 20071 liquid capacity to limit tank pressure to the cargo tank test pressure at the § 178.348—5 Pressure and leakage test. maximum loading or unloading rate. (a) Each cargo tank must be tested in The maximum loading and unloading accordance with §178.345-13 and this rates must be included on the metal section. specification plate. (b) Pressure test. Test pressure must (3) Cargo tanks used in dedicated be as follows: service for materials classed as corro (1) Using the hydrostatic test meth sive material, with no secondary haz od, the test pressure must be at least ard, may have a total venting capacity 1.5 times MAWP. which is less than required by § 178.34 5— (2) Using the pneumatic test method, 10(e).. The minimum total venting ca the test pressure must be at least 1.5 pacity for these cargo tanks must be times tank MAWP, and the inspection determined in accordance with the fol pressure is tank MAWP. lowing formula (use of approximate jAmdt. 178—89, 54 FR 25032, June 12, 1989. values Re given for the formula is accept designated by Amdt. 178-112, 61 FR 18934, able): Apr. 29, 1996]

995 § 178.350 49 CFR Ch. I (10—1—10 Edition) Subpart K—Specifications for 5 cm (2 inches) and gaps between mat Packagings for Class 7 (Ra ing surfaces must not exceed 5 mm (0.2 dioactive) Materials inch). Gaps between foam surface of top section and liner must not ex § 178.350 Specification 7A; general ceed 1 cm (0.4 inch) or 5 cm (2 inches) packaging, Type A. where taper is required for mold strip (a) Each packaging must meet all ap ping. For the specification 2OPF-l, the plicable requirements of subpart B of top section may consist of a plug of part 173 of this subchapter and be de foam insulation and a steel cover. The signed and constructed so that it meets liner and shell closures must each be the requirements of § 173.403, 173.410, gasketed against moisture penetration. 173.412, 173.415 and 173.465 of this sub The liner must have a bolted flange chapter for Type A packaging. closure. Shell closure must conform to (b) Each Specification 7A packaging paragraph (d) of this section. must be marked on the outside ‘USA (d) Drums over 5 gallons capacity DOT 7A Type A.” must be closed by means of 12-gauge (c) Each Specification 7A packaging bolted ring with drop forged lugs, one must comply with the marking re of which is threaded, and having 3/8 quirements of §178.3. In paragraph inch bolt and nut for drums not over 30 178.3(a) (2), the term “packaging manu gallons capacity and 5/8 inch bolt and facturer” means the person certifying nut for drums over 30 gallons capacity. that the package meets all require Five gallon drums must be of lug type ments of this section. closure with cover having at least 16 lugs. [Amdt. 178—109, 60 FR 50336, Sept. 28, 1995; 60 (e) Drawings in DOE CAPE-1662, Rev. 54409, Oct. 23, 1995, as amended at 69 FR FR 1 and Supplement 1 (IBR, see of 3696, Jan. 26, 2004; 70 FR 56099, Sept. 23, 2005] §171.7 this subchapter), which include bills of § 178.356 Specification 2OPF phenolic material, are a part of this specifica foam insulated, metal overpack. tion. 178—35, 39 FR 45247, Dec. 31, 1974. Re 178.356—1 General requirements. [Amdt. § designated by Amdt. 178-97, 55 FR 52716, Dec. (a) Each overpack must meet all of 21, 1990; 65 FR 58632, Sept. 29, 2000; 66 FR the applicable requirements of § 173.24 45386, 45389, Aug. 28, 2001; 68 FR 75757, Dec. 31, of this subchapter. 2003] (b) The maximum gross weight of the package, including the inner cylinder § 178.356—2 Materials of construction and other requirements. and its contents, must not exceed the following; (a) Phenolic foam insulation must be (1) Specification 2OPF—l—l38 kg (300 fire-resistant and fabricated in accord pounds). ance with USDOE Material and Equip (2) Specification 2OPF—2—320 kg (700 ment Specification SP-9, Rev. 1 and pounds). Supplement (IBR, see §171.7 of this sub (3) Specification 2OPF—3—455 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 SP-9 overpack must be a right cylinder, con and Rev. I 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 pieces must be securely attached to (3.5 inches); or both the liner and shell. No hole is per (3) Where alternate top section (spec mitted in the liner. Each joint between ification 2OPF—l) is used. Foam must sections must be stepped a minimum of not interfere with proper seating of

996 Pipeline and Hazardous Materials Safety Admin., DOT § 178.356—5

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 SP-9, Rev. 1 and cc (10 pcf) minimum for top section, ex Supplement, or equivalent. cept 0.1 g/cc (6.5 pcI) for the specifica tion 2OPF-1 top section. [Arndt. 178—35, 39 FR 45247, Dec. 31, 1974, as amended (b) Gaskets must be as follows: by Amdt. 178—56, 44 FR 49458, Aug. 23, 1979. Redesignated by (1) Inner Amdt. 178-97, 55 FR liner flange—Neoprene 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, 20031 ness or other equivalent gasket mate rial which is compatible with the spe § 178.356—3 Tests. cific contents. Leakage test—Each (2) Outer shell—Synthetic rubber (a) inner liner assembly conforming to MIL-R-6855 (available must be tested for leakage prior from the Naval Publications Forms to installation. Seam welds of the Center, 5801 Tabor Avenue, Philadel liner must be covered for a distance of least phia, Pennsylvania 19120) class 2, grade at 15 cm (6 inches) on either side 60. of the seam with soapsuds, heavy oil, (3) Support and pressure pads for or equivalent material, and interior air inner liner top and bottom must be pressure applied to at least 776 mm Hg sponge rubber or equivalent. (15 p.s.i.g.) above atmospheric pressure (c) Alternate top section (specifica must be held for at least 30 seconds. tion 2OPF-l only). Average insulation Liners failing to pass this test may not density must be 0.16 g/cc (10 pcf min be used until repairs are made, and imum). Thickness of plug must be 11 retests successfully passed. cm (4.3 inches) minimum, except thick (b) IReserved] ness may be reduced to 10 cm (4 inches) [Amdt. 178—35, 39 FR 45247, Dec. 31, 1974. Re to clear bolt heads. A flush mounted designated by Amdt. 178—97, 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, 20021 the foam. (d) Vent holes 5 mm (0.2-inch) diame § 178.356-4 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 (I) “USA-DOT-2OPF-l” or “-2,” as ap the foam insulation, must be spaced in propriate, and if the entire liner is accordance with DOE CAPE—1662, Rev. made of stainless steel, additional 1 and Supplement 1 (IBR, see of §171.7 marking such as “3041—SS” to this subchapter). indicate the type of stainless steel used. (e) Welding must be by a fusion weld ‘TARE ing process in accordance with Amer (2) WT: xxx lbs.” where xxx is the tare ican Welding Society Codes B—3.0 and weight of the assembled over- pack without D—l.0 (IBR, see §171.7 of this sub the inner container. chapter). Body seams and joints for the (3) Year of manufacture. liner or shell must be continuous [Amdt. 178—35, 39 FR 45247, Dec. 31, 1974. Re welds. designated by Amdt. 178-97, 55 FR 52716, Dec. (I) 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 § 178.356—5 Typical assembly detail. the screw. All exposed foam surfaces, (a) Specifications 2OPF—l.

997 § 178.356—5 49 CR Ch. I (10—1—10 Edition)

UFTNG RWG RING. BOLT

STEEL Pt.ATE

IS GAGE STEEL oRuu

(b) Specification 2OPF-2.

998 0 C, -J0

0

C E 0

C) C) 0 U) 0 0

0

0N C 0 C

C 0 c) a) C cf) 1) 0. C0) CD

—C U’ 01 C?) 01 01

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CD —C

CD CD

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cC —0 C) -n --C 01 C-) CD —C

I1

C’) -4 CD C m 0. CD (C 0 C?) z Pipeline and Hazardous Materials Safety Admin., DOT § 178.358—2

§ 178.358 Specification 21PF fire and (d) Specification 21PF-l overpacks in shock resistant, phenolic-foam insu use or under construction before April lated, metal overpack. 1, 1989, must be modified to Specifica tion 21FF—IA before April 1, 1991. All § 178.358—i General requirements. new construction to Specification (a) Each overpack must meet all of 21PF—l beginning after March 31, 1989, the applicable requirements of § 173.24, must meet Specification 21FF—lB. Use 173.411, and 173.412 of this subchapter. of unmodified 2IPF-l overpacks after (1) Specification 21FF—I overpacks in March 31, 1991, is prohibited. cludes the series of 21PF—l, 21FF—lA, [Amdt. 178—35, 39 FR 45250, Dec. and 21PF—lB 31, 1974; 40 FR models. Details of the 2435, Jan. 13, 1975, as amended by Amdt. 178- three models are included in DOE 90. 53 FR 36551, Sept. 20, 1988. Redesigntated CAPE-1662, Rev. I and Supplement 1 by Amdt. 178—97, 55 FR 52716, Dec. 21, 1990; 66 (IBR, see §171.7 of this subchapter). FR 45387, Aug. 28, 2001; 68 FR 75757, Dec. 31, (2) Drawings in CAPE—1662, Rev. 1 and 20031 Supplement 1. that include bills of ma 178.358—2 Materials terials, and KSS—471 (IBR, see §171.7 of § of construction and other requirements. this subchapter), are a part of this specification. (a) Phenolic foam insulation must be (b) Each overpack is authorized for fire resistant and fabricated in accord use in applications where the max ance with USDOE Material and Equip imum gross weight of the package, in ment Specification SP-9, Rev. I and cluding the inner container and con Supplement (IBR, see §171.7 of this sub tents does not exceed 3725 kg (8200 chapter), which is a part of this speci pounds), (horizontally-loaded specifica fication. (Note: Packagings manufac tion 21 PF—1 unit), or 3900 kg (8600 tured under USAEC Specification SF-9, pounds), (end-loaded specification 21 and Rev. 1 thereto are authorized for PF-2 unit). continued manufacture and use.) A 14 (c) The general configuration of the cm (5.5-inch) minimum thickness of overpack must be a right cylinder, con foam must be provided over the entire sisting of a steel inner liner (at least liner except where: 16-gauge) and steel outer shell (at least (1) Wood spacers replace the foam 14-gauge) with the intervening cavity material; or filled with a molded-in-place, fire-re (2) At protrusions of liner or shell, sistant, phenolic foam insulation and such as flanges, baffles, etc., where the interspersed wooden members for brac minimum thickness of foam, wood, or a ing and support. Two specific configu combination of these is 10 cm (4 rations are authorized; a horizontal inches). loading unit (specification 21FF-i) con (3) Solid wood or laminated wood sol sisting of insulated base and top sec idly glued may be used to replace the tions jointed in a longitudinal periph foam between liner and shell (i.e., in eral closure joint; or an end-loading ends of overpack). In this case, min unit (specification 21PF—2), consisting imum wood thickness is 10 cm (4 of an insulated main section, a steel inches), Average density of insulation plate liner lid, and an insulated end must be 0.lg/cc (6.75 pounds per cubic cap. For either type each joint between foot (pcf)) minimum, except that 0.13 g/ sections must be stepped at least 1.8 cc (8 pcf) is required in the removable cm (0.75-inch) and gaps between mating end cap of the specification 21PF-2, surfaces may not exceed 5 mm (0.2- which must have a minimum foam inch). Bolted closures, which must each thickness of 12.7 cm (5 inches). be gasketed against moisture penetra (b) Gaskets for inner liner, outer tion, must be in accordance with shell, or where otherwise specified in CAPE-l662. Each bolt must be equipped DOE CAPE-l662, Rev. 1 (IBR, see §171.7 with a locking device to prevent loos of this subchapter), must be as speci ening from vibration. Outer steel brac fied in DOE CAPE-1662, Rev. 1. ing and support framework must be at (c) Support and pressure pads for the tached to the shell to facilitate normal inner liner must be of neoprene, sponge handling. rubber, or equivalent. 1001 § 178.358—3 49 CR? Ch. I (10—1—10 Edition)

(d) Fire-retardant (intumescent) 1662, Revision 1, Supplement 1, for loca paint must be applied to any wood tions. blocking which is located at any joint (2) Weigh each packaging element in the shell. (top and bottom halves) separately to (e) Vent holes 5 mm (0.2-inch) diame an accuracy of ±2.3 kg (±5 pounds) and ter must be drilled in the outer shell to record the weights. If this measured provide pressure relief during the insu weight exceeds the initially measured lation foaming and in the event of a weight at the time of fabrication by fire. These holes, which must be drilled 11.3 kg (25 pounds) (indicating a signifi in all areas of the shell which made cant retained water content), the pack with the foam insulation, must be aging element must be dried. spaced in accordance with CAPE-1662. (3) Place overpack element in drying (f) Welding must be by a fusion proc oven; maintain temperature between ess in accordance with the American 87.8—98.9 °C (190° and 210 °F) for a min Welding Society Codes B—3.0 and D-1.0 imum of 72 hours. The oven should (IBR, see §171.7 of this subchapter). have a provision for air exchange or for the liner and Body seams and joints other means of removing moisture shell continuous welds. must be driven from the foam structure. Waterproofing. Each screw hole in (g) (4) Drying may be discontinued after the outer shell must be sealed with ap 72 hours if the weight of the packaging propriate resin-type sealing material, element does not exceed the initially or equivalent, during installation of the screw. All exposed foam surfaces, measured tare weight of that element including any vent hole, must be sealed at the time of fabrication by more than with either: 11.3 kg (25 pounds). If the weight of the (1) Waterproofing material as pre packaging element exceeds the initial scribed in USDOE Material and Equip fabricated weight (indicating a signifi ment Specification SP-9, Rev. 1 and cant remaining water content) by more Supplement, or than 11.3 kg (25 pounds), drying must (2) As specified in CAPE—1662, Revi be continued until the weight differen sion 1. tial is not higher than 11.3 kg (25 pounds), or until the rate of weight loss [Amdt. 178—35, 39 FR 45250, Dec. 31, 1974, as is less than 1.1 kg (2.5 pounds) per day. amended by Amdt. 178-56, 44 FR 49459. Aug. (5) As an alternate moisture meas 23, 1979; Amdt. 178—90. 53 FR 36551, Sept. 20, 1988. Redesigntated by Amdt. 178-97, 55 FR urement, a calibrated moisture meter 52716, Dec. 21, 1990; 66 FR 45387, Aug. 28, 2001; reading for 20 percent maximum water 68 FR 75757, Dec. 31, 20031 content may be used to indicate an end point in the drying cycle, which is de § 178.358—3 Modification of Specifica tailed in report “Renovation of DOT tion 21PF—1 overpacks. Specification 21PF—l Protective Ship (a) Each Specification 2IPF-l over- ping Packages,” Report No. K-2057, Re pack for which construction began or vision 1, November 21, 1986, available was completed before April 1, 1989, in from the USDOE and part of USDOE conformance with drawing E-S-3l536-J, Report No. KSS—47l (IBR, see §171.7 of Rev. 1 of DOE CAPE-1662 (IBR, see this subchapter). §171.7 of this subchapter), must be (6) Following drying, each overpack modified in conformance with drawing element (top and bottom halves) must DOE CAPE-1662, S1E-3l536-Jl-D of be weighed and the weight in both 1, before April 1, Rev. 1, Supplement pounds and kilograms must be en 1991. graved on the identification plate re such existing Specification (b) Each quired by 178.358—5(c). 21PF-l overpack must be dried and § After modification as provided for weighed in accordance with the fol (c) Specification 21PF-l over lowing procedures: herein, each pack must be marked “USA-DOT-21PF- (1) Drill out or otherwise clean the plug material from the vent holes originally provided for foam expansion. See drawing SlE-3l536-Jl-D of CAPE-

1002 Pipeline and Hazardous Materials Safety Admin., DOT § 178.358—6

lA’ See the marking requirements of (2) For Specification 21FF—I and § 178.358—5. 21FF-2 only, “TARE WT: * * * lbs. * * * ** [Amdt. 178—90, 53 FR 38551, Sept. 20, 1988. kg)” where is the tare Redesigntated by Amdt. 178-97, 55 FR 52716, weight in pounds and kilograms, re Dec. 21, 1990; Amdt. 178—110. 60 FR 49111, Sept. spectively, of the assembled overpack 21, 1995; 63 FR 37462. July 10, 1998; 66 FR 45389, without the inner product container. Aug. 28, 2001; 68 FR 75757, Dec. 31, 20031 (3) For Specification 21FF-IA and 21FF-lB § 178.358—4 Construction of Specifica only: “TARE WT. of Cover: ** * (* * * tion 21PF-1B overpacks. lbs kg) TARE WT. of BOT TOM: * * * lbs (* * * kg)” where (a) Each Specification 21FF-i over- * * * is the tare weight in pack for which construction began pounds and kilograms, respectively, of after March 31, 1989, must meet the re the sepa rate halves quirements of Specification 2IFF-lB, of the overpack without the in conformance with drawings E-S inner product container. For Specifica 31536-J-P, and SIE-31536-J2-B of DOE tion 2IPF-1A overpacks, the previous CAFE-1662, Rev. 1, Supplement 1 (IBR, tare weight must be changed to reflect see § 171.7 of this subchapter). the modified tare weight value or must (b) With the exception of the closure be covered or removed. nuts and bolts, all metal parts of the (4) Year of manufacture followed by Specification 2IPF-1B 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 lAmdt. 178—90. 53 FR 36551, Sept. 20, 1988. used, must be registered with the Asso Redesigntated by Amdt. 178-97, 55 FR 52716, ciate Administrator. Dec. 21, 1990; 68 FR 75757, Dec. 31, 20031 (c) For Specification 21FF-lA and -lB only, the markings required by this § 178.358-5 Required markings. section must be affixed to each over- (a) Markings must be as prescribed in pack by inscription upon a metal iden § 178.3. tification plate 11 inches wide x 15 (b) Specification marking on the out inches long (28 cm x 38 cm), fabricated side of each overpack must be as fol of 16 to 20 gauge stainless steel sheet, lows: “USA-DOT-21PF-l”, “IA”, “IB”, ASTM A—240/A 240M (IBR, see § 171.7 of or ‘2”, as appropriate. this subchapter), Type 304L. (1) For Specifications 21FF—l and 21FF—2 only, if the inner shell is con [Amdt. 178—90, 53 FR 36552, Sept. 20, 1988. Redesigntated structed of stainless steel, additional by Amdt. 178-97, 55 FR 52716, Dec. 21, 1990, and amended at Amdt. 178—97, 56 marking such as ‘304L-SS” are to be FR 66287, Dec. 20, 1991; 63 FR 37462, July 10. marked on the outside of the overpack 1998; 66 FR 45386, Aug. 28, 2001; 67 FR 51660, to indicate the type of stainless steel Aug. 8, 2002; 68 FR 75748, Dec. 31, 2003; 69 FR used. 54046, Sept. 7, 20041

§ 178.358—6 Typical assembly detail. (a) Specification 21FF-i (horizontal loading overpack).

1003 § 178.358—6 49 CFR Ch. I (10—1—10 Edition)

(b) Specification 21PF-1A and 21PF-1B (horizontal loading overpack).

1004 Pipeline and Hazardous Materials Safety Admin., DOT § 178.358—6

SECTION SECTION DOT SPECIFICATION 2IPF.1A DOT SPECIFICATION 2IPF.1B OVERPACK OVERPACK

UPPER STEP JOPfl NEPEIt STEP JOWl

ETAWLESS STEEL STAIILESS CAIIDOM STEEL CARa(H STEEL STEEL

NEW EEEETS ASKET STAWLESD WELD SEEL NEW CANNCW STEEL cOVENS WELD

IWOWE) JOUTDUJE) ETANESTS STEEL STEEL LESS STEEL LOWER STEP JOI4T LOWER STEP JOWT

JOINT DETAIL JOINT DETAIL DOT SPECIFICATION 21PF.IA DOT SPECIFICATION 2IPF-18 OVERPACK OVERPACK (c) Specification 21PF-2 (end loading overpack).

1005 § 178.358—6 49 CFR Ch. I (10—1—10 Edition)

NEOPRENE

• ‘ RUBBER GASKET

RESISTANT PHENOLIC FOAM

CORNER BUMPER

[Amdt. 178—90, 53 FR 36552, Sept. 20, 1988. Redesignated by Amdt. 178—97, 55 FR 52716, Dec. 21, 1990]

1006 Pipeline and Hazardous Materials Safety Admin., DOT § 178.360—4

§ 178.360 Specification 2R; inside con * 178.360—2 Manufacture. tainment vessel. The ends of the vessel must be fitted with screw-type § 178.360—1 General requirements. closures or flanges (see §178.360—4), except that one or both (a) Each vessel must be made of ends of the vessel may be permanently stainless steel, malleable iron, or brass, closed by a welded or brazed plate. or other material having equivalent Welded or brazed side seams are au physical strength and fire resistance, thorized. (b) Each vessel must meet all of the [Amdt. 178—35, 39 FR 45245, Dec. 31, 1974. Re applicable requirements of § 173.24 (c) designated by Amdt. 178-97, 55 FR 52716, Dec. and (d) of this subchapter. Letters and 21, 1990, as amended at 63 FR 37462, July 10, numerals at least 6 mm (1/4-inch) in 19981 height are authorized for the marking of a vessel not exceeding 5 cm (2 § 178.360—3 Dimensions. inches) inside diameter. (a) The inside diameter of the vessel may not exceed 30 cm (12 inches) exclu [Amclt. 178—35, 39 FR 45245, Dec. 31, 1974. Re sive of flanges for handling or fastening designated by Amdt. 55 FR 52716, 178-97, Dec. devices and must have wall thickness 21, 1990; 66 FR 45387, Aug. 28, 2001] and length in accordance with the fol lowing:

Inside diameter Threaded closure Length maximum maximum Wall thickness minimum—Flanged closure Inches Inches Cm Mm Inches Cm

2 5 % 2.5 Not less than that prescribed for schedule 40 pipe 16 41 6 15 ½ 3.2 72 183 12 30 ½ 6.5 72 183

(b) [Reserved]

]Amdt. 178—35, 39 FR 45245, Dec. 31, 1974. Redesignated by Amdt. 178—97, 55 FR 52716, Dec. 21, 1990: 66 FR 45387, Aug. 28, 2001]

§ 178.360—4 Closure devices. §171.7 of this subchapter). A torque wrench must used (a) Each closure device must be as be in securing the follows: flange with a corresponding torque of no more than twice the force necessary (1) Screw-type cap or plug; number of to seal the selected threads per inch must not be less than gasket. Gasket ma terial United States standard pipe threads must be capable of withstanding to 149 °C and must have sufficient length of up (300 °F) without loss of effi thread to engage at least 5 threads ciency. The flange, whether of ferrous when securely tightened. Pipe threads or nonferrous metal, must be con must be luted with an appropriate non- structed from the same metal as the hardening compound which must be ca vessel and must meet the dimensional pable of withstanding up to 149 °C (300 and fabrication specifications for weld °F) without loss of efficiency. Tight ed construction as follows: ening torque must be adequate to (i) Pipe flanges described in Tables maintain leak tightness with the spe 13, 14, 16, 17, 19, 20, 22, 23, 25 and 26 of cific luting compound. ANSI B16.5 (IBR, see § 171.7 of this sub (2) An opening may be closed by a se chapter). curely bolted flange and leak-tight gas (ii) For nominal pipe sizes, 6, 8, 10, ket. Each flange must be welded or and 12 inches, AWWA Standard C207-55, brazed to the body of the 2R vessel per Table 1, class B. may be used in place (ANSI) Standard Bl6.5 or (AWWA) of the tables prescribed by paragraph Standard C207—55, section 10 (IBR, see (a) (2) (i) of this section.

1007 § 178.500 49 CFR Ch. I (10—1—10 Edition)

(iii) Sizes under 6 inches, nominal AWVtIA C207-55, Table 1, class B, may pipe size, the following table with the be used in place of paragraph (a) (2) (i) of same configuration as illustrated in this section.

Flange O.D. Bolt circle Nominal pipe size Number diameter Diameter of bolts Flange thickness of bolts Inches Cm Inches cm Inches Cm Inches Cm Inches Cm

2 5 6 15 4 4¾ 11.8 ½ 1.2 5/ 1.6 2½ 6.2 7 17.5 4 5½ 13.8 ½ ¾ 3 7.5 7½ 18.8 4 6 15 ½ ¾ 3½ 8.8 8½ 21.3 8 7 17.5 ½ ¾ 4 10 9 22.5 8 7½ 18.8 ½ ¾ 5 12.6 10 25.4 8 8½ 21.3 ½ ¾

(iv) Cast iron flanges prohibited. (iii) “C” means natural wood. (b) [Reserved] (iv) “D” means plywood. (v) “F” means reconstituted [Amdt. 178-35, 39 FR 45245, Dec. 31, 1974; 40 FR wood. 2435, Jan. 13, 1975, as amended at 40 FR 44327, (vi) “G” means fiberboard. Sept. 26, 1975. Redesignated by Amdt. 178-97, (vii) “H” means plastic. 56 FR 66284, Dec. 20, 1991; 68 FR 75757, Dec. 31, (viii) “L” means textile. 2003] (ix) “M” means paper, multi-wall. (x) “N” means metal (other than Subpart L—Non-bulk Perform steel or aluminum). ance-Oriented Packaging (xi) “P” means glass, porcelain or Standards stoneware. (3) A numeral indicating the category of packaging within the kind to which SouRcE: Amdt. 178—97, 55 FR 52717, Dec. 21, the packaging belongs. For example, 1990, unless otherwise noted. for steel drums (“IA”), “I” indicates a non-removable § 178.500 Purpose, scope and defini head drum (i.e., “lAl”) tions. and “2” indicates a removable head drum (i.e., “lA2”). (a) This subpart prescribes certain re (b) For composite packagings, two quirements for non-bulk packagings for capital letters are used in sequence in hazardous materials. Standards for the second position of the code, the these packagings are based on the UN first indicating the material of the Recommendations. inner receptacle and the second, that of (b) Terms used in this subpart are de the outer packaging. For example, a subchapter. fined in §171.8 of this plastic receptacle in a steel drum is designated § 178.502 Identification codes for pack “6HA1”. agings. (c) For combination packagings, only the code number for the outer pack (a) Identification codes for desig aging is used. packagings consist of nating kinds of (d) Identification codes are set forth following; the in the standards for packagings in (1) A numeral indicating the kind of § 178.504 through 178.523 of this sub packaging, as follows; part. (i)”1” means a drum. (ii)”2” means a wooden . NOTE TO § 178.502: Plastics materials in (iii) “3” means ajerrican. clude other polymeric materials such as rub (iv) “4” means a box. ber. (v) “5” means a . [Amdt. 178—97, 55 FR 52717, Dec. 21, 1990, as (vi) “6” means a composite pack amended by Amdt. 178-106, 59 FR 67519. Dec. aging. 29. 1994; 74 FR 2269, Jan. 14, 2009] (vii) ‘7” means a pressure receptacle. (2) A capital letter indicating the § 178.503 Marking of packagings. material of construction, as follows; (a) A manufacturer must mark every (i) “A” means steel (all types and packaging that is represented as manu surface treatments). factured to meet a UN standard with (ii) “B” means aluminum. the marks specified in this section. The

1008 Pipeline and Hazardous Materials Safety Admin., DOT § 178.503

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 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 marked (2) A packaging identification code and in the United States in compliance designating the type of packaging, the with the provisions of this subchapter; material of construction and, when ap propriate, the category of packaging (8) The name and address or symbol of the manufacturer under 178.504 through 178.523 of this or the approval § agency certifying subpart within the type to which the compliance with sub part L and subpart packaging belongs. The letter “V., M of this part. Symbols, if used, must follow the packaging identifica must be registered with the Associate tion code on packagings tested in ac Administrator; (9) For metal cordance with §178.601(g)(2); for exam or plastic drums or jerricans intended for ple, ‘4GV”. The letter ‘W” must fol reuse or recondi tioning as single low the packaging identification code packagings or the outer packagings of on packagings when required by an ap a composite pack aging, the thickness proval under the provisions of of the packaging material, §178.601(h) of this part; expressed in mm (rounded to the nearest 0.1 mm), as follows: (3) A letter identifying the perform (1) Metal drums or jerricans must be ance standard under which the pack marked with the nominal thickness aging design type has been successfully of the metal used in the body. tested, as follows: The marked nominal thickness must not (i) X—for packagings meeting Pack exceed the minimum thickness of the ing Group I, II and Ill tests; steel used by more than the thickness (ii) Y—for 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) Z—for packagings only meeting dix C of this part.) The unit of measure Packing Group III tests; is not required to be marked. When the (4) A designation of the specific grav nominal thickness of either head of a ity or mass for which the packaging de metal drum is thinner than that of the sign type has been tested, as follows: body. the nominal thickness of the top 1009 § 178.503 49 CFR Ch. I (10—1—10 Edition)

head, body, and bottom head must be • (ii) The name and address or symbol marked (e.g., “1.0—1.2—1.0” or “0.9—1.0— 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 § passing a leakproofness test, the addi required to be marked; (10) In addition to the markings pre tional letter “L”. scribed in paragraphs (a)(l) 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)(l) 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 drum’s characteristics at the time it greater performance capability. The was manufactured, and the information markings applied in accordance with in paragraphs (a)(l) 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 be permanent head, the markings may not be applied (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)(l) 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”); (l)(i) The United Nations symbol is:

1010 Pipeline and Hazardous Materials Safety Admin., DOT § 178.503

(ii) The circle that surrounds the let ters u” and “n’ may have small breaks provided the following provi sions are met: 1A1/Yl .4/150/83 (A) The total gap space does not ex ceed 15 percent of the circumference of USA[VL824 the circle; (B) There are no more than four gaps in the circle; 1.0 (C) The spacing between gaps is sepa rated by no less than 20 percent of the (as in § 178.503 (a) (1) through (a) (10) of circumference of the circle (72 degrees); this subpart). and (iii) For a steel drum to transport (D) The letters ‘u” and n’ appear solids or inner packagings: exactly as depicted in § 178.503 Ce) (1) (i) with no gaps. (2) Examples of markings for a new 1 A2/Y1 50/S/83 packaging are as follows: (i) For a fiberboard box designed to contain an inner packaging: USA/VL825

4G/Y1 45/S/83 (as in §178.503 (a)(1) through (a)(8) of this subpart). (3) Examples of markings for recondi USA/RA tioned packagings are as follows:

IAI1YI .41150192 (as in §178.503 (a)(l) through (a)(9) of USAIRBI93 RL this subpart). (ii) For a steel drum designed to con tain liquids:

(as in §178.503(c) (1)). (f) A manufacturer must mark every UN specification package represented as manufactured to meet the require ments of § 178.609 for packaging of in fectious substances with the marks specified in this section. The markings 1011 § 178.504 49 CFR Ch. I (10—1—10 Edition)

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 follows: marked as 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 solids or 40 packaging and material of construc 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 of agency certifying compliance with sub or heads non removable parts L and M of this part. Symbols, if 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 (lA2). 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. 178—97, 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 178—102, 59 FR 28493, June 2, 1994; Amdt. 178— leakproof. 106, 59 FR 67520, 67521, Dec. 29, 1994; Amdt. (6) Closure devices for removable 178—107, 60 FR 26806, May 18, 1995; 62 FR 51561, head drums must Oct. 1, 1997; 66 FR 45386, Aug. 28, 2001; 67 FR 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, 20101 normal conditions of transport. Gas kets or other sealing elements must be Standards § 178.504 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) lAl for a non-removable head selves compatible with the contents to steel drum; and be transported, suitable internal pro for a removable head steel (2) 1A2 tective or treatments must be drum. applied. These coatings or treatments (b) Construction requirements for must retain their protective properties steel drums are as follows: under (I) Body and heads must be con 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

1012 Pipeline and Hazardous Materials Safety Admin., DOT § 178.506

(9) Maximum net mass: 400 kg (882 other sealing elements must be used pounds). with all removable heads. [Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, as (6) Maximum capacity of drum: 450 L amended at 56 FR 66284, Dec. 20, 1991; Amdt. (119 gallons). 178—110, 60 FR 49111, Sept. 21, 1995] (7) Maximum net mass: 400 kg (882 pounds). § 178.505 Standards for aluminum drums. lAmdt. 178—97, 55 FR 52717, Dec. 21, 1990, as amended at 56 FR 66284, Dec. 20, 1991: Amdt. (a) The following are the identifica 178—102, 59 FR 28494. June 2, 19941 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) iNi 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 (lB 1) 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 (lB2). 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 (lNl) 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 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. 1013 § 178.507 49 CFR Ch. I (10—1—10 Edition) (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 , 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. 178—97, 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 178—102, 59 FR 28494, June 2, 1994] propriate to the capacity and intended use of the drum. § 178.507 Standards for plywood 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. 178—97, 55 FR 52717, Dec. 21, 1990, as tended. A material other than plywood, amended by Amdt. 178-106, 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) lHl for a non-removable grains crosswise. head plastic (3) The body and heads of the drum drum; and their joints must be of a design ap (2) lH2 for a removable head plastic propriate to the capacity of the drum drum; and its intended use. (3) 3Hl for a non-removable head (4) In order to prevent sifting of the jerrican; and contents, 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. 178—97, 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 fiber drums are as follows: diation. Any permeation of the sub (1) The body of the drum must be stance contained may not constitute a constructed of multiple plies of heavy danger under normal conditions of paper or fiberboard (without corruga transport.

1014 Pipeline and Hazardous Materials Satety Admin., DOT §178.511

(2) If protection against ultra-violet (7) Maximum capacity of drums and radiation is required, it must be pro jerricans: 1H1, 1H2: 450 L (119 gallons); vided by the addition of carbon black 3H1, 3H2: 60 L (16 gallons). or other suitable pigments or inhibi (8) Maximum net mass: 1HI, lH2: 400 tors. These additives must be compat kg (882 pounds); 3Hl, 3H2: 120 kg (265 ible with the contents and remain ef pounds). fective throughout the life of the pack [Amdt. 178-.97. 55 FR 52717. aging. Where Dec. 21, 1990, as use is made of carbon amended by Amdt. 178.-102, 59 FR 28494, June black, pigments or inhibitors other 2, 1994; 64 FR 10782, Mar. 5, 1999; 66 FR 45386, than those used in the manufacture of Aug. 28, 2001] the design type, retesting may be omit ted if the carbon black content does § 178.510 Standards for wooden bar not exceed 2 percent by mass or if the rels. pigment content does not exceed 3 per (a) The following are identification cent by mass; the content of inhibitors codes for wooden barrels: of ultra-violet radiation is not limited. (1) 2Cl for a hung type wooden barrel; (3) Additives serving purposes other and than protection against ultra-violet ra (2) 2C2 for a slack type (removable diation may be included in the com head) wooden barrel. position of the plastic material pro (b) Construction requirements for vided they do not adversely affect the wooden barrels are as follows: chemical and physical properties of the (1) The wood used must be of good packaging material. quality, straight-grained, well-sea (4) The wall thickness at every point soned and free from knots, bark, rotten of the packaging must be appropriate wood, sapwood or other defects likely to its capacity and its intended use, to lessen the effectiveness of the barrel for the purpose taking into account the stresses to intended. (2) The which each point is liable to be ex body and heads must be of a design posed. Minimum thickness and mark appropriate to the capacity and intended use of the barrel. ing requirements in 173.28(b) (4) and § (3) Staves 178.503(a) (9) of this subchapter apply and heads must be sawn or to cleft with drums intended for reuse. the grain so that no annual ring extends over more than half the (5) Openings for filling, emptying and thickness of a stave or head. venting in the bodies or heads of non (4) Barrel hoops must be of steel or removable head (1H1) drums and iron of good quality. The hoops of 2C2 jerricans (3Hl) may not exceed 7.0 cm (3 barrels may be of a suitable hardwood. inches) in diameter. Drums and (5) For wooden barrels 2C1, the di jerricans with larger openings are con ameter of the bung-hole may not ex sidered to be of the removable head ceed half the width of the stave in type (lH2 and 3HZ). Closures for open which it is placed. ings in the bodies or heads of drums (6) For wooden barrels 2C2, heads and jerricans must be so designed and must fit tightly into crozes. applied that they remain secure and (7) Maximum capacity of barrel: 250 L leakproof under normal conditions of (66 gallons). transport. Gaskets or other sealing ele (8) Maximum net mass: 400 kg (882 ments must be used with closures un pounds). less the closure is inherently leakproof. (6) Closure devices for removable § 178.511 Standards for aluminum and head drums and jerricans must be so steel jerricans. designed and applied that they remain (a) The following are identification secure and leakproof under normal con codes for aluminum and steel jerricans: ditions of transport. Gaskets must be (1) 3Al for a non-removable head used with all removable heads unless steel jerrican; 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 orjerrican is in (3) 3Bl for a non-removable head alu herently leakproof. minum jerrican; and

1015 § 178.512 49 CFR Ch. I (10—1—10 Edition)

(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 l78.503(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. 178—97, 55 FR 52717, Dec. 21, 1990, as lons) or less must be mechanically amended by Amdt. 178-106, 59 FR 67521, Dec. seamed or welded. 29, 19941 (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) 4Cl 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 of the box. The tops and bottoms may must retain their protective properties be made of water-resistant reconsti under normal conditions of transport. tuted wood such as hard board, particle capacity of jerrican: 60 (6) Maximum board or other suitable type. gallons). L (16 (2) Fastenings must be resistant to 120 kg (265 (7) Maximum net mass: vibration experienced under normal pounds). conditions of transportation. End grain [Amdt. 178—97, 55 FR 52717, Dec. 21, 1990, as nailing must be avoided whenever prac amended by Amdt. 178-102, 59 FR 28494, June ticable. Joints which are likely to be 2, 1994; Amdt. 178—119, 62 FR 24742, May 6, highly stressed must be made using 1997] clenched or annular ring nails or equiv alent fastenings.

1016 Pipeline and Hazardous Materials Safety Admin., DOT §178.517 (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 one of the following methods of glued for a fi berboard box is 4G. assembly is used: Linderman joint, (b) Construction requirements tongue and groove joint, ship for fi lap or berboard boxes are as follows: rabbet joint, or butt joint with at least (1) Strong, solid or two corrugated double-faced cor metal fasteners at each rugated fiberboard joint. (single or multi- wall) must be used, appropriate (4) Maximum to the net mass: 400 kg (882 capacity and intended pounds). use of the box. The water resistance of the outer sur [Amdt. 178—97. 55 FR 52717, Dec. 21, 1990, as face must be such that the increase in amended by Amdt. 178-106, 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 . 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. 178—97, 55 FR 52717, Dec. 21, the material used and 1990, and the method of amended by Amdt. 178-99, 58 FR 51534, Oct. 1, construction must be appropriate to 1993; Amdt. 178—106, 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 (3) Boxes must be securely assembled codes for plastic boxes: by means of suitable devices. (1) 4Hl for an expanded plastic box; (4) Maximum net mass: 400 kg (882 and pounds). (2) 4H2 for a solid plastic box. 1017 § 178.518 49 CFR Ch. I (10—1—10 Edition)

(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 intended use. The box § 178.518 Standards for woven plastic capacity and 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 ; 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. (b) Construction requirements and interlocking with the bottom sec for woven plastic fabric bags are tion. The top and bottom sections must as fol 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. 178—97, 55 FR 52717, Dec. 21, 1990, and than protection against ultra-violet ra amended by Amdt. 178-99, 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. 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:

1018 Pipeline and Hazardous Materials Safety Admin., DOT § 178.522 (1) Bags must be made of a suitable (2) 5M2 for a multi-wall water-resist plastic material. The strength of the ant . 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) 5Ll 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 (2) Bags, sift-proof, 5L2: The bag liners, must also be placed must be made sift-proof, by appropriate next to the substance. Seams and clo means, such as by the use of paper sures must be waterproof. bonded to the inner surface of the bag (3) Maximum net mass: 50 kg (110 by a water-resistant adhesive such as pounds). bitumen, plastic film bonded to the [Amdt. 178—97, 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 178—106, 59 FR 67521, Dec. 29, 19941 material. 178.522 (3) Bags, water-resistant, 5L3: To pre § Standards for composite 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; 6HA2 the bag, or one or more inner liners (2) for a plastic receptacle with made of plastic material or metalized in a protective steel or box; film or foil. (3) 6HB1 for a plastic receptacle with (4) Maximum net mass: 50 kg (110 in a protective aluminum drum. pounds). (4) 6HB2 for a plastic receptacle with in a protective aluminum crate or box. [Amdt. 178—97, 55 FR 52717, Dec. 21, 1990, as (5) 6HC for a plastic receptacle within amended at 56 FR 66285, Dec. 20, 19911 a protective . (6) 6HD1 for a plastic receptacle with 178.521 Standards for bags. § paper in a protective plywood drum; (a) The following are identification (7) 6HD2 for a plastic receptacle with codes for paper bags: in a protective plywood box; (I) 5M1 for a multi-wall paper bag; (8) 6HG1 for a plastic receptacle with and in a protective fiber drum; 1019 § 178.523 49 CFR Ch. 1(10—1—10 Edition)

(9) 6HG2 for a plastic receptacle with (5) Maximum net mass is as follows: in a protective fiberboard box; 6HA1, 6HB1, 6HD1, 6HG1, 6HH1—400kg (10) 6HHI for a plastic receptacle (882 pounds); 6HB2, 6HC, 6HD2, 6HG2, within a protective plastic drum; and 6HH2—75 kg (165 pounds). (11) 6HH2 for a plastic receptacle [Amdt. 178—97. 55 FR 52717, Dec. 21, 1990, as protective plastic box. within a amended by Amdt. 178-106, 59 FR 67521, Dec. (b) Construction requirements for 29, 19941 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) 6PAI 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) 6HHI: 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: tacles is as follows: 6HA1, 6HB1, 6HD1, (1) Receptacles must be of suitable 6HG1, 6HH1—250 L (66 gallons); 6HA2, form (cylindrical or pear-shaped), be 6HB2, 6HC, 6HD2, 6HG2, 6HH2—60 L (16 made of good quality materials free gallons). from any defect that could impair their 1020 Pipeline and Hazardous Materials Safety Admin., DOT § 178.601

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 6PA1, 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 M—Testing 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. 178—97, 55 FR 52723, Dec. 21, (C) If the protective crate surrounds 1990, unless otherwise noted. pear-shaped a 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. 178—97, 55 FR 52717, Dec. 21, 1990, and apply to the protective packaging. amended by Amdt. 178-99, 58 FR 51534, Oct. 1, (iv) For receptacles with protective 19931 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 (viii) For receptacles with protective extent that a package assembly func fiber drum 6PGI, 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, 1021 § 178.601 49 CFR Ch. I (10—1—10 Edition)

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 paragraph quency specified in (e) of retests must be conducted at least once this section. every 24 months. For infectious sub is the perform (3) Production testing stances packagings, the periodic leakproofness test pre ance of the retests must be conducted at least once 178.604 of this subpart on scribed in § every 24 months. each single or composite packaging in (f) samples. tended to contain a liquid. Test The manufacturer shall conduct the design qualification (4) A different packaging is one that 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 §l73.27(c)(l) 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 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,

1022 Pipeline and Hazardous Materials Safety Admin., DOT § 1786O1 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 (1) of this section. Permitted of cushioning between inner pack variations are as follows: agings may not be less than the thick (1) 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 agings (i.e. shape—round, rectangular, packagings are etc.); used (as compared to the inner pack agings (B) The material of construction of used in the drop test), sufficient 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 (B) 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 does not exceed that originally tested. is in tended to contain (ii) A lesser number of the tested inner packagings for liquids inner packagings, or of the alternative and is not leakproof, or is in 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 half the gross mass of inner packagings filled inner pack agings of used for the drop test; the tested combination pack aging. In (iii) The thickness of cushioning ma addition, the marking re terial between inner packagings and quired by §178.503(a)(2) of this part between inner packagings and the out- must include the letter cv”.

1023 § 178.601 49 CFR Ch. 1(10—1—10 Edition)

(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 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 1024 Pipeline and Hazardous Materials Safety Admin., DOT § 178.601 of the substance used in the qualifying to a higher packing group, hydrostatic drop test was the same or greater than test pressure, or specific gravity to the specific gravity of the liquid used which the packaging has been tested); in the design type tests of the pack (vi) Type of side seam welding; aging with replacement closure devices (vii) Type of steel; or gasketing.) (viii) An increase greater than 10% or (6) The provisions in Variations 1, 2. any decrease in the steel thickness of and 4 in paragraphs (g)(l), (2) and (4) of the head, body, or bottom; this section for combination pack (ix) End seam type, (e.g., triple or agings may be applied to packagings ); containing articles, where the provi (x) A reduction in the number of roll sions for inner packagings are applied ing hoops (beads) which equal or exceed analogously to the articles. In this the diameter over the chimes; case, inner packagings need not comply (xi) The location, type or size, and with §l73.27(c)(l) and (c)(2) of this sub material of closures (other than the chapter. cover of UN 1A2 drums); (7) Approval of selective testing. In ad (xii) The location (e.g., from the head dition to the provisions of § 178.601(g) (1) to the body), type (e.g., mechanically through (g) (6) of this subpart, the Asso seamed or welded flange), and mate ciate Administrator may approve the rials of closure (other than the cover of selective testing of packagings that UN lA2 drums); and differ only in minor respects from a (xiii) For UN lA2 drums: tested type. (A) Gasket material (e.g., plastic), or (8) For a steel drum with a capacity properties affecting the performance of greater than 12 L (3 gallons) manufac the gasket; tured from low carbon, cold-rolled (B) Configuration or dimensions of sheet steel meeting ASTM designations the gasket; A 366/A 366M or A 568/A 568M, vari (C) Closure ring style including bolt ations in elements other than the fol size (e.g.. square or round back, 0.625 lowing design elements are considered inches bolt); and minor and do not constitute a different (D) Closure ring thickness, drum design type, or “different pack (E) Width of lugs or extensions in aging” as defined in paragraph (c) of crimp/lug cover. this section for which design qualifica (h) Approval of equivalent packagings. tion testing and periodic retesting are A packaging having specifications dif required. Minor variations authorized ferent from those in § 178.504—178.523 of without further testing include this part, or which is tested using changes in the identity of the supplier methods or test intervals, other than of component material made to the those specified in subpart M of this same specifications, or the original part, may be used if approved by the manufacturer of a DOT specification or Associate Administrator. Such pack UN standard drum to be remanufac agings must be shown to be equally ef tured. A change in any one or more of fective, and testing methods used must the following design elements con be equivalent. stitutes a different drum design type: (i) Proof of compliance. Notwith (i) The packaging type and category standing the periodic retest intervals of the original drum and the remanu specified in paragraph (e) of this sec factured drum, i.e., lAl or 1A2; tion, the Associate Administrator may (ii) The style, (i.e., straight-sided or at any time require demonstration of tapered); compliance by a manufacturer, (iii) Except as provided in paragraph through testing in accordance with (g)(3) of this section, the rated this subpart, that packagings meet the (marked) capacity and outside dimen requirements of this subpart. As re sions; quired by the Associate Administrator, (iv) The physical state for which the the manufacturer shall either— packaging was originally approved (1) Conduct performance tests, or (e.g., tested for solids or liquids); have tests conducted by an inde (v) An increase in the marked level of pendent testing facility, in accordance performance of the original drum (i.e., with this subpart; or 1025 § 178.602 49 CFR Ch. I (10—1—10 Edition)

(2) Supply packagings, in quantities for testing and tests must be carried sufficient to conduct tests in accord out in the same manner as if prepared ance with this subpart, to the Asso for transportation, including inner ciate Administrator or a designated packagings in the case of combination representative of the Associate Admin packagings. istrator. (b) For the drop and stacking test, (j) Coatings. If an inner treatment or inner and single-unit receptacles other coating of a packaging is required for than bags must be filled to not less safety reasons, the manufacturer shall than 95% of maximum capacity (see design the packaging so that the treat § 171.8 of this subchapter) in the case of ment or coating retains its protective solids and not less than 98% of max even after withstanding properties the imum in the case of liquids. Bags con prescribed this subpart. tests by taining solids shall be filled to the (k) Number of test samples. Except as maximum mass at which they may be provided in this section, one test sam used. The material to be transported in ple must be used for each test per the packagings may be replaced by a formed under this subpart. non-hazardous material, except for (1) Stainless steel drums. Provided the chemical compatibility testing or validity of the test results is not af where this would fected, a person may perform the de invalidate the results of sign qualification testing of stainless the tests. steel drums using three (3) samples (c) If the material to be transported rather than the specified eighteen (18) is replaced for test purposes by a non- samples under the following provisions: hazardous material, the material used (i) The packaging must be tested in must be of the same or higher specific accordance with this subpart by sub gravity as the material to be carried, jecting each of the three containers to and its other physical properties the following sequence of tests: (grain, size, viscosity) which might in (A) The stacking test in § 178.606, fluence the results of the required tests (B) The leakproofness test in § 178.604, must correspond as closely as possible (C) The hydrostatic pressure test in to those of the hazardous material to §178.608, and be transported. Water may also be used (D) Diagonal top chime and flat on for the liquid drop test under the con the side drop tests in § 178.603. Both ditions specified in § 178.603(e) of this drop tests may be conducted on the subpart. It is permissible to use addi same sample. tives, such as bags of lead shot, to (ii) For periodic retesting of stainless achieve the requisite total package steel drums, a reduced sample size of mass, so long as they are placed so that one container is authorized. the test results are not affected. (2) Packagings other than stainless steel (d) Paper or fiberboard packagings drums. Provided the validity of the test must be conditioned for at least 24 results is not affected, several tests hours immediately prior to testing in may be performed on one sample with an atmosphere maintained— the approval of the Associate Adminis (1) At 50 percent ±2 percent relative trator. humidity, and at a temperature of 23 [Amdt. 178—97, 55 FR 52723, Dec. 21, 1990, as C±2 °C (73 °F±4 °F). Average values amended at 56 FR 66285, Dec. 20, 1991: 57 FR should fall within these limits. Short- 45465, Oct. 1, 1992: Amdt. 178—102, 59 FR 28494. term fluctuations and measurement June 2, 1994: Amdt. 178—106, 59 FR 67521, 67522, limitations may cause individual meas Dec. Amdt. 178—117, 61 FR 50628, 29, 1994; Sept. urements to vary by up to ±5 percent 26, 1996: 66 FR 45386, Aug. 28, 2001; 67 FR 53143, relative humidity Aug. 14, 2002; 68 FR 75758, Dec. 31, 2003: 68 FR without significant 61942, Oct. 30, 2003: 75 FR 5396, Feb 2, 2010: 75 impairment of test reproducibility; FR 60339, Sept. 30. 2010] (2) At 65 percent ±2 percent relative humidity, and at a temperature of 20 § 178.602 Preparation of packagings °C±2 C (68 °F±4 °F), or 27 °C±2 CC (81 and packages for testing. °F±4 °F). Average values should fall (a) Except as otherwise provided in within these limits. Short-term fluc this subchapter, each packaging and tuations and measurement limitations package must be closed in preparation may cause individual measurements to 1026 Pipeline and Hazardous Materials Safety Admin., DOT § 178.603

vary by up to ±5 percent relative hu § 178.603 Drop test. midity without significant impairment of test reproducibility; or (a) General. The drop test must be (3) For testing at periodic intervals conducted for the qualification of all only (i.e., other than initial design packaging design types and performed qualification testing), at ambient con periodically as specified in §178.601(e). ditions. For other than flat drops, the center of (e) Except as otherwise provided, gravity of the test packaging must be each packaging must be closed in prep vertically over the point of impact. aration for testing in the same manner Where more than one orientation is as if prepared for actual shipment. All possible for a given drop test, the ori closures must be installed using proper entation most likely to result in fail techniques and torques. ure of the packaging must be used. The Bung-type (f) barrels made of natural number of drops required and the pack wood must be left filled with water for ages’ orientations are as follows: at least 24 hours before the tests. lAmdt. 178.-97, 55 FR 52723, Dec. 21, 1990, as amended at 56 FR 66286, Dec. 20, 1991; Amdt. 178—106, 59 FR 67522, Dec. 29, 1994; 69 FR 76186, Dec. 20, 2004; 71 FR 78635, Dec. 29, 20061

Packaging No. of tests (samples) Drop orientation of samples

Steel drums, Aluminum drums, Metal Six—(three for each First drop (using three samples): The package must strike the drums (other than steel or 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—(onn 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, Corn- Flat on the short side (using the fourth sample). Fifth drop: posite packagings which are in the On a corner (using the fifth sample). shape of a box. Bags—single-ply with a side seam Three—(three drops First drop: Flat on a wide face (using all three samples). Sac 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). Bags—single-ply without a side seam, Three—(two drops per First drop: Flat on a wide face (using all three samples). Sen or multi-ply bag). and drop: On an end of the bag (using all three samples).

(b) Exceptions. For testing of single or rial), and combination packagings with composite packagings constructed of plastic inner packagings other than stainless steel, nickel, or monel at plastic bags intended to contain solids periodic intervals only (i.e., other than or articles must be carried out when design qualification testing), the drop the temperature of the test sample and test may be conducted with two sam its contents has been reduced to —18 °C ples, one sample each for the two drop (0 °F) or lower. Test liquids must be orientations. These samples may have kept in the liquid state, if necessary, been previously used for the hydro by the addition of anti-freeze. Water/ static pressure or stacking test. Excep anti-freeze solutions with a minimum tions for the number of steel and alu specific gravity of 0.95 for testing at minum packaging samples used for — 18 °C (0 °F) or lower are considered conducting the drop test are subject to acceptable test liquids. Test samples the approval of the Associate Adminis prepared in this way are not required trator. to be conditioned in accordance with (c) Special preparation of test samples § 178.602(d). for the drop test. (1) Testing of plastic (d) Target. The target must be a rigid, drums, plastic jerricans, plastic boxes non-resilient, flat and horizontal other than expanded polystyrene sur boxes, face. composite packagings (plastic mate- 1027 § 178.604 49 CFR Ch. I (10—1—10 Edition)

(e) Drop height. Drop heights, meas any damage likely to adversely affect ured as the vertical distance from the safety during transport; target to the lowest point on the pack (4) For a composite or combination age, must be equal to or greater than packaging, there is no damage to the the drop height determined as follows: outer packaging likely to adversely af (1) For solids and liquids, if the test fect safety during transport, and there is performed with the solid or liquid to is no leakage of the filling substance be transported or with a non-hazardous from the inner packaging; material having essentially the same (5) Any discharge from a closure is physical characteristic, the drop height slight and ceases immediately after must be determined according to pack impact with no further leakage; and ing group, as follows: (6) No rupture is permitted in pack (i) Packing Group I: 1.8 m (5.9 feet). agings for materials in Class I which (ii) Packing Group II: 1.2 m (3.9 feet). would permit spillage of loose explo (iii) Packing Group III: 0.8 m (2.6 sive substances or articles from the feet). outer packaging. (2) For liquids in single packagings lAmdt. 178—97, 55 FR 52723, Dec. 21, 1990, as and for inner packagings of combina amended at 56 FR 66286, Dec. 20, 1991: 57 FR tion packagings, if the test is per 45465, Oct. 1, 1992; Amdt. 178—99, 58 FR 51534, formed with water: Oct. 1, 1993; Amdt. 178—106, 59 FR 67522, Dec. (1) Where the materials to be carried 29, 1994; 65 FR 50462, Aug. 18, 2000: 66 FR 45386, have a specific gravity not exceeding Aug. 28, 2001; 67 FR 61016. Sept. 27. 2002; 69 FR 76186, Dec. 20, 2004] 1.2, drop height must be determined ac cording to packing group, as follows: § 178.604 Leakproofness test. (A) Packing Group 1: 1.8 m (5.9 feet). (a) General. The leakproofness test (B) Packing Group II: 1.2 m (3.9 feet). must be performed with compressed air (C) Packing Group III: 0.8 m (2.6 feet). or other suitable gases on all pack (ii) Where the materials to be trans agings intended to contain liquids, ex ported have a specific gravity exceed cept that: ing 1.2, the drop height must be cal (1) The inner receptacle of a com culated on the basis of the specific posite packaging may be tested with gravity (SG) of the material to be car out the outer packaging provided the ried, rounded up to the first decimal, as test results are not affected; and follows: (2) This test is not required for inner (A) Packing Group I: SG x 1.5 m (4.9 packagings of combination packagings. feet). (b) Number of packagings to be tested— (B) Packing Group II: SC x 1.0 m (3.3 (1) Production testing. All packagings feet). subject to the provisions of this section (C) Packing Group III: SC x 0.67 m must be tested and must pass the (2.2 feet). leakproofness test: (f) Criteria for passing the test. A pack (i) Before they are first used in trans age is considered to successfully pass portation; and the drop tests if for each sample test (ii) Prior to reuse, when authorized ed— for reuse by § 173.28 of this subchapter. (I) For packagings containing liquid, (2) Design qualification and periodic each packaging does not leak when testing. Three samples of each different equilibrium has been reached between packaging must be tested and must the internal and external pressures, ex pass the leakproofness test. Exceptions cept for inner packagings of combina for the number of samples used in con tion packagings when it is not nec ducting the leakproofness test are sub essary that the pressures be equalized; ject to the approval of the Associate (2) For removable head drums for sol Administrator. ids, the entire contents are retained by (c) Special preparation—(l) For design an inner packaging (e.g., a plastic bag) qualification and periodic testing, even if the closure on the top head of packagings must be tested with clo the drum is no longer sift-proof; sures in place. For production testing, (3) For a bag, neither the outermost packagings need not have their clo ply nor an outer packaging exhibits sures in place. Removable heads need

1028 Pipeline and Hazardous Materials Safety Admin., DOT § 178.605 not be installed during production test (c) Special preparation of receptacles ing. for testings. Vented closures must ei (2) For testing with closures in place, ther be replaced by similar non-vented vented closures must either be replaced closures or the vent must be sealed. by similar non-vented closures or the (d) Test method and pressure to be ap vent must be sealed. plied. Metal packagings and composite (d) Test method. The packaging must packagings other than plastic (e.g., be restrained under water while an in glass, porcelain or stoneware), includ ternal air pressure is applied; the ing their closures, must be subjected method of restraint must not affect the to the test pressure for minutes. results of the test. The test must 5 Plastic be packagings conducted, for other than production and composite packagings (plastic material), testing, for a minimum time of five including their clo sures, minutes. Other methods, at least must be subjected to the test pressure equally effective, may be used in ac for 30 minutes. This pressure cordance with appendix B of this part. is the one to be marked as required in (e) Pressure applied. An internal air § 178.503(a)(5). The receptacles must be pressure (gauge) must be applied to the supported in a manner that does not packaging as indicated for the fol invalidate the test. The test pressure lowing packing groups: must be applied continuously and even (1) Packing Group I: Not less than 30 ly, and it must be kept constant kPa (4 psi). throughout the test period. In addition, (2) Packing Group II: Not less than 20 packagings intended to contain haz kPa (3 psi). ardous materials of Packing Group I (3) Packing Group III: Not less than must be tested to a minimum test pres 20 kPa (3 psi). sure of 250 kPa (36 psig). The hydraulic (f) Criteria for passing the test. A pack pressure (gauge) applied, taken at the aging passes the test if there is no top of the receptacle, and determined leakage of air from the packaging. by any one of the following methods must lAmdt. 178—97, 55 FR 52723, Dec. 21, 1990. as be: amended at 56 FR 66286, Dec. 20, 1991; Amdt. (1) Not less than the total gauge pres 178—106, 59 FR 67522, Dec. 29, 1994; 66 FR 45386, sure measured in the packaging (i.e., Aug. 28, 20011 the vapor pressure of the filling mate rial and the partial pressure of the air § 178.605 Hydrostatic pressure test. or other inert gas minus 100 kPa (15 (a) General. The hydrostatic pressure psi)) at 55 °C (131 CF), multiplied by a test must be conducted for the quali safety factor of 1.5. This total gauge fication of all metal, plastic, and com pressure must be determined on the posite packaging design types intended basis of a maximum degree of filling in to contain liquids and be performed pe accordance with § 173.24a(d) of this sub riodically as specified in §178.601(e). chapter and a filling temperature of 15 This test is not required for inner C (59 °F); packagings of combination packagings. (2) Not less than 1.75 times the vapor For internal pressure requirements for pressure at 50 C (122 °F) of the mate inner packagings of combination pack rial to be transported minus 100 kPa (15 agings intended for transportation by psi) but with a minimum test aircraft, see §173.27(c) pressure of this sub of 100 kPa (15 chapter. psig); or (3) Not less than 1.5 times (b) Number of test samples. Three test the vapor pressure at 55 samples are required for each different °C (131 °F) of the mate rial to be packaging. For packagings constructed transported minus 100 kPa (15 psi), of stainless steel, monel, or nickel, but with a minimum test pressure only one sample is required for periodic of 100 kPa (15 psig). retesting of packagings. Exceptions for Packagings intended to contain haz the number of aluminum and steel ardous materials of Packing Group I sample packagings used in conducting must be tested to a minimum test pres the hydrostatic pressure test are sub sure of 250 kPa (36 psig). ject to the approval of the Associate (e) Criteria for passing the test. A pack Administrator. age passes the hydrostatic test if, for 1029 § 178.606 49 CFR Ch. I (10—1—10 Edition)

each test sample, there is no leakage of Plastic packagings must be cooled to liquid from the package. ambient temperature before this stack ing stability [Amdt. 178.97, 55 FR 52723, Dec. 21, 1990, as assessment. amended at 56 FR 66286, Dec. 20, 1991; Amdt. (2) Periodic retesting. The test sample 178—99, 58 FR 51534, Oct. 1, 1993; Amdt. 178—102, must be tested in accordance with: 59 FR 28494, June 2, 1994; 65 FR 50462, Aug. 18, (i) Section 178.606(c) (1) of this sub 2000; 66 FR 45386, 45390, Aug. 28, 2001; 73 FR part; or 57007, Oct. 1, 20081 (ii) The packaging may be tested using a dynamic compression testing § 178.606 Stacking test. machine. The test must be conducted (a) General. All packaging design at room temperature on an empty, un types other than bags must be sub sealed packaging. The test sample jected to a stacking test. must be centered on the bottom platen (b) Number of test samples. Three test of the testing machine. The top platen samples are required for each different must be lowered until it comes in con packaging. For periodic retesting of tact with the test sample. Compression packagings constructed of stainless must be applied end to end. The speed steel, monel, or nickel, only one test of the compression tester must be one- sample is required. Exceptions for the half inch plus or minus one-fourth inch number of aluminum and steel sample per minute. An initial preload of 50 packagings used in conducting the pounds must be applied to ensure a stacking test are subject to the ap definite contact between the test sam proval of the Associate Administrator. ple and the platens. The distance be Notwithstanding the provisions of tween the platens at this time must be § 178.602(a) of this subpart, combination recorded as zero deformation. The force packagings may be subjected to the A to then be applied must be calculated stacking test without their inner pack using the formula: agings, except where this would invali date the results of the test. Liquids: A (n—l) [w ± (s x v x 8.3 x (c) Test method—(l) Design qualifica .98)] x 1.5; tion testing. The test sample must be Solids: A (n— 1) (m x 2.2 x 1.5) subjected to a force applied to the top Where: surface of the test sample equivalent to A = applied load in pounds the total weight of identical packages m = the certified maximum gross mass for which might be stacked on it during the container in kilograms. transport; where the contents of the n = minimum number of containers that, test sample are non-hazardous liquids when stacked, reach a height of 3 meters. with specific gravities different from s specific gravity of lading. that of the liquid to be transported, the w maximum weight of one empty container force must be calculated based on the in pounds. specific gravity that will be marked on v = actual capacity of container (rated ca the packaging. The minimum height of pacity ± outage) in gallons. the stack, including the test sample, And: must be 3.0 m (10 feet). The duration of 8.3 corresponds to the weight in pounds of 1.0 the test must be 24 hours, except that gallon of water. plastic drums, jerricans, and composite .98 corresponds to the minimum filling per packagings 6HH intended for liquids centage of the maximum capacity for liq uids. shall be subjected to the stacking test 1.5 is a compensation factor that converts for a period of 28 days at a temperature the static load of the stacking test into a of not less than 40°C (104°F). Alter load suitable for dynamic compression native test methods which yield equiv testing. alent results may be used if approved 2.2 is the conversion factor for kilograms to by the Associate Administrator. In pounds. guided load tests, stacking stability (d) Criteria for passing the test. No test must be assessed after completion of sample may leak. In composite pack the test by placing two filled pack agings or combination packagings, agings of the same type on the test there must be no leakage of the filling sample. The stacked packages must substance from the inner receptacle, or maintain their position for one hour. inner packaging. No test sample may 1030 Pipeline and Hazardous Materials Safety Admin., DOT § 178.609 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 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 expected contents; in no case may the aging passes the vibration test if there maximum deflection exceed one inch. is no rupture or leakage from any of [Amdt. 178—97, 55 FR 52723, Dec. 21, 1990, as the packages. No test sample should amended at 56 FR 66286, Dec. 20, 1991; 57 FR show any deterioration which could ad 45465, Oct. 1, 1992; Amdt. 178—102, 59 FR 28494, versely affect transportation safety or June 2, 1994; Amdt. 178—106, 59 FR 67522, Dec. any distortion liable to reduce pack 29, 1994; 65 FR 58632, Sept. 29, 2000; 66 FR aging strength. 45386, Aug. 28, 2001; 70 FR 34076. June 13, 2005; 72 FR 55696, Oct. 1, 20071 [Amdt. 178—97, 55 FR 52723, Dec. 21, 1990, as amended at 56 FR 66286, Dec. 20, 1991; 66 FR § 178.607 Cooperage test for hung-type 45386, Aug. 28, 2001] wooden barrels. § 178.609 Test requirements for pack. (a) Number of samples. One barrel is agings for infectious substances. required for each different packaging. (a) Samples (b) Method of testing. Remove all of each packaging must be prepared for hoops above the bilge of an empty bar testing as described in paragraph rel at least two days old. (b) of this section and then subjected to the tests in paragraphs (c) Criteria for passing the test. A pack (d) through (1) of this section. aging passes the cooperage test only if (b) Samples the diameter of the cross-section of the of each packaging must be prepared upper part of the barrel does not in as for transport except that crease by more than 10 percent. a liquid or solid infectious sub stance should be replaced by water or, § 178.608 Vibration standard. where conditioning at —18 °C (0 °F) is specified, by water/antifreeze. Each pri (a) Each packaging must be capable mary receptacle must be filled to 98 of withstanding, without rupture or percent capacity. Packagings for live leakage, the vibration test procedure animals should be tested with the live outlined in this section. animal being replaced by an appro (b) Test method. (1) Three sample priate dummy of similar mass. packagings, selected at random, must (c) Packagings prepared as for trans be filled and closed as for shipment. port must be subjected to the tests in (2) The three samples must be placed Table I of this paragraph (c), which, for on a vibrating platform that has a test purposes, categorizes packagings vertical or rotary double-amplitude according to their material character (peak-to-peak displacement) of one istics. For outer packagings, the head inch. The packages should be con ings in Table I relate to fiberboard or strained horizontally to prevent them similar materials whose performance from falling off the platform, but must may be rapidly affected by moisture; be left free to move vertically, bounce plastics that may embrittle at low and rotate. temperature; and other materials, such (3) The test must be performed for as metal, for which performance is not one hour at a frequency that causes the significantly affected by moisture or package to be raised from the vibrating temperature. Where a primary recep platform to such a degree that a piece tacle and a secondary packaging of an of material of approximately 1.6 mm inner packaging are made of different (0.063 inch) thickness (such as steel materials, the material of the primary or ) can be passed receptacle determines the appropriate 1031 § 178.609 49 CFR Ch. I (10—1—10 Edition)

test. In instances where a primary re- damaged determines the appropriate ceptacle is made of more than one ma- test. terial, the material most likely to be

TABLE I—TESTS REQUIRED

Material of Tests required Outer packaging Inner packaging Refer to pars. (d) Refer to para. (h) Fiberboard Plastics Other Plastics Other (d) (e) (f) (g)

x X X X Whendryice X is used x x x x x x x x x x x x x x x x x x x x

(d) Samples must be subjected to (f) The sample must be conditioned in free-fall drops onto a rigid, nonresil an atmosphere of —18 C (0 °F) or less ient, flat, horizontal surface from a for a period of at least 24 hours and height of 9 m (30 feet). within 15 minutes of removal from that The drops must be performed as fol atmosphere be subjected to the test de lows: scribed in paragraph (d) of this section. (I) Where the samples are in the Where the sample contains dry ice, the shape of a box, five samples must be conditioning period may be reduced to dropped, one in each of the following 4 hours. orientation: Where packaging intended (i) Flat on the base: (g) is to (ii) Flat on the top: contain dry ice, a test additional to (iii) Flat on the longest side: that specified in paragraph (d) or (e) or (iv) Flat on the shortest side; and (f) of this section must be carried out. (v) On a corner. One sample must be stored so that all (2) Where the samples are in the the dry ice dissipates and then be sub shape of a drum, three samples must be jected to the test described in para dropped, one in each of the following graph (d) of this section. orientations: (h) Packagings with a gross mass of 7 (i) Diagonally on the top chime, with kg (15 pounds) or less should be sub the center of gravity directly above the jected to the tests described in para point of impact; graph (h) (1) of this section and pack (ii) Diagonally on the base chime; agings with a gross mass exceeding 7 and kg (15 pounds) to the tests in paragraph (iii) Flat on the side. (h) (2) of this section. (3) While the sample should be re (1) Samples must be placed on a leased in the required orientation, it is level, hard surface. A cylindrical steel accepted that for aerodynamic reasons rod with the impact may not take place in that a mass of at least 7 kg (15 orientation. pounds), a diameter not exceeding 38 (4) Following the appropriate drop se mm (1.5 inches), and, at the impact end quence, there must be no leakage from edges, a radius not exceeding 6 mm (0.2 the primary receptacle(s) which should inches), must be dropped in a vertical remain protected by absorbent mate free fall from a height of 1 m (3 feet), rial in the secondary packaging. measured from the impact end of the (e) The samples must be subjected to sample’s impact surface. One sample a water spray to simulate exposure to must be placed on its base. A second rainfall of approximately 50 mm (2 sample must be placed in an orienta inches) per hour for at least one hour. tion perpendicular to that used for the They must then be subjected to the first. In each instance, the steel rod test described in paragraph (d) of this must be aimed to impact the primary section. receptacle(s). For a successful test,

1032 Pipeline and Hazardous Materials Safety Admin., DOT § 178.609

there must be no leakage from the pri the same manner as in the tested pack mary receptacle(s) following each im age. pact. (2) Variation 2. A lesser number of the (2) Samples must be dropped onto the tested primary receptacles, or of the end of a cylindrical steel rod. The rod alternative types of primary recep must be set vertically in a level, hard tacles identified in paragraph (i)(l) of surface. It must have a diameter of 38 this section, may be used provided suf mm (1.5 inches) and a radius not ex ficient cushioning is added to fill the ceeding 6 mm (0.2 inches) at the edges void space(s) and to prevent significant of the upper end. The rod must pro movement of the primary receptacles. trude from the surface a distance at (3) Variation 3. Primary receptacles of least equal to that between the pri any type may be placed within a sec mary receptacle(s) and the outer sur ondary packaging and shipped without face of the outer packaging with a min testing in the outer packaging provided imum of 200 mm (7.9 inches). One sam all of the following conditions are met: ple must be dropped in a vertical free (i) The secondary and outer pack fall from a height of 1 m (3 feet), meas aging combination must be success ured from the top of the steel rod. A fully tested in accordance with para second sample must be dropped from graphs (a) through (h) of this section the same height in an orientation per with fragile (e.g., glass) inner recep pendicular to that used for the first. In tacles. each instance, the packaging must be (ii) The total combined gross weight oriented so the steel rod will impact of inner receptacles may not exceed the primary receptacle(s). For a suc one-half the gross weight of inner re cessful test, there must be no leakage ceptacles used for the drop test in para from the primary receptacle(s) fol graph (d) of this section. lowing each impact. (iii) The thickness of cushioning ma (1) Variations. The following vari terial between inner receptacles and ations in the primary receptacles between inner receptacles and the out placed within the secondary packaging side of the secondary packaging may are allowed without additional testing not be reduced below the corresponding of the completed package. An equiva thicknesses in the originally tested lent level of performance must be packaging. If a single inner receptacle maintained. was used in the original test, the thick (1) Variation 1. Primary receptacles of ness of cushioning between the inner equivalent or smaller size as compared receptacles must be no less than the to the tested primary receptacles may thickness of cushioning between the be used provided they meet all of the outside of the secondary packaging and following conditions: the inner receptacle in the original (i) The primary receptacles are of test. When either fewer or smaller similar design to the tested primary re inner receptacles are used (as com ceptacle (e.g., shape: round, rectan pared to the inner receptacles used in gular, etc.). the drop test), sufficient additional (ii) The material of construction of cushioning material must be used to the primary receptacle (glass, plastics, fill the void. metal, etc.) offers resistance to impact (iv) The outer packaging must pass and a stacking force equal to or greater the stacking test in § 178.606 while than that of the originally tested pri empty. The total weight of identical mary receptacle. packages must be based on the com (iii) The primary receptacles have bined mass of inner receptacles used in the same or smaller openings and the the drop test in paragraph (d) of this closure is of similar design (e.g., screw section. cap, friction lid, etc.). (v) For inner receptacles containing (iv) Sufficient additional cushioning liquids, an adequate quantity of ab material is used to fill void spaces and sorbent material must be present to to prevent significant movement of the absorb the entire liquid contents of the primary receptacles. inner receptacles. (v) Primary receptacles are oriented (vi) If the outer packaging is in within the intermediate packaging in tended to contain inner receptacles for 1033 § 178.700 49 CFR Ch. I (10—1—10 Edition)

liquids and is not leakproof, or is in specified in paragraph (a) (1) of this sec tended to contain inner receptacles for tion; followed by the capital letter(s) solids and is not sift proof, a means of specified in paragraph (a) (2) of this sec containing any liquid or solid contents tion; followed, when specified in an in in the event of leakage must be pro dividual section, by a numeral indi vided. This can be a leakproof liner, cating the category of intermediate plastic bag, or other equally effective bulk container. means of containment. (1) IBC code number designations are (vii) In addition, the marking re as follows: quired in §178.503(f) of this subchapter must be followed by the letter ‘U”. For solids, discharged 52723, Dec. 21, 1990, Under pres [Amdt. 178—97, 55 FR as Type sure of For liquids amended by Amdt. 178-111, 60 FR 48787, Sept. by gravity more than 20, 1995; 67 FR 53143, Aug. 14, 2002; 69 FR 54046, 10 kPa Sept. 7, 20041 (1.45 psig) Rigid 11 21 31 Subpart N—IBC Performance- Flexible 13 Oriented Standards (2) Intermediate bulk container code § 178.700 Purpose, scope and defini letter designations are as follows: tions. “A” means steel (all types and surface treat (a) This subpart prescribes require ments). ments applying to IBCs intended for ‘B” means aluminum. the transportation of hazardous mate “C” means natural wood. rials. Standards for these packagings ‘D” means plywood. are based on the UN Recommendations. F” means reconstituted wood. (b) Terms used in this subpart are de means fiberboard. fined in § 171.8 of this subchapter and in ‘H” means plastic. paragraph (c) of this section. L” means textile. (c) The following definitions pertain means paper, multiwall. to the IBC standards in this subpart. ‘N” means metal (other than steel or alu (1) Body means the receptacle proper minum). (including openings and their closures, (b) For composite IBCs, two capital but not including service equipment) letters are used in sequence following that has a volumetric capacity of not the numeral indicating IBC design more than 3 cubic meters (3,000 L, 793 type. The first letter indicates the ma gallons, or 106 cubic feet). terial of the IBC inner receptacle. The (2) Service equipment means filling and second letter indicates the material of discharge, pressure relief, safety, heat the outer IBC. For example, 3lHAl is a ing and heat-insulating devices and composite IBC with a plastic inner re measuring instruments. ceptacle and a steel outer packaging. (3) Structural equipment means the re inforcing, fastening, handling, protec [Amdt. 178—103, 59 FR 38068, July 26, 1994, as tive or stabilizing members of the body amended at 66 FR 45386, Aug. 28, 2001] or stacking load bearing structural members (such as metal ). § 178.703 Marking of IBCs. (4) Maximum permissible gross mass (a) The manufacturer shall: means the mass of the body, its service (1) Mark every IBC in a durable and equipment, structural equipment and clearly visible manner. The marking the maximum net mass (see § 171.8 of may be applied in a single line or in this subchapter). multiple lines provided the correct se [Amdt. 178-103, 59 FR 38068. July 26, 1994, as quence is followed with the informa amended by Amdt. 178-108, 60 FR 40038, Aug. tion required by this section in letters, 4, 1995; 66 FR 45386, 45387, Aug. 28, 2001; 73 FR numerals and symbols of at least 12 57008, Oct. 1, 2008; 75 FR 5396, Feb. 2, 20101 mm in height. This minimum marking size applies only to IBCs manufactured § 178.702 IBC codes. after October 1, 2001). The following in (a) Intermediate bulk container code formation is required in the sequence designations consist of: two numerals presented:

1034 Pipeline and Hazardous Materials Safety Admin., DOT § 178.703 (i) Except as provided in (iv) The month (designated numeri § 178.503(e)(1)(ii), the United Nations cally) and year (last two digits) of symbol as illustrated in manufacture. §l78.503(e)(l)(i). For metal IBCs on (v) The country authorizing the allo which the marking is stamped or em cation of the mark. The letters ‘USA’ bossed, the capital letters ‘UN” may indicate that the IBC is manufactured be applied instead of the symbol. and marked in the United States in (ii) The code number designating IBC compliance with the design type according to §178.702(a). provisions of this subchapter. The letter “W” must follow the IBC de sign type identification code on an IBC (vi) The name and address or symbol when the IBC differs from the require of the manufacturer or the approval ments in subpart N of this part, or is agency certifying compliance with sub tested using methods other than those parts N and 0 of this part. Symbols, if specified in this subpart, and is ap used, must be registered with the Asso proved by the Associate Administrator ciate Administrator. in accordance with the provisions in (vii) The stacking test load in kilo § 178.801(1). grams (kg). For IBCs not designed for (iii) A capital letter identifying the stacking, the figure “0” must be performance standard under which the shown. design type has been successfully test (viii) The maximum permissible ed, as follows: gross mass or, for flexible IBCs, the (A) X—for IBCs meeting Packing maximum net mass, in kg. Group I, II and III tests; (2) The following (B) Y—for IBCs meeting Packing are examples of symbols Group II and III tests; and and required markings: (C) Z—for IBCs meeting only Packing (i) For a metal IBC containing solids Group III tests. discharged by gravity made from steel:

1.1A/Y/02 92/UBA/ABC/5500/1500

(ii) For a flexible IBC containing sol ids discharged by gravity and made from woven plastic with a liner:

13H3/Z/03 92/USA/ABC/O/1500

(iii) For a rigid plastic IBC con stack load and with a manufacturer’s taining liquids, made from plastic with symbol in place of the manufacturer’s structural equipment withstanding the name and address:

1035 § 178.703 49 CFR Ch. I (10—1—10 Edition)

U 33.H1/Y/04 93/USA/M9399/1OBOO/1200

(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

31.Hkl/Y/05 93/USA/+ZT1235/10800/1200

(b) Additional marking. In addition to (3) Markings required by paragraph markings required in paragraph (a) of (b) (1) or (b) (2) of this section may be this section, each IBC must be marked preceded by the narrative description as follows in a place near the markings of the marking, e.g. Tare Mass: ** required in paragraph (a) of this sec where the ‘ * “ are replaced with the tion that is readily accessible for in tare mass in kilograms of the IBC. spection. Where units of measure are (4) For each fiberboard and wooden used, the metric unit indicated (e.g., IBC, the tare mass in kg must be 450 L) must also appear. shown. each rigid plastic and com (1) For (5) Each flexible IBC may be marked posite IBC, the following markings with a pictogram displaying rec must be included: ommended lifting methods. (i) Rated capacity in L of water at 20 (6) For each °C (68 CF); composite IBC, the inner (ii) Tare mass in kilograms: receptacle must be marked with at least the following information: (iii) Gauge test pressure in kPa: (iv) Date of last leakproofness test, if (i) The code number designating the applicable (month and year): and IBC design type, the name and address (v) Date of last inspection (month or symbol of the manufacturer, the and year). date of manufacture and the country (2) For each metal IBC, the following authorizing the allocation of the mark markings must be included on a metal as specified in paragraph (a) of this sec corrosion-resistant plate: tion: (i) Rated capacity in L of water at 20 (ii) When a composite IBC is designed °C (68 °F): in such a manner that the outer casing (ii) Tare mass in kilograms: is intended to be dismantled for trans (iii) Date of last leakproofness test, if port when empty (such as, for the re applicable (month and year): turn of the IBC for reuse to the origi (iv) Date of last inspection (month nal consignor), each of the parts in and year): tended to be detached when so disman (v) Maximum loading/discharge pres tled must be marked with the month sure, in kPa, if applicable: and year of manufacture and the name (vi) Body material and its minimum or symbol of the manufacturer. thickness in mm: and (7) The symbol applicable to an IBC (vii) Serial number assigned by the designed for stacking or not designed manufacturer. for stacking, as appropriate, must be

1036 Pipeline and Hazardous Materials Safety Admin., DOT § 178.704 marked on all IBCs manufactured, re (i) paired or remanufactured after Janu ary 1, 2011 as follows:

F 1 F -I

L I L I

(ii) Display the symbol in a durable port. An IBC intended for stacking and visible manner. must be designed for stacking. Any (iii) The symbol must not be less lifting or securing features of an IBC than 100 mm (3.9 inches) by 100 mm (3.9 must be of sufficient strength to with inches). stand the normal conditions of han (iv) For IBCs designed for stacking, dling and transportation without gross the maximum permitted stacking load distortion or failure and must be posi applicable when the IBC is in use must tioned so as to cause no undue stress in be displayed with the symbol. The any part of the IBC. mass in kilograms marked (kg) above (d) An IBC consisting of a packaging the symbol must not exceed the load within a framework must be so con imposed during the design test, indi as structed that: cated by the marking in paragraph (1) The body is not (a)(l)(vii) of this section, divided by 1.8. damaged by the framework; The letters and numbers indicating the mass must be at least 12 mm (0.48 (2) The body is retained within the inches). framework at all times; and (3) The service and structural equip [Amdt. 178—103, 59 FR 38068, July 26, 1994, as ment are fixed in such a way that they amended by Amdt. 62 FR 24743, 178-119. May cannot be 6, 1997: 64 FR 10782, Mar. 5, 1999; 65 FR 50462, damaged if the connections Aug. 18, 2000; 65 FR 58632, Sept. 29, 2000; 66 FR between body and frame allow relative 33451, June 21, 2001; 66 FR 45387, Aug. 28, 2001; expansion or motion. 74 FR 2269, Jan. 14, 2009; 75 FR 74, Jan. 4, 2010: (e) Bottom discharge valves must be 75 FR 5396, Feb. 2, 20101 secured in the closed position and the discharge system suitably protected § 178.704 General IBC standards. from damage. Valves having lever clo (a) Each IBC must be resistant to, or sures must be secured against acci protected from, deterioration due to dental opening. The open or closed po exposure to the external environment. sition of each valve must be readily ap IBCs intended for solid hazardous ma parent. For each IBC containing a liq terials must be sift-proof and water-re uid, a secondary means of sealing the sistant. discharge aperture must also be pro All (b) service equipment must be so vided, e.g., by a blank flange or equiva positioned or protected as to minimize lent device. potential loss of contents resulting (f) IBC design types must from damage during IBC handling and be con transportation. structed in such a way as to be bottom- lifted or top-lifted (c) Each IBC, including attachments, as specified in §l78.8ll and service and structural equipment, and 178.812. must be designed to withstand, without [Amdt. 178-103, 59 FR 38068, July 26, 1994, as loss of hazardous materials, the inter amended at 66 FR 45386, Aug. 28, 2001; 68 FR nal pressure of the contents and the 61942. Oct. 30, 2003] stresses of normal handling and trans

1037 § 178.705 49 CFR Ch. I (10—1—10 Edition)

§ 178.705 Standards for metal IBCs. (A) For steel, the percentage elon (a) The provisions in this section gation at fracture must not be less apply to metal IBCs intended to con than l0,000/Rm with a minimum of 20 tain liquids and solids. Metal IBC types percent; where Rm = minimum tensile are designated: strength of the steel to be used, in NI (1) ilA, liB, 11N for solids that are mm5; if U.S. Standard units of psi are loaded or discharged by gravity. used for tensile strength then the ratio (2) 21A, 21B, 2lN for solids that are becomes 10,000 x (l45IRm). loaded or discharged at a gauge pres (B) For aluminum, the percentage sure greater than 10 kPa (1.45 psig). elongation at fracture must not be less (3) 3lA, 31B, 31N for liquids or solids. than lO,000/(6Rm) with an absolute min (b) Definitions for metal IBCs: imum of eight percent; if U.S. Standard (1) Metal IBC means an IBC with a units of psi are used for tensile metal body, together with appropriate strength then the ratio becomes 10,000 service and structural equipment. x 145 / (6Rm). (2) Protected means providing the IBC body with additional external protec (C) Specimens used to determine the tion against impact and abrasion. For elongation at fracture must be taken example, a multi-layer (sandwich) or transversely to the direction of rolling double wall construction or a frame and be so secured that: with a metal lattice-work casing. Lo 5d (c) Construction requirements for metal IBCs are as follows: or (1) Body. The body must be made of ductile metal materials. Welds must be Lo = 5.65 JA made so as to maintain design type in where: tegrity of the receptacle under condi Lo = gauge length of the specimen before the tions normally incident to transpor test tation. d diameter (i) The use of dissimilar metals must A = cross-sectional area of test specimen. not result in deterioration that could affect the integrity of the body. (iv) Minimum wall thickness: (ii) Aluminum IBCs intended to con (A) For a reference steel having a tain flammable liquids must have no product of Rm x Ao = 10,000, where Ao movable parts, such as covers and clo is the minimum elongation (as a per sures, made of unprotected steel liable centage) of the reference steel to be to rust, which might cause a dangerous used on fracture under tensile stress reaction from friction or percussive (Rm x Ao = 10,000 x 145; if tensile contact with the aluminum. strength is in U.S. Standard units of (iii) Metals used in fabricating the pounds per square inch), the wall body of a metal IBC must meet the fol thickness must not be less than: lowing requirements:

Wall thickness (T) in mm Capacity (C) in liters1 Types hA, 11B, uN Types 21A, 21B, 21N, 31A, 31B, 31N Unprotected Protected Unprotected Protected

C1000 2.0 1.5 2.5 2.0

1000

2000

(B) For metals other than the ref FORMULA FOR METRIC UNITS erence steel described in paragraph (c)(1)(iii)(A) of this section, the min 21.4xe0 imum wall thickness is the greater of e1 = 1.5 mm (0.059 inches) or as determined xA1 by use of the following equivalence for mula:

1038 Pipeline and Hazardous Materials Safety Admin., DOT § 178.706

FORMULA FOR U.S. STANDARD devices are the only source of pressure UNITS relief for the IBC. Pressure relief de vices must be fitted in the vapor space. 21.4xe0 (d) Metal IBCs may not have a volu e1 = metric capacity greater than 3,000 L 3J(Rmi xA1)/145 (793 gallons) or less than 450 L (119 gal- ions). where: [Amdt. 178—103, 59 FR 38068, July 26, 1994, as e = required equivalent thickness wall of the amended by Amdt. 178-108. 60 metal to be used if FR 40038, Aug. (in mm or e,, is in 4, 1995; Amdt. 178—117, 61 FR inches, use formula 50629, Sept. 26. for U.S. Standard 1996; 66 FR units). 33452, June 21. 2001; 66 FR 45386, 45387, Aug. 28, 2001; 68 FR 45041, July 31, 2003; = required minimum thickness wall for 75 FR 5396, Feb. 2, 20101 the reference steel (in mm or if e0 is in inches, use formula for U.S. Standard §178.706 Standards for rigid plastic units). IBCs. Rm1 = guaranteed minimum tensile strength of the metal to be used (in N/mm2 or for (a) The provisions in this section U.S. Standard units, use psi). apply to rigid plastic IBCs intended to = minimum elongation (as a percentage) contain solids or liquids. Rigid plastic of the metal to be used on fracture under IBC types are designated: tensile stress (see paragraph (c) (1) of this 11H1 section). (1) fitted with structural equip ment designed to withstand the whole (C) For purposes of the calculation load when IBCs are stacked, for solids described in paragraph (c) (1) (iv) (B) of which are loaded or discharged by grav this section, the guaranteed minimum ity. tensile strength of the metal to be used (2) llH2 freestanding, for solids which (Rim) must be the minimum value ac are loaded or discharged by gravity. cording to material standards. How (3) 2lHl fitted with structural equip ever, for austenitic (stainless) steels, ment designed to withstand the whole the specified minimum value for Rm, load when IBCs are stacked, for solids according to the material standards, which are loaded or discharged under may be increased by up to 15% when a pressure. greater value is provided in the mate (4) 2lH2 freestanding, for solids which rial inspection certificate. When no are loaded or discharged under pres material standard exists for the mate sure. rial in question, the value of Rm must (5) 3lHl fitted with structural equip be the minimum value indicated in the ment designed to withstand the whole material inspection certificate. load when IBCs are stacked, for liquids. (2) Pressure relief The following pres (6) 3lH2 freestanding, for liquids. sure relief requirements apply to IBCs (b) Rigid plastic IBCs consist of a intended for liquids: rigid plastic body, which may have (i) IBCs must be capable of releasing structural equipment, together with a sufficient amount of vapor in the appropriate service equipment. event of fire engulfment to ensure that (c) Rigid plastic IBCs must be manu no rupture of the body will occur due factured from plastic material of to pressure build-up. This can be known specifications and be of a achieved by spring-loaded or non-re- strength relative to its capacity and to closing pressure relief devices or by the service it is required to perform. In other means of construction. addition to conformance to §173.24 of (ii) The start-to-discharge pressure this subchapter, plastic materials must may not be higher than 65 kPa (9 psig) be resistant to aging and to degrada and no lower than the vapor pressure of tion caused by ultraviolet radiation. the hazardous material plus the partial (1) If protection against ultraviolet pressure of the air or other inert gases, radiation is necessary, it must be pro measured in the IBC at 55 °C (131 CF), vided by the addition of a pigment or determined on the basis of a maximum inhibiter such as carbon black. These degree of filling as specified in additives must be compatible with the § 173.35(d) of this subchapter. This does contents and remain effective through not apply to fusible devices unless such out the life of the IBC body. Where use 1039 § 178.707 49 CFR Ch. 1(10—1—10 Edition)

is made of carbon black, pigments or (4) 21HZ2 Composite IBCs with a inhibitors, other than those used in the flexible plastic inner receptacle for sol manufacture of the tested design type, ids loaded or discharged under pres retesting may be omitted if changes in sure. the carbon black content, the pigment (5) 3lHZl Composite IBCs with a rigid content or the inhibitor content do not plastic inner receptacle for liquids. adversely affect the physical properties (6) 31HZ2 Composite IBCs with a of the material of construction. flexible plastic inner receptacle for liq (2) Additives may be included in the uids. composition of the plastic material to (b) Definitions for composite IBC improve the resistance to aging or to types: serve other purposes, provided they do (1) A composite IBC is an IBC not adversely affect the physical or which consists of a rigid chemical properties of the material of outer packaging en construction. closing a plastic inner receptacle to gether with any service or other struc (3) No used material other than pro tural equipment. The outer duction residues or regripd from the packaging same manufacturing process may be of a composite IBC is designed to bear used in the manufacture of rigid plastic the entire stacking load. The inner re IBCs. ceptacle and outer packaging form an (4) Rigid plastic IBCs intended for the integral packaging and are filled, transportation of liquids must be capa stored, transported, and emptied as a ble of releasing a sufficient amount of unit. vapor to prevent the body of the IBC (2) The term plastic means polymeric from rupturing if it is subjected to an materials (i.e., plastic or rubber). internal pressure in excess of that for (3) A “rigid” inner receptacle is an which it was hydraulically tested. This inner receptacle which retains its gen may be achieved by spring-loaded or eral shape when empty without clo non-reclosing pressure relief devices or sures in place and without benefit of by other means of construction. the outer casing. Any inner receptacle (d) Rigid plastic IBCs may not have a that is not “rigid” is considered to be volumetric capacity greater than 3,000 “flexible.” L (793 gallons) or less than 450 L (119 (c) Construction requirements for gallons). composite IBCs with plastic inner re ceptacles are as follows: [Amdt. 178—103, 59 FR 38068, July 26, 1994, as amended at 66 FR 45386, 45387, Aug. 28, 2001; (1) The outer packaging must consist 75 FR 5396, Feb. 2, 2010] of rigid material formed so as to pro tect the inner receptacle from physical § 178.707 Standards for composite damage during handling and transpor IBCs. tation, but is not required to perform (a) The provisions in this section the secondary containment function. It apply to composite IBCs intended to includes the base where appro contain solids and liquids. To complete priate. The inner receptacle is not in- the marking codes listed below, the tended to perform a containment func letter “Z” must be replaced by a cap tion without the outer packaging. ital letter in accordance with (2) A composite IBC with a fully en § l78.702(a)(2) to indicate the material closing outer packaging must be de used for the outer packaging. Com signed to permit assessment of the in posite IBC types are designated: tegrity of the inner container following (1) 11HZ1 Composite IBCs with a rigid the leakproofness and hydraulic tests. plastic inner receptacle for solids load The outer packaging of 31HZ2 com ed or discharged by gravity. posite IBCs must enclose the inner re (2) 11HZ2 Composite IBCs with a ceptacles on all sides. flexible plastic inner receptacle for sol (3) The inner receptacle must be ids loaded or discharged by gravity. manufactured from plastic material of (3) 21HZ1 Composite IBCs with a rigid known specifications and be of a plastic inner receptacle for solids load strength relative to its capacity and to ed or discharged under pressure. the service it is required to perform. In

1040 Pipeline and Hazardous Materials Safety Admin., DOT § 178.707

addition to conformance with the re particle board. Materials other than quirements of § 173.24 of this sub natural wood may be used for construc chapter, the material must be resistant tion of structural equipment of the to aging and to degradation caused by outer packaging. ultraviolet radiation. The inner recep (ii) Outer packagings of plywood tacle of 31HZ2 composite IBCs must must be made of well-seasoned, rotary consist of at least three plies of film. cut, sliced, or sawn veneer, commer (i) If necessary, protection against cially dry and free from defects that ultraviolet radiation must be provided would materially lessen the strength of by the addition of pigments or inhibi the casing. All adjacent plies must be tors such as carbon black. These addi glued with water-resistant adhesive. tives must be compatible with the con Materials other than plywood may be tents and remain effective throughout used for construction of structural the life of the inner receptacle. Where equipment of the outer packaging. use is made of carbon black, pigments, Outer packagings must be firmly or inhibitors, other than those used in nailed or secured to corner posts or the manufacture of the tested design ends or be assembled by equally suit type, retesting may be omitted if the able devices. carbon black content, the pigment con (iii) Outer packagings of reconsti tent, or the inhibitor content do not tuted wood must be constructed of adversely affect the physical properties water-resistant reconstituted wood of the material of construction. such as hardboard or particle board. (ii) Additives may be included in the Materials other than reconstituted composition of the plastic material of wood may be used for the construction the inner receptacle to improve resist of structural equipment of reconsti ance to aging, provided they do not ad tuted wood outer packaging. versely affect the physical or chemical properties of the material. (iv) Fiberboard outer packagings (iii) No used material other than pro must be constructed of strong, solid, or double-faced duction residues or regrind from the same manufacturing process may be (single or multiwall). used in the manufacture of inner recep (A) Water resistance of the outer sur tacles. face must be such that the increase in (iv) Composite IBCs intended for the mass, as determined in a test carried transportation of liquids must be capa out over a period of 30 minutes by the ble of releasing a sufficient amount of Cobb method of determining water ab vapor to prevent the body of the IBC sorption, is not greater than 155 grams from rupturing if it is subjected to an per square meter (0.0316 pounds per internal pressure in excess of that for square foot)—see ISO 535 (E) (IBR, see which it was hydraulically tested. This §171.7 of this subchapter). Fiberboard may be achieved by spring-loaded or must have proper bending qualities. Fi non-reclosing pressure relief devices or berboard must be cut, creased without by other means of construction. cutting through any thickness of fiber (4) The strength of the construction board, and slotted so as to permit as material comprising the outer pack sembly without cracking, surface aging and the manner of construction breaks, or undue bending. The fluting must be appropriate to the capacity of of corrugated fiberboard must be firm the composite IBC and its intended use. ly glued to the facings. The outer packaging must be free of (B) The ends of fiberboard outer any projection that might damage the packagings may have a wooden frame inner receptacle. or be constructed entirely of wood. (i) Outer packagings of natural wood Wooden battens may be used for rein must be constructed of well seasoned forcements. wood that is commercially dry and free (C) Manufacturers’ joints in the bod from defects that would materially ies of outer packagings must be taped, lessen the strength of any part of the lapped and glued, or lapped and outer packaging. The tops and bottoms stitched with metal staples. may be made of water-resistant recon (0) Lapped joints must have an ap stituted wood such as hardboard or propriate overlap. 1041 § 178.708 49 CFR Ch. I (10—1—10 Edition)

(F) Where closing is effected by glu ice and structural equipment, and if ing or taping, a water-resistant adhe necessary an inner liner (but no inner sive must be used. packaging). (F) All closures must be sift-proof. (2) Liner means a separate tube or (v) Outer packagings of plastic mate bag, including the closures of its open rials must be constructed in accord ings, inserted in the body but not form ance with the relevant provisions of ing an integral part of it. paragraph (c) (3) of this section. (c) Construction requirements for fi (5) Any integral pallet base forming berboard IBCs are as follows: part of an IBC, or any detachable pal (1) Top lifting devices are prohibited let, must be suitable for the mechan in fiberboard IBCs. of an IBC filled to its ical handling (2) Fiberboard IBCs must be con permissible gross maximum mass. structed of strong, solid or double- pallet or integral base must (1) The faced corrugated fiberboard (single or be designed to avoid protrusions that multiwall) that is appropriate to the may damage to the IBC in han cause capacity of the outer packaging and its dling. intended use. Water resistance of the (ii) The outer packaging must be se outer surface must be such that the in cured to any detachable pallet to en crease in mass, as determined in a test sure stability in handling and transpor carried out over a period of 30 minutes tation. Where a detachable pallet is by the Cobb method of determining used, its top surface must be free from water absorption, is not greater than sharp protrusions that might damage 155 grams per square meter (0.0316 the IBC. pounds per square foot)—see ISO 535 (F) (iii) Strengthening devices, such as (IBR, see of this subchapter). Fi timber supports to increase stacking §171.7 berboard must have proper bending performance, may be used but must be qualities. Fiberboard external to the inner receptacle. must be cut, (iv) The load-bearing surfaces of IBCs creased without cutting through any intended for stacking must be designed thickness of fiberboard, and slotted so to distribute loads in a stable manner. as to permit assembly without crack An IBC intended for stacking must be ing, surface breaks, or undue bending. designed so that loads are not sup The fluting of corrugated fiberboard ported by the inner receptacle. must be firmly glued to the facings. (6) Intermediate IBCs of type 31HZ2 (i) The walls, including top and bot must be limited to a capacity of not tom, must have a minimum puncture more than 1,250 L. resistance of 15 Joules (11 foot-pounds (d) Composite IBCs may not have a of energy) measured according to ISO volumetric capacity greater than 3,000 3036 (IBR, see § 171.7 of this subchapter). L (793 gallons) or less than 450 L (119 (ii) Manufacturers’ joints in the bod gallons). ies of IBCs must be made with an ap propriate overlap and be taped, glued, 178—103, 59 FR 38068, July 26, 1994, as [Amdt. stitched with metal staples or fastened amended by Amdt. 178—119, 62 FR 24743, May 6, 1997; 66 FR 45387, Aug. 28, 2001; 67 FR 61016, by other means at least equally effec Sept. 27. 2002; 68 FR 75758, Dec. 31, 2003; 69 FR tive. Where joints are made by gluing 54046, Sept. 7, 2004; 75 FR 5396, Feb. 2, 2010] or taping, a water-resistant adhesive must be used. Metal staples must pass § 178.708 Standards for fiberboard completely through all pieces to be fas IBCs. tened and be formed or protected so (a) The provisions of this section that any inner liner cannot be abraded apply to fiberboard IBCs intended to or punctured by them. contain solids that are loaded or dis (3) The strength of the material used charged by gravity. Fiberboard IBCs and the construction of the liner must are designated: 11G. be appropriate to the capacity of the (b) Definitions for fiberboard IBC IBC and the intended use. Joints and types: closures must be sift-proof and capable (I) Fiberboard IBCs consist of a fiber of withstanding pressures and impacts board body with or without separate liable to occur under normal conditions top and bottom caps, appropriate serv of handling and transport.

1042 Pipeline and Hazardous Materials Safety Admin., DOT § 178.709 (4) Any integral pallet base forming (i) Natural wood used in the con part of an IBC, or any detachable pal struction of an IBC must be well-sea let, must be suitable for the mechan soned, commercially dry, and free from ical handling of an IBC filled to its defects that would materially lessen maximum permissible gross mass. the strength of any part of the IBC. (i) The pallet or integral base must Each IBC part must consist of uncut be designed to avoid protrusions that wood or a piece equivalent in strength may cause damage to the IBC in han and integrity. IBC parts are equivalent dling. to one piece when a suitable method of (ii) The outer packaging must be se glued assembly is used (i.e., a cured to any detachable pallet to en Lindermann joint, tongue and groove sure stability in handling and trans joint, ship lap or rabbet joint, or butt port. Where a detachable pallet is used, joint with at least two corrugated its top surface must be free from sharp metal fasteners at each joint, or when protrusions that might damage the other methods at least equally effec IBC. tive are used). Materials other than (iii) Strengthening devices, such as natural wood may be used for the con timber supports increase to stacking struction of structural equipment of performance, may be used but must be the outer packaging. external to the inner liner. (ii) Plywood used in construction (iv) The load-bearing surfaces of IBCs of bodies must be at least 3-ply. intended for stacking must be designed Plywood must be made of well-seasoned, to distribute loads in a stable manner. rotary cut, sliced or sawn veneer, (d) Fiberboard IBCs may not have a commer cially dry, and free volumetric capacity greater than 3,000 from defects that would materially lessen L (793 gallons) or less than 450 L (119 the strength of gallons). the body. All adjacent plies must be glued with water-resistant adhesive. [Amdt. 178—103, 59 FR 38068, July 26, 1994, as Materials other than plywood may be amended at 66 FR 45386, Aug. 28, 2001; 68 FR used for the construction of structural 75758, Dec. 2003; 31, 75 FR 5396, Feb. 2, 20101 equipment of the outer packaging. § 178.709 Standards for wooden IBCs. (iii) Reconstituted wood used in con struction of bodies must be water re (a) The provisions in this section sistant reconstituted wood such apply to wooden IBCs intended to as con hardboard or particle board. tain solids that loaded Materials are or dis other than charged by gravity. reconstituted wood may be Wooden IBC types used are designated; for the construction of structural equipment of the outer packaging. (1) IIC Natural wood with inner liner. (2) llD Plywood with inner liner. (iv) Wooden IBCs must be firmly (3) hF Reconstituted wood with nailed or secured to corner posts or inner liner. ends or be assembled by similar de (b) Definitions for wooden IBCs: vices. (1) Wooden IBCs consist of a rigid or (3) The strength of the material used collapsible wooden body together with and the construction of the liner must an inner liner (but no inner packaging) be appropriate to the capacity of the and appropriate service and structural IEC and its intended use. Joints and equipment. closures must be sift-proof and capable (2) Liner means a separate tube or of withstanding pressures and impacts bag. including the closures of its open liable to occur under normal conditions ings, inserted in the body but not form of handling and transportation. ing an integral part of it. (4) Any integral pallet base forming (c) Construction requirements for part of an IBC, or any detachable pal wooden IBCs are as follows: let, must be suitable for the mechan (I) Top lifting devices are prohibited ical handling of an IBC filled to its in wooden IBCs. maximum permissible gross mass. (2) The strength of the materials used (i) The pallet or integral base must and the method of construction must be designed to avoid protrusions that be appropriate to the capacity and in may cause damage to the IBC in han tended use of the IBC. dling.

1043 § 178.710 49 CFR Ch. I (10—1—10 Edition)

(ii) The outer packaging must be se (I) 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. used, its top surface must be free from (2) All materials used in the con sharp protrusions that might damage struction of flexible IBCs of types 13M1 the IBC. and 13M2 must, after complete immer (iii) Strengthening devices, such as sion in water for not less than 24 hours, timber supports to increase stacking retain at least 85 percent of the tensile performance, may be used but must be strength as measured originally on the external to the inner liner. material conditioned to equilibrium at (iv) The load-bearing surfaces of IBCs 67 percent relative humidity or less. intended for stacking must be designed (3) Seams must be stitched or formed to distribute loads in a stable manner. by heat sealing, gluing or any equiva (d) Wooden IBCs may not have a vol lent method. All stitched seam-ends umetric capacity greater than 3,000 L must be secured. (793 gallons) or less than 450 L (119 gal (4) In addition to conformance with lons). the requirements of § 173.24 of this sub [Amdt. 178—103, 59 FR 38068, July 26, 1994, as chapter, flexible IBCs must be resistant amended at 66 FR 45386, Aug. 28, 2001; 75 FR to aging and degradation caused by ul 5397, Feb. 2, 2010] traviolet radiation. § 178.710 Standards for flexible IBCs. (5) For plastic flexible IBCs, if nec essary, protection against ultraviolet (a) The provisions of this section radiation must be provided by the addi apply to flexible IBCs intended to con tion of pigments or inhibitors such as tain solid hazardous materials. Flexi carbon black. These additives must be ble IBC types are designated: compatible with the contents and re woven plastic without coat (I) l3Hl main effective throughout the life of ing or liner. the container. Where use is made of (2) 13H2 woven plastic, coated. carbon black, pigments, or inhibitors, (3) l3H3 woven plastic with liner. other than those used in the manufac (4) 13H4 woven plastic, coated and ture of the design with liner. tested type, Fe- testing may be omitted if the carbon (5) 13H5 plastic film. (6) l3Ll textile without coating or black content, the pigment content or liner. the inhibitor content does not ad (7) 13L2 textile, coated. versely affect the physical properties (8) 13L3 textile with liner. of the material of construction. Addi (9) l3L4 textile, coated and with tives may be included in the composi liner. tion of the plastic material to improve (10) 13M1 paper, multiwall. resistance to aging, provided they do (11) l3M2 paper, multiwall, water re not adversely affect the physical or sistant. chemical properties of the material. (b) Definitions for flexible IBCs: (6) No used material other than pro (1) Flexible IBCs consist of a body con duction residues or regrind from the structed of film, woven plastic, woven same manufacturing process may be fabric, paper, or combination thereof, used in the manufacture of plastic together with any appropriate service flexible IBCs. This does not preclude equipment and handling devices, and if the re-use of component parts such as necessary, an inner coating or liner. fittings and pallet bases, provided such (2) Woven plastic means a material components have not in any way been made from stretched tapes or damaged in previous use. monofilaments. (7) When flexible IBCs are filled, the (3) Handling device means any sling, ratio of height to width may not be loop, eye, or frame attached to the more than 2:1. body of the IBC or formed from a con (d) Flexible IBCs: (1) May not have a tinuation of the IBC body material. volumetric capacity greater than 3,000 (c) Construction requirements for L (793 gallons) or less than 56 L (15 gal flexible IBCs are as follows: lons); and

1044 Pipeline and Hazardous Materials Safety Admin., DOT § 178.801

(2) Must be designed and tested to a specified in paragraph (c) (2) of this sec capacity of no less than 50 kg (110 tion on an IBC design type, in order to pounds). requalify the design for continued pro duction [Amdt. 178—103, 59 FR 38068, July 26, 1994, as at the frequency specified in amended by Amdt. 178-108, 60 FR 40038, Aug. paragraph (e) of this section. 4, 1995; 66 FR 45386, Aug. 28, 2001; 75 FR 5397, (4) Production inspection is the inspec Feb. 2, 2010] tion that must initially be conducted on each newly manufactured IBC. Subpart 0—Testing of IBCs (5) Production testing is the perform ance of the leakproofness test in ac § 178.800 Purpose and scope. cordance with paragraph (f) of this sec This subpart prescribes certain test tion on each IBC intended to contain ing requirements for IBCs identified in solids discharged by pressure or in subpart N of this part. tended to contain liquids. (6) Periodic retest and inspection is per [Arndt. 178—103, 59 FR 38074, July 26, 1994, as formance of the applicable test and in amended by 66 FR 45386, Aug. 28. 20011 spections on each IBC at the frequency specified in 180.352 § 178.801 General requirements. § of this subchapter. (7) Different IBC design type is one (a) General. The test procedures pre that differs from a previously qualified scribed in this subpart are intended to IBC design type in structural design, ensure that IBCs containing hazardous size, material of construction, wall materials can withstand normal condi thickness, or manner of construction, tions of transportation and are consid but does not include: ered minimum requirements. Each (1) A packaging which differs in sur packaging must be manufactured and face treatment; assembled so as to be capable of suc (ii) A rigid plastic IBC or composite cessfully passing the prescribed tests IBC which differs with regard to addi and of conforming to the requirements tives used to comply with §5178.706(c), of § 173.24 of this subchapter at all 178.707(c) or 178.710(c); times while in transportation. (iii) A packaging which differs only (b) Responsibility. It is the responsi in its lesser external dimensions (i.e., bility of the IBC manufacturer to as height, width, length) provided mate sure that each IBC is capable of passing rials of construction and material the prescribed tests. To the extent that thicknesses or fabric weight remain an IBC assembly function, including the same; final closure, is performed by the per (iv) A packaging which differs in son who offers a hazardous material for service equipment. transportation, that person is respon (d) Design qualification testing. The sible for performing the function in ac packaging manufacturer shall achieve cordance with §5173.22 and 178.2 of this successful test results for the design subchapter. qualification testing at the start of (c) Definitions. For the purpose of this production of each new or different IBC subpart: design type. The service equipment se (1) IBC design type refers to an IBC lected for this design qualification that does not differ in structural de testing shall be representative of the sign, size, material of construction, type of service equipment that will be wall thickness, manner of construction fitted to any finished IBC body under and representative service equipment. the design. Application of the certifi (2) Design qualification testing is the cation mark by the manufacturer shall performance of the drop, leakproofness, constitute certification that the IBC hydrostatic pressure, stacking, bot design type passed the prescribed tests tom-lift or top-lift, tear, topple, right in this subpart. ing and vibration tests, as applicable, (e) Periodic design requalification test prescribed in this subpart, for each dif ing. (1) Periodic design requalification ferent IBC design type, at the start of must be conducted on each qualified production of that packaging. IBC design type if the manufacturer is (3) Periodic design requalification test is to maintain authorization for contin the performance of the applicable tests ued production. The IBC manufacturer 1045 § 178.801 49 CFR Ch. I (10—1—10 Edition) shall achieve successful test results for subpart N of this part, or tested using the periodic design requalification at methods other than those specified in sufficient frequency to ensure each this subpart, may be used if approved packaging produced by the manufac by the Associate Administrator. Such turer is capable of passing the design IBCs must be shown to be equally effec qualification tests. Design requalifica tive, and testing methods used must be tion tests must be conducted at least equivalent. once every 12 months. (j) Proof of compliance. Notwith (2) Changes in the frequency of design standing the periodic design requali requalification testing specified in fication testing intervals specified in paragraph (e) (1) of this section are au paragraph (e) of this section, the Asso thorized if approved by the Associate ciate Administrator, or a designated Administrator. These requests must be representative, may at any time re based on: quire demonstration of compliance (i) Detailed quality assurance pro by a manufacturer, grams that assure that proposed de through testing in ac creases in test frequency maintain the cordance with this subpart, that pack integrity of originally tested IBC de agings meet the requirements of this sign types; and subpart. As required by the Associate (ii) Demonstrations that each IBC Administrator, or a designated rep produced is capable of withstanding resentative, the manufacturer shall ei higher standards (e.g., increased drop ther: height, hydrostatic pressure, wall (1) Conduct performance tests or thickness, fabric weight). have tests conducted by an inde (f) Production testing and inspection. pendent testing facility, in accordance (I) Production testing consists of the with this subpart; or leakproofness test prescribed in (2) Make a sample IBC available to §178.813 of this subpart and must be the Associate Administrator, or a des performed on each IBC intended to con ignated representative, for testing in tain solids discharged by pressure or accordance with this subpart. intended to contain liquids. For this (k) Coatings. If an inner treatment or test: coating of an IBC is required for safety (i) The IBC need not have its closures reasons, the manufacturer shall design fitted, except that the IBC must be the IBC so that the treatment or coat fitted with its primary bottom closure. ing retains its protective properties (ii) The inner receptacle of a com even after withstanding the tests pre posite IBC may be tested without the scribed by this subpart. outer IBC body, provided the test re (1) Record retention. (1) The person suits are not affected. who certifies an IBC design (2) Applicable inspection require type shall keep records of ments in § 180.352 of this subchapter design qualification must be performed on each IBC ini tests for each IBC design type and for tially after production. each periodic design requalification as (g) Test samples. The IBC manufac specified in this part. These records turer shall conduct the design quali must be maintained at each location fication and periodic design requali where the IBC is manufactured and at fication tests prescribed in this subpart each location where design qualifica using random samples of IBCs, accord tion and periodic design requalification ing to the appropriate test section. testing is performed. These records (h) Selective testing of IBCs. Variation must be maintained for as long as IBCs of a tested IBC design type is permitted are manufactured in accordance with without further testing, provided selec each qualified design type and for at tive testing demonstrates an equiva least 2.5 years thereafter. These lent or greater level of safety than the records must include the following in design type tested and which has been formation: name and address of test fa approved by the Associate Adminis cility; name and address of the person trator. certifying the IBC; a unique test report (i) Approval of equivalent packagings. identification; date of test report; man An IBC differing from the standards in ufacturer of the IBC; description of the 1046 Pipeline and Hazardous Materials Safety Admin., DOT § 178.803 IBC design type (e.g. dimensions, ma (2) At 65 percent ±2 percent relative terials, closures, thickness, representa humidity, and at a temperature of 20° tive service equipment, etc.); max ±2°C (68°F ±4°F), or 27°C ±2°C (81 °F imum IBC capacity; characteristics of ±4°F). test contents; test descriptions and re (b) Average values for temperature suits (including drop heights, hydro and humidity must fall within the lim static pressures, tear propagation its in paragraph (a) of this section. length, etc.). Each test report must be Short-term fluctuations signed with the name of the person and measure ment limitations conducting the test, and name of the may cause individual person responsible for testing. measurements to vary by up to ±5 per (2) The person who certifies each IBC cent relative humidity without signifi must make all records of design quali cant impairment of test reproduc fication tests and periodic design re ibility. qualification tests available for inspec (c) For purposes of periodic design re tion by a representative of the Depart qualification only, fiberboard IBCs or ment upon request. composite IBCs with fiberboard outer [Amdt. 178—103, 59 FR 38074, July 26, 1994, as packagings may be at ambient condi amended by Amdt. 178-108, 60 FR 40038, Aug. tions. 4, 1995; 66 FR 45386. Aug. 28, 2001; 66 FR 33452, [Amdt. 178—103, 59 June 21, 2001; 68 FR 75758, Dec. 31, 2003: 73 FR FR 38074, July 26, 1994, as amended 57008, Oct. 1, 2008; 74 FR 2269, Jan. 14, 2009: 75 at 66 FR 45386, Aug. 28, 2001] FR 5397, Feb. 2, 2010] § 178.803 Testing and certification of § 178.802 Preparation of fiberboard IBCs. IBCs testing. for Tests required for the certification of (a) Fiberboard IBCs and composite each IBC design type are specified in IBCs with fiberboard outer packagings the following table. The letter X indi must be conditioned for at least 24 cates that one IBC (except where hours in an atmosphere maintained: noted) of each design type must be sub (1) At 50 percent ±2 percent relative jected to the tests in the order pre humidity, and at a temperature of 23° sented: ±2 °C (73 °F ±4 °F); or

IBC type Performance test Rigid plastic Composite Fiber-board Metal IBCs Wooden lBCs Flexible IBCs

Vibration 6)( ‘5X Bottomlift 2> X X X X Top lift 2 X 2 X 2 X 2.5 X Stacking 7X 7X 7X Leakproofness 3 X X 3 X Hydrostatic 3 X X X Drop 4X Topple Righting 2,5 X Tear ‘Flexible l8Cs must be capable of withstanding the vibration test. 2This test must be performed only it lBCs are designed to be handled this way. For metal lBCs, at least one of the bottom lift or top lift tests must be performed. 3The leakproofness and hydrostatic pressure tests are required only for IBCs intended to contain liquids or intended to contain solids loaded or discharged under pressure. BC of the same design type may be used for the drop test set forth in § 178.810 of this subchapter. °Another different flexible BC of the same design type may be used for each test. °The vibration test may be performed in another order for BCe 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. 7This test must be performed only if the IBC is designed to be stacked.

[Amdt. 178—108, 60 FR 40039, Aug. 4, 1995, as amended at 64 FR 51919, Sept. 27, 1999; 66 FR 45386, 45390, Aug. 28. 20011

1047 § 178.810 49 CFR Ch. 1(10—1—10 Edition)

§ 178.810 Drop test. (2) Drop tests are to be performed (a) General. The drop test must be with the solid or liquid to be trans conducted for the qualification of all ported or with a non-hazardous mate IBC design types and performed peri rial having essentially the same phys odically as specified in §178.801(e) of ical characteristics. this subpart. (3) The specific gravity and viscosity (b) Special preparation for the drop test. of a substituted non-hazardous mate (1) Metal, rigid plastic, and composite rial used in the drop test for liquids IBCs intended to contain solids must must be similar to the hazardous mate be filled to not less than 95 percent of rial intended for transportation. Water their maximum capacity, or if intended also may be used for the liquid drop to contain liquids, to not less than 98 test under the following conditions: percent of their maximum capacity. (i) Where the substances to be carried Pressure relief devices must be re have a specific gravity not exceeding moved and their apertures plugged or 1.2, the drop heights must be those rendered inoperative. specified in paragraph (d) (1) of this sec (2) Fiberboard and wooden IBCs must tion for each IBC design type; and be filled with a solid material to not (ii) Where the substances to be car less than 95 percent of their maximum ried have a specific gravity exceeding capacity; the contents must be evenly 1.2, the drop heights must be as fol distributed. lows: (3) Flexible IBCs must be filled to the (A) Packing Group I: SG x 1.5 m (4.9 maximum permissible gross mass; the feet). contents must be evenly distributed. (B) Packing Group II: SG x 1.0 m (3.3 (4) Rigid plastic IBCs and composite feet). IBCs with plastic inner receptacles (C) Packing Group III: SG x 0.67 m must be conditioned for testing by re (2.2 feet). ducing the temperature of the pack (e) Criteria for passing the test. For all aging and its contents to —18 °C (0 °F) IBC design types, there may be no dam or lower. Test liquids must be kept in age which renders the IBC unsafe to be the liquid state, if necessary, by the transported for salvage or for dispos addition of anti-freeze. Water/anti able, and no loss of contents. The IBC freeze solutions with a minimum spe shall be capable of being lifted by an cific gravity of 0.95 for testing at — 18 appropriate means until clear of the °C (0 °F) or lower are considered ac floor for five minutes. A slight dis ceptable test liquids, and may be con charge from a closure upon impact is sidered equivalent to water for test not considered to be a failure of the purposes. IBCs conditioned in this way IBC provided that no further leakage are not required to be conditioned in occurs. A slight discharge (e.g., from accordance with 178.802. § closures or stitch holes) upon impact is (c) Test method. (1) Samples of all IBC not considered a failure of the flexible design types must be dropped onto a IBC provided that no further leakage rigid, non-resilient, smooth, flat and occurs after the IBC has been horizontal surface. The point of impact raised clear of the ground. must be the most vulnerable part of the base of the IBC being tested. Fol [Amdt. 178—103, 59 FR 38074, July 26, 1994, as lowing the drop, the IBC must be re amended at 66 FR 45386, Aug. 28, 2001; 69 FR stored to the upright position for ob 76186, Dec. 20, 2004; 71 FR 78635, Dec. 29, 2006; servation. 74 FR 2269, Jan. 14, 2009; 75 FR 5397, Feb. 2, (2) IBC design types with a capacity 20101 of 0.45 cubic meters (15.9 cubic feet) or § 178.811 Bottom lift test. less must be subject to an additional drop test. (a) General. The bottom lift test must (d) Drop height. (1) For all IBCs, drop be conducted for the qualification of heights are specified as follows: all IBC design types designed to be lift (i) Packing Group I: 1.8 m (5.9 feet). ed from the base. (ii) Packing Group II: 1.2 m (3.9 feet). (b) Special preparation for the bottom (iii) Packing Group III: 0.8 m (2.6 lift test. The IBC must be loaded to 1.25 feet). times its maximum permissible gross

1048 Pipeline and Hazardous Materials Safety Admin., DOT § 178.813

mass, the load being evenly distrib (i) Fill the flexible IBC to 95% full uted. with a material representative of the (c) Test method. All IBC design types product to be shipped. must be raised and lowered twice by a (ii) Suspend the flexible IBC by its lift truck with the forks centrally posi lifting devices. tioned and spaced at three quarters of (iii) Apply a constant downward force the dimension of the side of entry (un through a specially designed platen. less the points of entry are fixed). The The platen will be a minimum of 60% forks must penetrate to three quarters and a maximum of 80% of the cross sec of the direction of entry. The test must tional surface area of the flexible IBC. be repeated from each possible direc (iv) The combination of the mass of tion of entry. the filled flexible IBC and the force ap (d) Criteria for passing the test. For all plied through the platen must be a minimum IBC design types designed to be lifted of six times the maximum net mass of from the base, there may be no perma the flexible IBC. The test must be conducted nent deformation which renders the for a period of five minutes. IBC unsafe for transportation and no (v) Other loss of contents. equally effective methods of top lift testing and preparation may [Amdt. 178—103, 59 FR 38074, July 26, 1994. as be used with approval of the Associate amended at 66 FR 45386, Aug. 28, 2001] Administrator. (d) Criteria for passing the test. For all § 178.812 Top lift test. IBC design types designed to be lifted (a) General. The top lift test must be from the top, there may be no perma conducted for the qualification of all nent deformation which renders the IBC design types designed to be lifted IBC, including the base when from the top or, for flexible IBCs, from applicable, unsafe for transportation, the side. and no loss of contents. (b) Special preparation for the top lift lAmdt 178—103, 59 FR 38074. July 26. 1994, as test. (I) Metal, rigid plastic, and com amended at 66 FR 33452, June 21, 2001; 66 FR posite IBC design types must be loaded 45386, Aug. 28, 2001; 68 FR 45042, July 31, 2003] to twice the maximum permissible 178.813 Leakproofness gross mass with the load being evenly § test. distributed. (a) General. The leakproofness test (2) Flexible IBC design types must be must be conducted for the qualification filled to six times the maximum net of all IBC design types and on all pro mass, the load being evenly distrib duction units intended to contain sol uted. ids that are loaded or discharged under (c) Test method. (1) A metal or flexible pressure or intended to contain liquids. IBC must be lifted in the manner for (b) Special preparation for the leakproofness which it is designed until clear of the test. Vented closures must either be floor and maintained in that position replaced by similar non-vent ed closures for a period of five minutes. or the vent must be sealed. For metal IBC design types, the initial (2) Rigid plastic and composite IBC test must be carried out before the fit design types must be: ting of any thermal insulation equip (i) Lifted by each pair of diagonally ment. The inner receptacle of a com opposite lifting devices, so that the posite IBC may be tested without the hoisting forces are applied vertically, outer packaging provided the test re for a period of five minutes; and sults are not affected. (ii) Lifted by each pair of diagonally (c) Test method and pressure applied. opposite lifting devices, so that the The leakproofness test must be carried hoisting forces are applied towards the out for a suitable length of time using center at 45° to the vertical, for a pe air at a gauge pressure of not less than rind of five minutes. 20 kPa (2.9 psig). Leakproofness of IBC (3) If not tested as indicated in para design types must be determined by graph (c) (1) of this section, a flexible coating the seams and joints with a IBC design type must be tested as fol heavy oil, a soap solution and water, or lows: other methods suitable for the purpose 1049 § 178.814 49 CFR Ch. I (10—1—10 Edition)

of detecting leaks. Other methods, if at (5) For rigid plastic IBC design types least equally effective, may be used in 3lHl and 3lH2 and composite IBC de accordance with appendix B of this sign types 31HZ1 and 31HZ2: whichever part, or if approved by the Associate is the greater of: Administrator, as provided in (i) The pressure determined by any § 178.801(i)). one of the following methods: (d) Criterion for passing the test. For (A) The gauge pressure (pressure in all IBC design types intended to con the IBC above ambient atmospheric tain solids that are loaded or dis pressure) measured in the IBC at 55 °C intended charged under pressure or to (131 °F) multiplied by a safety factor of contain liquids, there may be no leak 1.5. This pressure must be determined age of air from the IBC. on the basis of the IBC being filled and [Amdt. 178—103, 59 FR 38074, July 26, 1994, as closed to no more than 98 percent ca amended at 64 FR 10782, Mar. 5, 1999; 66 FR pacity at 15 °C (60 °F); 45185, 45386, Aug. 28, 2001] (B) If absolute pressure (vapor pres sure of the hazardous material plus at § 178.814 Hydrostatic pressure test. mospheric pressure) is used, 1.5 multi (a) General. The hydrostatic pressure plied by the vapor pressure of the haz test must be conducted for the quali ardous material at 55 °C (131 °F) minus fication of all metal, rigid plastic, and 100 kPa (14.5 psi). If this method is cho composite IBC design types intended to sen, the hydrostatic test pressure ap solids that are loaded or dis contain plied must be at least 100 kPa gauge charged under pressure or intended to pressure (14.5 psig); or contain liquids. (C) If absolute pressure (vapor pres (b) Special preparation for the hydro sure of the hazardous material static pressure test. For metal IBCs, the plus at test must be carried out before the fit mospheric pressure) is used, 1.75 multi ting of any thermal insulation equip plied by the vapor pressure of the haz ment. For all IBCs, pressure relief de ardous material at 50 °C (122 °F) minus vices and vented closures must be re 100 kPa (14.5 psi). If this method is cho moved and their apertures plugged or sen, the hydrostatic test pressure ap rendered inoperative. plied must be at least 100 kPa gauge (c) Test method. Hydrostatic gauge pressure (14.5 psig); or pressure must be measured at the top (ii) Twice the greater of: (A) The of the IBC. The test must be carried static pressure of the hazardous mate out for a period of at least 10 minutes rial on the bottom of the IBC filled to applying a hydrostatic gauge pressure 98 percent capacity; or not less than that indicated in para (B) The static pressure of water on graph (d) of this section. The IBCs may the bottom of the IBC filled to 98 per not be mechanically restrained during cent capacity. the test. (e) Criteria for passing the test(s). (1) (d) Hydrostatic gauge pressure applied. For metal IBCs, subjected to the 65 (1) For metal IBC design types, 3lA, kPa (9.4 psig) test pressure specified in 3lB, 3lN: 65 kPa gauge pressure (9.4 paragraph (d) (1) of this section, there psig). may be no leakage or permanent defor (2) For metal IBC design types 2lA, mation that would make the IBC un 31B, 3lN: 200 kPa (29 2lB, 2lN, 31A, safe for transportation. psig). For metal IBC design types 3lA, (2) For metal IBCs intended to con 31B and 31N, the tests in paragraphs tain liquids, when subjected to the 200 (d) (1) and (d) (2) of this section must be conducted consecutively. kPa (29 psig) and the 250 kPa (36 psig) test in (3) For metal IBCs design types 21A, pressures specified paragraphs 21B, and 2lN, for Packing Group I sol (d) (2) and (d) (3) of this section, respec ids: 250 kPa (36 psig) gauge pressure. tively, there may be no leakage. (4) For rigid plastic IBC design types (3) For rigid plastic IBC types 2lHl, 2lHl and 21H2 and composite IBC de 21H2, 31H1, and 31H2, and composite sign types 21HZ1 and 21HZ2: 75 kPa (11 IBC types 21HZ1, 21HZ2, 3lHZl, and psig). 31HZ2, there may be no leakage and no 1050 Pipeline and Hazardous Materials Safety Admin., DOT § 178.815

permanent deformation which renders machine. The test must be conducted the IBC unsafe for transportation. at room temperature on an empty, un [Amdt. 178—103, 59 FR 38074, July 26, 1994, as sealed packaging. The test sample amended at 66 FR 45185, 45386, Aug. 28, 20011 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 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 sign types must be loaded to their max definite contact between the test sam- imum permissible gross mass. pie and the platens. The distance be (2) The flexible IBC must be filled to tween the platens at this time must be not less than 95 percent of its capacity recorded as zero deformation. The force and to its maximum net mass, with the ‘A” then to be applied must be cal load being evenly distributed. culated using the applicable formula: (c) Test method. (1) Design Qualifica Liquids: A = (l.8)(n —1) [w + (s xv x8.3 tion Testing. All IBCs must be placed on x .98)] x 1.5; their base on level, hard ground and or subjected to a uniformly distributed superimposed test load for a period of Solids: A = (l.8)(n — 1) [w ÷ (s xv x 8.3 at least five minutes (see paragraph x .95)] x 1.5 (c) (5) of this section). Where: (2) Fiberboard, wooden and composite A = applied load in pounds. IBCs with outer packagings con n = maximum number of IBCs being stacked structed of other than plastic mate during transportation. rials must be subject to the test for 24 w = maximum weight of one empty container hours. in pounds. (3) Rigid plastic IBC types and com s = specific gravity (liquids) or density (sol ids) of the posite IBC types with plastic outer lading. v = actual capacity of container (rated packagings (1 1HHI, 1 1HH2, ca 21HH1, pacity + outage) in gallons. 21HH2, 31HH1 and 31HH2) which bear and: the stacking load must be subjected to 8.3 corresponds to the weight in pounds of 1.0 the test for 28 days at 40 C (104 °F). gallon of water. (4) For all IBCs, the load must be ap 1.5 is a compensation factor converting the plied by one of the following methods: static load of the stacking test into a load (i) One or more IBCs of the same type suitable for dynamic compression testing. loaded to their maximum permissible (e) Criteria for passing the test. (I) For gross mass and stacked on the test metal, rigid plastic, and composite IBC; IBCs, there may be no permanent de (ii) The calculated superimposed test formation, which renders the IBC un load weight loaded on either a flat safe for transportation, and no loss of plate or a reproduction of the base of contents. the IBC, which is stacked on the test (2) For fiberboard and wooden IBCs, IBC. there may be no loss of contents and no (5) Calculation of superimposed test permanent deformation, which renders load. For all IBCs, the load to be placed the whole IBC, including the base pal on the IBC must be 1.8 times the com let, unsafe for transportation. bined maximum permissible gross mass (3) For flexible IBCs, there may be no of the number of similar IBCs that may deterioration, which renders the IBC be stacked on top of the IBC during unsafe for transportation, and no loss transportation. of contents. (d) Periodic Retest. (1) The package (4) For the dynamic compression must be tested in accordance with test, a container passes the test if, paragraph (c) of this section; or after application of the required load, (2) The packaging may be tested there is no permanent deformation to using a dynamic compression testing the IBC, which renders the whole IBC, 1051 § 178.816 49 CFR Ch. I (10—1—10 Edition)

including the base pallet, unsafe for § 178.818 Tear test. transportation; in no case may the (a) General. The tear test must be maximum deflection exceed one inch. conducted for the qualification of all [75 FR 5397, Feb. 2, 2010] flexible IBC design types. (b) Special preparation for the tear test. § 178.816 Topple test. The flexible IBC must be filled to not (a) General. The topple test must be less than 95 percent of its capacity and conducted for the qualification of all to its maximum net mass, the load flexible IBC design types. being evenly distributed. (c) Test (b) Special preparation for the topple method. Once the IBC is placed on the test. The flexible IBC must be filled to ground. a 100-mm (4-inch) knife score, not less than 95 percent of its capacity completely penetrating the wall of a wide is 450 and to its maximum net mass, with the face, made at a angle to the load being evenly distributed. principal axis of the IBC, halfway between the bottom surface (c) Test method. A flexible IBC must and the top level of the contents. The be toppled onto any part of its top IBC must then be subjected to a uni upon a rigid, non-resilient, smooth, formly distributed superimposed load flat, and horizontal surface. equivalent to twice the maximum net (d) Topple height. For all flexible mass. The load must be applied for at IBCs, the topple height is specified as least five minutes. An IBC which is de follows: signed to be lifted from the top or the (I) Packing Group I: 1.8 m (5.9 feet). side must, after removal of the super (2) Packing Group II: 1.2 m (3.9 feet). imposed load, be lifted clear of the (3) Packing Group III: 0.8 m (2.6 feet). floor and maintained in that position (e) Criteria for passing the test. For all for a period of five minutes. flexible IBCs, there may be no loss of (d) Criterion for passing the test. The contents. A slight discharge (e.g., from IBC passes the tear test if the cut does closures or stitch holes) upon impact is not propagate more than 25 percent of not considered to be a failure, provided its original length. no further leakage occurs. jAmdt. 178—103, 59 FR 38074, July 26. 1994, as [Amclt. 178—103, 59 FR 38074, July 26, 1994, as amended at 66 FR 45386, Aug. 28, 2001] amended at 66 FR 45386, Aug. 28. 2001] § 178.819 Vibration test. § 178.817 Righting test. (a) General. The vibration test must (a) General. The righting test must be be conducted for the qualification of conducted for the qualification of all all rigid IBC design types. Flexible IBC flexible IBCs designed to be lifted from design types must be capable of with the top or side. standing the vibration test. (b) Special preparation for the righting (b) Test method. (1) A sample IBC, se test. The flexible IBC must be filled to lected at random, must be filled and not less than 95 percent of its capacity closed as for shipment. IBCs intended and to its maximum net mass, with the for liquids may be tested using water load being evenly distributed. as the filling material for the vibration test. (c) Test method. The flexible IBC, (2) The lying on its side, must be lifted at a sample IBC must be placed on a vibrating platform with speed of at least 0.1 rn/second (0.33 ft/s) a vertical or rotary double-amplitude to an upright position, clear of the (peak-to-peak displacement) floor, by one lifting device, or by two of one inch. The IBC must be lifting devices when four are provided. constrained horizontally to prevent it from falling off the plat (d) Criterion for passing the test. For form, but must be left free to move all flexible IBCs, there may be no dam vertically and bounce. age to the IBC or its lifting devices (3) The test must be performed for which renders the IBC unsafe for trans one hour at a frequency that causes portation or handling. the package to be raised from the vibrating [Amdt. 178-103, 59 FR 38074, July 26, 1994, as platform to such a degree that a piece amended at 66 FR 45386, Aug. 28, 2001] of material of approximately 1.6-mm 1052 Pipeline and Hazardous Materials Safety Admin., DOT § 178.910

(0.063-inch) thickness (such as steel (1) Mark every Large Packaging in a strapping or paperboard) can be passed durable and clearly visible manner. between the bottom of the IBC and the The marking may be applied in a single platform. Other methods at least line or in multiple lines provided the equally effective may be used (see correct sequence is followed with the § 178.801(i)). information required by this section. (c) Criteria for passing the test. An IBC The following information is required passes the vibration test if there is no in the sequence presented: rupture or leakage. (i) Except as provided in [Amdt. 178—103, 59 FR 38074, July 26, 1994, as § l78.503(e)(1)(ii), the United Nations amended by Amdt. 178-108, 60 FR 40038, Aug. packaging symbol as illustrated in 4, 1995; Amdt. 178—110, 60 FR 49111, Sept. 21. § 178.503(e) (1) (i). For metal Large Pack 1995; 66 FR 45386, Aug. 28. 2001; 75 FR 5397, Feb. 2, 20101 agings on which the marking is stamped or embossed, the capital let Subpart P—Large ters “UN” may be applied instead of Packagings the symbol; Standards (ii) The code number designating the Large Packaging design type according to SOURCE: 75 FR 5397, Feb. 2. 2010, unless oth §178.905. The letter “W” must follow erwise noted. the Large Packaging design type iden § 178.900 Purpose and scope. tification code on a Large Packaging when the Large Packaging differs from (a) This subpart prescribes require the requirements in subpart P of ments for Large Packaging intended this part, or is tested using methods for the transportation of hazardous other than those specified in this materials. Standards for these pack subpart, and is approved by the agings are based on the UN Rec Associate Ad ommendations. ministrator in accordance with the provisions in 178.955; (b) Terms used in this subpart are de § fined in §171.8 of this subchapter. (iii) A capital letter identifying the performance standard under which the § 178.905 Large Packaging identifica design type has been successfully test tion codes. ed, as follows: Large packaging code designations (A) X—for Large Packagings meeting consist of: two numerals specified in Packing Groups I, II and III tests; paragraph (a) of this section; followed (B) Y—for Large Packagings meeting by the capital letter(s) specified in Packing Groups II and III tests; and paragraph (b) of this section. (C) Z—for Large Packagings meeting (a) Large packaging code number Packing Group III test. designations are as follows: 50 for rigid (iv) The month (designated numeri Large Packagings; or 51 for flexible cally) and year (last two digits) of Large Packagings. manufacture; (b) Large Packagings code letter des (v) The country authorizing the allo ignations are as follows: cation of the mark. The letters “USA” (1) “A” means steel (all types and indicate that the Large Packaging surface treatments). is manufactured and marked (2) “B” means aluminum. in the United States in compliance (3) “C” means natural wood. with the provisions (4) “D” means plywood. of this subchapter. (5) “F” means reconstituted wood. (vi) The name and address or symbol (6) “G” means fiberboard. of the manufacturer or the approval (7) “H” means plastic. agency certifying compliance with sub (8) “M” means paper, multiwall. part P and subpart Q of this part. Sym (9) “N” means metal (other than bols, if used, must be registered with steel or aluminum). the Associate Administrator. (vii) The stacking test load in kilo § 178.910 Marking of Large Pack grams (kg). For Large Packagings not agings. designed for stacking the figure “0” (a) The manufacturer must: must be shown.

1053 § 178.915 49 CFR Ch. I (10—1—10 Edition)

(viii) The maximum permissible (i) For a steel Large Packaging suit gross mass or for flexible Large Pack able for stacking: stacking load: 2,500 agings, the maximum net mass, in kg. kg: maximum gross mass: 1,000 kg. (2) The following are examples of symbols and required markings:

50A/X/05 05/USA/M9399/2500/1000

(ii) For a plastic Large Packaging not suitable for stacking: maximum gross mass: 800 kg.

U 50R/Y/11 04/USA/M9399/O/BOO

(iii) For a Flexible Large Packaging not suitable for stacking: maxirrum gross mass: 500 kg.

U 51E/Z/06 04/USA/+ZT1235/O/500

(b) [Reserved] (c) Each Large Packaging, including attachments and service and structural FR 5397, Feb. 2, 2010, as amended at 75 FR [75 equipment, must be designed to with 60339, Sept. 30. 2010] stand, without loss of hazardous mate rials, § 178.915 General Large Packaging the internal pressure of the con standards. tents and the stresses of normal han dling and transport. A Large Pack (a) Each Large Packaging must be re aging intended for stacking must be de sistant to, or protected from, deterio signed for stacking. Any lifting or se ration due to exposure to the external curing features of a Large Packaging environment. Large Packagings in must be sufficient strength to with tended for solid hazardous materials stand the normal conditions of han must be sift-proof and water-resistant. dling and transportation without gross (b) All service equipment must be po distortion or failure and must be posi sitioned or protected to minimize po tioned so as to cause no undue stress in tential loss of contents resulting from any part of the Large Packaging. damage during Large Packaging han (d) A Large Packaging consisting of dling and transportation. packagings within a framework must 1054 Pipeline and Hazardous Materials Safety Admin., DOT § 178930 be so constructed that the packaging is (1) If protection against ultraviolet not damaged by the framework and is radiation is necessary, it must be pro retained within the framework at all vided by the addition of a pigment or times. inhibiter such as carbon black to plas (e) Large Packaging design types tic materials. These additives must be must be constructed in such a way as compatible with the contents and re to be bottom-lifted or top-lifted as main effective throughout the life of specified in § 178.970 and 178.975. the plastic Large Packaging body. Where use is made of carbon [75 FR 5397, Feb. 2, 2010, as amended at 75 FR black, pig 60339, Sept. 30. 2010[ ments or inhibitors, other than those used in the manufacture of the tested § 178.920 Standards for metal Large design type, retesting may be omitted Packagings. if changes in the carbon black content, the pigment (a) The provisions in this section content or the inhibitor content do apply to metal Large Packagings in not adversely affect the physical tended to contain liquids and solids. properties of the material of construction. Metal Large Packaging types are des ignated: (2) Additives may be included in the composition (1) 50A steel of the plastic material to improve the resistance (2) 50B aluminum to aging or to serve other purposes, provided (3) 50N metal (other they do than steel or alu not adversely affect minum) the physical or chemical properties of the material of (b) Each Large Packaging must be construction. made of suitable ductile metal mate (3) No used material other than pro rials. Welds must be made so as to duction residues or regrind from the maintain design type integrity of the same manufacturing process may be receptacle under conditions normally used in the manufacture of rigid plastic incident to transportation. Low-tem Large Packagings. perature performance must be taken (c) Rigid plastic Large Packagings: into account when appropriate. (1) May not have a volumetric capac (c) The use of dissimilar metals must ity greater than 3,000 L (793 gallons): not result in deterioration that could and affect the integrity the of Large Pack (2) May not have a volumetric capac aging. ity less than 450 L (119 gallons). (d) Metal Large Packagings may not have a volumetric capacity greater § 178.930 Standards for fiberboard than 3,000 L (793 gallons) and not less Large Packagings. than 450 L (119 gallons). (a) The provisions in this section apply to fiberboard Large Packagings § 178.925 Standards for rigid plastic Large Packagings. intended to contain solids. Rigid fiber board Large Packaging types are des (a) The provisions in this section ignated: apply to rigid plastic Large Packagings (1) 50G fiberboard intended to contain liquids and solids. (2) [Reserved] Rigid plastic Large Packaging types (b) Construction requirements for fiber are designated: board Large Packagings. (1) Fiberboard (1) 50H rigid plastics. Large Packagings must be constructed (2) [Reserved] of strong, solid or double-faced cor (b) A rigid plastic Large Packaging rugated fiberboard (single or must be manufactured from plastic multiwall) that is appropriate to the material of known specifications and capacity of the Large Packagings and be of a strength relative to its capacity to their intended use. Water resistance and to the service it is required to per of the outer surface must be such that form. In addition to conformance to the increase in mass, as determined in § 173.24 of this subchapter, plastic mate a test carried out over a period of 30 rials must be resistant to aging and to minutes by the Cobb method of deter degradation caused by ultraviolet radi mining water absorption, is not greater ation. than 155 grams per square meter (0.0316 1055 § 178.935 49 CFR Ch. I (10—1—10 Edition)

pounds per square foot) —see Iso 535 (E) § 178.935 Standards for wooden Large (IBR, see §171.7 of this subchapter). Fi Packagings. berboard must have proper bending (a) The provisions in this section qualities. Fiberboard must be cut, 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. The fluting or corrugated fiberboard (2) SOD plywood. must be firmly glued to the facings. (3) 50F reconstituted wood. (i) The walls, including top and bot (b) Construction requirements for tom, must have a minimum puncture wooden Large Packagings are as fol resistance of 15 Joules (11 foot-pounds lows: of energy) measured according to 150 (1) The strength of the materials used 3036 (IBR, see §171.7 of this subchapter). and the method of construction must (ii) Manufacturers’ joints in the be appropriate to the capacity and in outer packaging of Large Packagings tended use of the Large Packagings. must be made with an appropriate overlap and be taped, glued, stitched (i) Natural wood used in the con with metal staples or fastened by other struction of Large Packagings must be means at least equally effective. Where well-seasoned, commercially dry and joints are made by gluing or taping, a free from defects that would materially water resistant adhesive must be used. lessen the strength of any part of the Metal staples must pass completely Large Packagings. Each Large Pack through all pieces to be fastened and be aging part must consist of uncut wood formed or protected so that any inner or a piece equivalent in strength and liner cannot be abraded or punctured integrity. Large Packagings parts are by them. equivalent to one piece when a suitable (2) Integral and detachable pallets. (i) method of glued assembly is used (i.e., Any integral pallet base forming part a Lindermann joint, tongue and groove of a Large Packaging or any detach joint, ship, lap or babbet joint: or butt able pallet must be suitable for me joint with at least two corrugated chanical handling with the Large metal fasteners at each joint, or when Packaging filled to its maximum per other methods at least equally effec missible gross mass. tive are used). (ii) The pallet or integral base must (ii) Plywood used in construction avoid protrusions be designed to caus must be at least 3-ply. Plywood must ing damage to the fiberboard Large be made of well-seasoned rotary cut, Packagings in handling. sliced or sawn veneer, commercially (iii) The body must be secured to any detached pallet to ensure stability in dry and free from defects that would handling and transport. Where a de materially lessen the strength of the tachable pallet is used, its top surface Large Packagings. All adjacent piles must be free from protrusions that must be glued with water resistant ad might damage the Large Packaging. hesive. Materials other than plywood (3) strengthening devices, such as may be used for the construction of the timber supports to increase stacking Large Packaging. performance may be used but must be (iii) Reconstituted wood used in the external to the liner. construction of Large Packagings must (4) The load-bearing surfaces of Large be water resistant reconstituted wood Packagings intended for stacking must such as hardboard, particle board or be designed to distribute the load in a other suitable type. stable manner. (iv) Wooden Large Packagings must (c) Fiberboard Large Packagings may be firmly nailed or secured to corner not have a volumetric capacity greater posts or ends or be assembled by simi than 3,000 L (793 gallons) and not less lar devices. than 450 L (119 gallons). (2) Integral and detachable paliets. (i) [75 FR 5397, Feb. 2, 2010, as amended at 75 FR Any integral pallet base forming part 60339, Sept. 30, 20101

1056 Pipeline and Hazardous Materials Safety Admin., DOT § 178.955

of a Large Packaging, or any detach (4) In addition to conformance with able pallet must be suitable for me the requirements of § 173.24 of this sub chanical handling of a Large Pack chapter, flexible Large Packaging must aging filled to its maximum permis be resistant to aging and degradation sible gross mass. caused by ultraviolet radiation. (ii) The pallet or integral base must (5) For plastic flexible Large Pack be designed to avoid protrusion that agings, if necessary, protection against may cause damage to the Large Pack ultraviolet radiation must be provided aging in handling. by the addition of pigments or inhibi (iii) The body must be secured to any tors such as carbon black. These addi detachable pallet to ensure stability in tives must be compatible with the con handling and transportation. Where a tents and remain effective throughout detachable pallet is used, its top sur the life of the Large Packaging. Where face must be free from protrusions that use is made of carbon black, pigments might damage the Large Packaging. or inhibitors other than those used in (3) Strengthening devices, such as the manufacture of the tested design timber supports to increase stacking type, retesting may be omitted if the performance, may be used but must be carbon black content, the pigment con external to the liner. tent or the inhibitor content do not ad versely (4) The load bearing surfaces of the affect the physical properties of the material Large Packaging must be designed to of construction. (6) distribute loads in a stable manner. Additives may be included in the composition (c) Wooden Large Packagings: of the material of the Large Packaging to improve the resist (1) May not have a volumetric capac ance to aging, provided they do ity greater than not ad 3,000 L (793 gallons); versely affect the physical and or chemical properties of the material. (2) May not have a volumetric capac (7) When flexible material Large ity less than 450 L (119 gallons). Packagings are filled, the ratio of height to width must be no more than § 178.940 Standards for flexible Large Packagings. 2:1. (c) Flexible Large Packagings: (a) The provisions in this section (1) May not have a volumetric capac apply to flexible Large Packagings in ity greater than 3,000 L (793 gallons); tended to contain liquids and solids. (2) May not have a volumetric capac Flexible Large Packagings types are ity less than 56 L (15 gallons); and designated: (3) Must be designed and tested to a (1) 51H flexible plastics. capacity of not less than 50 kg (110 (2) 51M flexible paper. pounds). (b) Construction requirements for flexible Large Packagings are as fol Subpart Q—Testing of Large lows: Packagings (1) The strength of the material and the construction of the flexible Large SOURCE: 75 FR 5400, Feb. 2, 2010, unless oth Packagings must be appropriate to its erwise noted. capacity and its intended use. (2) All materials used in the con § 178.950 Purpose and scope. struction of flexible Large Packagings This subpart prescribes certain test of types 51M must, after complete im ing requirements for Large Packagings mersion in water for not less than 24 identified in subpart P of this part. hours, retain at least 85 percent of the tensile strength as measured originally § 178.955 General requirements. on the material conditioned to equi (a) General. The test procedures pre librium at 67 percent relative humidity scribed in this subpart are intended to or less. ensure that Large Packagings con (3) Seams must be stitched or formed taining hazardous materials can with by heat sealing, gluing or any equiva stand normal conditions of transpor lent method. All stitched seam-ends tation. These test procedures are con must be secured. sidered minimum requirements. Each 1057 § 178.955 49 CFR Ch. 1(10—1—10 Edition)

packaging must be manufactured and thickness or fabric weight remain the assembled so as to be capable of suc same; cessfully passing the prescribed tests (d) Design qualification testing. The and to conform to the requirements of packaging manufacturer must achieve §173.24 of this subchapter while in successful test results for the design transportation. qualification testing at the start of (b) Responsibility. The Large Pack production of each new or different aging manufacturer is responsible for Large Packaging design type. Applica ensuring each Large Packaging is capa tion of the certification mark by the ble of passing the prescribed tests. To manufacturer constitutes certification the extent a Large Packaging’s assem that the Large Packaging design type bly function, including final closure, is passed the prescribed tests in this sub performed by the person who offers a part. hazardous material for transportation, (e) Periodic design requalification test that person is responsible for per ing. (I) Periodic design requalification forming the function in accordance must be conducted on each qualified with § 173.22 and 178.2 of this sub Large Packaging design type if the chapter. manufacturer is to maintain authoriza (c) Definitions. For the purpose of this tion for continued production. The subpart: Large Packaging manufacturer must (I) Large packaging design type refers achieve successful test results for the to a Large Packaging which does not periodic design requalification at suffi differ in structural design, size, mate cient frequency to ensure each pack rial of construction and packing. aging produced by the manufacturer is (2) Design qualification testing is the capable of passing the design qualifica performance of the drop, stacking, and tion tests. Design requalification tests bottom-lift or top-lift tests, as applica must be conducted at least once every ble, prescribed in this subpart, for each 24 months. different Large Packaging design type, at the start of production of that pack (2) Changes in the frequency of design aging. requalification testing specified in (3) Periodic design requalification test is paragraph (e) (I) of this section are au the performance of the applicable tests thorized if approved by the Associate specified in paragraph (c) (2) of this sec Administrator. tion on a Large Packaging design type, (f) Test samples. The manufacturer to requalify the design for continued must conduct the design qualification production at the frequency specified and periodic tests prescribed in this in paragraph (e) of this section. subpart using random samples of pack (4) Production inspection is the inspec agings, in the numbers specified in the tion, which must initially be conducted appropriate test section. on each newly manufactured Large (g) Selective testing. The selective Packaging. testing of Large Packagings, which dif (5) Different Large Packaging design fer only in minor respects from a test type is one which differs from a pre ed type is permitted as described in viously qualified Large Packaging de this section. For air transport, Large sign type in structural design, size, ma Packagings must comply with terial of construction, wall thickness, § 173.27(c) (1) and (c) (2) of this sub or manner of construction, but does chapter. Variations are permitted in not include: inner packagings of a tested Large (i) A packaging which differs in sur Packaging, without further testing of face treatment; the package, provided an equivalent (ii) A rigid plastic Large Packaging, level of performance is maintained and which differs with regard to additives the methodology used to determine used to comply with §178.925(b) or that the inner packaging, including § 178.940(b); closure, maintains an equivalent level (iii) A packaging which differs only of performance is documented in writ in its lesser external dimensions (i.e., ing by the person certifying compli height, width, length) provided mate ance with this paragraph and retained rials of construction and material in accordance with paragraph (1) of this 1058 Pipeline and Hazardous Materials Safety Admin., DOT § 178.960

section. Permitted variations are as odic retest on a Large Packaging, a follows: test report must be prepared. The test (1) Inner packagings of equivalent or report must be maintained at each lo smaller size may be used provided— cation where the Large Packaging is (i) The inner packagings are of simi manufactured and each location where lar design to the tested inner pack the design qualification tests are con agings (i.e., shape—round, rectangular, ducted, for as long as the Large Pack etc.): aging is produced and for at least two (ii) The material of construction of years thereafter, and at each location the inner packagings (glass, plastic, where the periodic retests are con metal, etc.) offers resistance to impact ducted until such tests are successfully and stacking forces equal to or greater performed again and a new test report than that of the originally tested inner produced. In addition, a copy of the packaging: test report must be maintained by a (iii) The inner packagings have the person certifying compliance with this same or smaller openings and the clo part. The test report must be made sure is of similar design (e.g., screw available to a user of a Large Pack cap, friction lid, etc.): aging or a representative of the De (iv) Sufficient additional cushioning partment upon request. The test re material is used to take up void spaces port, at a minimum, must contain the and to prevent significant movement of following information: the inner packagings; (1) Name and address of test facility; (v) Inner packagings are oriented (2) Name and address of applicant within the outer packaging in the same (where appropriate): manner as in the tested package: and (3) A unique test report identifica (vi) The gross mass of the package tion: does not exceed that originally tested. (4) Date of the test report: (2) A lesser number of the tested (5) Manufacturer of the packaging: inner packagings, or of the alternative (6) Description of the packaging de types of inner packagings identified in sign type (e.g., dimensions, materials, paragraph (g) (1) of this section, may be closures, thickness, etc.), including used provided sufficient cushioning is methods of manufacture (e.g., blow added to fill void space(s) and to pre ) and which may include draw vent significant movement of the inner ing(s) and/or photograph(s); packagings. (7) Maximum capacity; (h) Proof of compliance. In addition to (8) Characteristics of test contents, the periodic design requalification e.g., viscosity and relative density for testing intervals specified in paragraph liquids and particle size for solids; (e) of this section, the Associate Ad (9) Mathematical calculations per ministrator, or a designated represent formed to conduct and document test ative, may at any time require dem ing (for example, drop height, test ca onstration of compliance by a manu pacity, outage requirements, etc.); facturer, through testing in accordance (10) Test descriptions and results: and with this subpart, to ensure packagings (11) Signature with the name and meet the requirements of this subpart. title of signatory. As required by the Associate Adminis L75 FR 5400, Feb. 2, 2010, as amended at 75 FR trator, or a designated representative, 60339, Sept. 30, 20101 the manufacturer must either: (1) Conduct performance tests or § 178.960 Preparation of Large Pack have tests conducted by an inde agings for testing. pendent testing facility, in accordance (a) Except as otherwise provided in with this subpart; or this subchapter, each Large Packaging (2) Make a sample Large Packaging and package must be closed in prepara available to the Associate Adminis tion for testing and tests must be car trator, or a designated representative, ried out in the same manner as if pre 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 pen- torques. 1059 § 178.965 49 CFR Ch. 1(10—1—10 Edition) (b) For the drop and stacking test, qualification testing), at ambient con inner receptacles must be filled to not ditions. less than 95 percent of maximum ca pacity (see §171.8 of this subchapter) in § 178.965 Drop test. the case of solids and not less than 98 (a) Genera]. The drop test must be percent of maximum in the case of liq conducted for the qualification of all uids. Bags must be filled to the max Large Packaging design types and per imum mass at which they may be used. formed periodically as specified in For Large Packagings where the inner § 178.955(e) of this subpart. packagings are designed to carry liq (b) Special preparation for the drop test. uids and solids, separate testing is re Large Packagings must be filled in ac quired for both liquid and solid con cordance with § 178.960. tents. The material to be transported (c) Conditioning. Rigid plastic Large in the packagings may be replaced by a Packagings and Large Packagings with non-hazardous material, except for plastic inner receptacles must be con chemical compatibility testing or ditioned for testing by reducing the where this would invalidate the results temperature of the packaging and its of the tests. contents to — 18 °C (0 F) or lower. Test (c) If the material to be transported liquids must be kept in the liquid is replaced for test purposes by a non- state, if necessary, by the addition of hazardous material, the material used anti-freeze. Water/anti-freeze solutions must be of the same or higher specific with a minimum specific gravity of 0.95 gravity as the material to be carried, for testing at —18 °C (0 °F) or lower are and and its other physical properties considered acceptable test liquids, (grain, size, viscosity) which might in may be considered equivalent to water fluence the results of the required tests for test purposes. Large Packagings not re must correspond as closely as possible conditioned in this way are to in accordance to those of the hazardous material to quired be conditioned be transported. It is permissible to use with §178.960(d). Test method. (I) Samples of all additives, such as bags of lead shot, to (d) Large Packaging design types must be achieve the requisite total package dropped onto a rigid, non-resilient, mass, so long as they do not affect the smooth, flat and horizontal surface. test results. The point of impact must be the most fiberboard Large Pack (d) Paper or vulnerable part of the base of the Large for at least agings must be conditioned Packaging being tested. Following the prior to testing 24 hours immediately drop, the Large Packaging must be re maintained— in an atmosphere stored to the upright position for ob (1) At 50 percent ± 2 percent relative servation. humidity, and at a temperature of 23 °C (2) Large Packaging design types ± 2 °C (73 °F ± 4 °F). Average values with a capacity of 0.45 cubic meters should fall within these limits. Short- (15.9 cubic feet) or less must be subject term fluctuations and measurement to an additional drop test. limitations may cause individual meas (e) Drop height. (1) For all Large urements to vary by up to ± 5 percent Packagings, drop heights are specified relative humidity without significant as follows: impairment of test reproducibility; (i) Packing group I: 1.8 m (5.9 feet) (2) At 65 percent ± 2 percent relative (ii) Packing group II: 1.2 m (3.9 feet) humidity, and at a temperature of 20 °C (iii) Packing group III: 0.8 m (2.6 feet) ± 2 °C (68 °F ± 4 °F), or 27 °C ± 2 C (81 (2) Drop tests are to be performed °F ± 4 °F). Average values should fall with the solid or liquid to be trans within these limits. Short-term fluc ported or with a non-hazardous mate tuations and measurement limitations rial having essentially the same phys may cause individual measurements to ical characteristics. 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 1060 Pipeline and Hazardous Materials Safety Admin., DOT § 178.975

also may be used for the liquid drop safe for transport and there must be no test under the following conditions: loss of contents. (i) Where the substances to be carried have a specific gravity not exceeding § 178.975 Top lift test. 1.2, the drop heights must be those (a) General. The top lift test must be specified in paragraph (e) (1) of this sec conducted for the qualification of all of tion for each Large Packaging design Large Packagings design types to be type; and lifted from the top or, for flexible (ii) Where the substances to be car Large Packagings, from the side. ried have a specific gravity exceeding (b) Special preparation for the top lift 1.2, the drop heights must be as fol test. (1) Metal and rigid plastic Large lows: Packagings design types must be load (A) Packing Group I: SG x 1.5 m (4.9 ed to twice its maximum permissible feet). gross mass. (B) Packing Group II: SG x 1.0 m (3.3 (2) Flexible Large Packaging design feet). types must be filled to six times the (C) Packing Group III: SG x 0.67 m maximum permissible gross mass, the (2.2 feet). load being evenly distributed. (f) Criteria for passing the test. For all (c) Test method. (1) A Large Pack Large Packaging design types there aging must be lifted in the manner for may be no loss of the filling substance which it is designed until clear of the from inner packaging(s) or article(s). floor and maintained in that position Ruptures are not permitted in Large for a period of five minutes. Packaging for articles of Class 1 which (2) Rigid plastic Large Packaging de permit the spillage of loose explosive sign types must be: substances or articles from the Large (1) Lifted by each pair of diagonally Packaging. Where a Large Packaging opposite lifting devices, so that the undergoes a drop test, the sample hoisting forces are applied vertically passes the test if the entire contents for a period of five minutes; and are retained even if the closure is no (ii) Lifted by each pair of diagonally longer sift-proof. opposite lifting devices so that the [75 FR 5400, Feb. 2, 2010, as amended at 75 FR hoisting forces are applied towards the 60339, Sept. 30, 2010] center at 45° to the vertical, for a pe riod of five minutes. § 178.970 Bottom lift test. (3) If not tested as indicated in para (a) General. The bottom lift test must graph (c) (I) of this section, a flexible be conducted for the qualification of Large Packaging design type must be all Large Packagings design types de tested as follows: signed to be lifted from the base. (i) Fill the flexible Large Packaging (b) Special preparation for the bottom to 95% full with a material representa lift test. The Large Packaging must be tive of the product to be shipped. loaded to 1.25 times its maximum per (ii) Suspend the flexible Large Pack missible gross mass, the load being aging by its lifting devices. evenly distributed. (iii) Apply a constant downward force (c) Test method. All Large Packaging through a specially designed platen. design types must be raised and low The platen will be a minimum of 60 ered twice by a lift truck with the percent and a maximum of 80 percent forks centrally positioned and spaced of the cross sectional surface area of at three quarters of the dimension of the flexible Large Packaging. the side of entry (unless the points of (iv) The combination of the mass of entry are fixed). The forks must pene the filled flexible Large Packaging and trate to three quarters of the direction the force applied through the platen of entry. must be a minimum of six times the (d) Criteria for passing the test. For all maximum net mass of the flexible Large Packagings design types de Large Packaging. The test must be signed to be lifted from the base, there conducted for a period of five minutes. may be no permanent deformation (v) Other equally effective methods which renders the Large Packaging Un- of top lift testing and preparation may 1061 § 178.980 49 CFR Ch. I (10—1—10 Edition) be used with approval of the Associate Large Packaging during transpor Administrator. tation. (d) Criterion for passing the test. For (d) Periodic Retest. (1) The package all Large Packagings design types de must be tested in accordance with signed to be lifted from the top, there § 178.980(c) of this subpart; or may be no permanent deformation (2) The packaging may be tested which renders the Large Packagings using a dynamic compression testing unsafe for transport and no loss of con machine. The test must be conducted tents. at room temperature on an empty, un sealed packaging. The test sample § 178.980 Stacking test. must be centered on the bottom platen (a) General. The stacking test must of the testing machine. The top platen be conducted for the qualification of must be lowered until it comes in con all Large Packagings design types in tact with the test sample. Compression tended to be stacked. must be applied end to end. The speed (b) Special preparation for the stacking of the compression tester must be one- test. (1) All Large Packagings except half inch plus or minus one-fourth inch flexible Large Packaging design types per minute. An initial preload of 50 must be loaded to their maximum per pounds must be applied to ensure a missible gross mass. definite contact between the test sam- pie and the platens. The distance be (2) Flexible Large Packagings must tween the platens at this time must be be filled to not less than 95 percent of recorded as zero deformation. The force their capacity and to their maximum A” to then be applied must be cal net mass, with the load being evenly culated using the applicable formula: distributed. (c) Test method. (1) All Large Pack Liquids: A = (1.8)(n—1) [w + (s xv x 8.3 agings must be placed on their base on x .98)] x 1.5; level, hard ground and subjected to a uniformly distributed superimposed or test load for a period of at least five Solids: A = (1.8)(n—1) [w ± (s xv x 8.3 x minutes (see paragraph (c)(5) of this .95)] xl.5 section). Where: (2) Fiberboard and wooden Large Packagings must be subjected to the A = applied load in pounds. n = maximum number of Large Packagings test for 24 hours. that may be stacked during transpor (3) Rigid plastic Large Packagings tation. which bear the stacking load must be w = maximum weight of one empty container subjected to the test for 28 days at 40 in pounds. °C (104 °F). s = specific gravity (liquids) or density (sol (4) For all Large Packagings, the ids) of the lading. = (rated ca load must be applied by one of the fol v actual capacity of container pacity ± outage) in gallons. lowing methods: and: (i) One or more Large Packagings of 8.3 corresponds to the weight in pounds of 1.0 the same type loaded to their max gallon of water. imum permissible gross mass and 1.5 is a compensation factor that converts stacked on the test Large Packaging; the static load of the stacking test into a (ii) The calculated superimposed test load suitable for dynamic compression load weight loaded on either a flat testing. plate or a reproduction of the base of (e) Criterion for passing the test. (1) For the Large Packaging, which is stacked metal or rigid plastic Large Pack on the test Large Packaging; or agings, there may be no permanent de (5) Calculation of superimposed test formation which renders the Large load. For all Large Packagings, the Packaging unsafe for transportation load to be placed on the Large Pack and no loss of contents. aging must be 1.8 times the combined (2) For flexible Large Packagings, maximum permissible gross mass of there may be no deterioration which the number of similar Large Packaging renders the Large Packaging unsafe for that may be stacked on top of the transportation and no loss of contents. 1062 Pipeline and Hazardous Materials Safety Admin., DOT Pt. 178, App. A

(3) For the dynamic compression constrained horizontally to prevent it test, a container passes the test if, from falling off the platform, but must after application of the required load, be left free to move vertically and there is no permanent deformation to bounce. the Large Packaging which renders the (3) The sample Large Packaging must whole Large Packaging; including the be placed on a vibrating platform that base pallet, unsafe for transportation; has a vertical double-amplitude (peak- in no case may the maximum deflec to-peak displacement) of one inch. The tion exceed one inch. Large Packaging must be constrained 175 FR 5400, Feb. 2, 2010, as amended at 75 FR horizontally to prevent it from falling 60339, Sept. 30, 2010] off the platform. but must be left free to move vertically and bounce. § 178.985 Vibration test. (4) The test must be performed for (a) General. All rigid Large Pack one hour at a frequency that causes the aging and flexible Large Packaging de package to be raised from the vibrating sign types must be capable of with platform to such a degree that a piece standing the vibration test. of material of approximately 1.6-mm (b) Test method. (1) A sample Large (0.063-inch) in thickness (such as steel Packaging, selected at random, must strapping or paperboard) can be passe.d be filled and closed as for shipment. between the bottom of the Large Pack Large Packagings intended for liquids aging and the platform. Other methods may be tested using water as the filling at least equally effective may be used material for the vibration test. (see § 178.801(i)). (2) The sample Large Packaging must (c) Criterion for passing the test. A be placed on a vibrating platform that Large Packaging passes the vibration has a vertical or rotary double-ampli test if there is no rupture or leakage. tude (peak-to-peak displacement) of [75 FR 5400,’ Feb. 2, 2010, as amended at 75 FR one inch. The Large Packaging must be 60339, Sept. 30. 2010]

APPENDIX A TO PART 178—SPECIFICATIONS FOR STEEL

TABLE 1 [Open-hearth, basic oxygen, or electric steel of uniform quality. The following chemical composition limits are based on ladle analysis:]

Chemical composition, percent-ladle analysis Designation Grade 1 Grade 212 Grade 32A.5

Carbon 0.10/0.20 0.24 maximum 0.22 maximum. Manganese 1.10/1.60 0,50/1.00 1.25 maximum. Phosphorus, maximum 0.04 0.14 0045.6 Sulfur, maximum 0.05 0.05 0.05. Silicon 0.15/0.30 0.30 maximum Copper, maximum 0.40 Columbium 0.01/0.04 Heat treatment authorized (3) (3) (3) Maximum stress (psi.) 35,000 35,000 35,000. ‘Addition of other elements to obtain alloying effect is not authorized. 2 Ferritic grain size 6 or finer according to ASTM E 112—96 (tBR, see § 171.7 of this subchapter). 3Any suitable heat treatment in excess of 1,100 CF., except that liquid quenching is not permitted. Other alloying elements may be added and shall be reported. 5For compositions with a maximum carbon content of 0.15 percent of ladle analysis, the maximum limit for manganese on ladle analysis may be 1.40 percent. GRephosphorized Grade 3 steels containing no more than 0.15 percent phosphorus are permitted if carbon content does not exceed 0.15 percent and manganese does not exceed I percent.

1063 Pt. 178, App. B 49 CFR Ch. I (10—1—10 Edition)

CHECK ANALYSIS ToLERANcES [A heat of steel made under any of the above grades, the ladle analysis of which is slightly out of the specified range is acceptable if the check analysis is within the following variations:]

Tolerance (percent) over the maximum limit or under the minimum limit Element Limit or maximum specified (percent) Under mm- Over max imum limit imum limit

Carbon To 0.15 inclusive 0.02 0.03 Over 0.15 to 0.40 inclusive 0.03 0.04 Manganese To 0.60 inclusive 0.03 0.03 Over 0.60 to 1.15 inclusive 0.04 0.04 Over 1.15 to 250 inclusive 0.05 0.05 Phosphorus7 All ranges 0.01 Sulfur All ranges 0.01 Silicon To 0.30 inclusive 0.02 0.03 Over 0.30 to 1.00 inclusive 0.05 0.05 Copper To 1.00 inclusive 0.03 0.03 Over 1.00 to 2.00 inclusive 0.05 0.05 Nickel To 1.00 inclusive 0.03 0.03 Over 1.00 to 2.00 inclusive 0.05 0.05 Chromium To 0.90 inclusive 0.03 0.03 Over 0.90 to 2.10 inclusive 0.05 0.05 Molybdenum To 0.20 inclusive 0.01 0.01 Over 0.20 to 040 inclusive 0.02 0.02 Zirconium All ranges 0.01 0.05 Columbium To 0.04 inclusive 0.005 0.01 Aluminum Over 0.10 to 0.20 inclusive 0.04 0.04 Over 0.20 to 0.30 inclusive 0.05 0.05 7Rephosphorized steels not subject to check analysis for phosphorus.

[Amdt. 178—3, 34 FR 12283, July 25, 1969; 34 FR 12593, Aug. 1, 1969, as amended by Amdt. 178— 64, 45 FR 81573, Dec. 11, 1980; Amdt. 178—97, 55 FR 52728, Dec. 21, 1990: 68 FR 75758, Dec. 31, 2003]

APPENDIX B TO PART 178—ALTERNATIVE test. The test must be conducted for a period LEAKPROOFNESS TEST METHODS of time sufficient to appropriately pressurize or evacuate the interior of the packaging In addition to the method prescribed in and to determine if there is leakage into or §178.604 of this subchapter, the following out of the packaging. A packaging passes the leakproofness test methods are authorized: pressure differential test if there is no (I) Helium test. The packaging must be change in measured internal pressure. filled with at least I L inert helium gas, air (3) Solution over seams. The packaging must tight closed, and placed in a testing cham be restrained while an internal air pressure ber. The testing chamber must be evacuated is applied: the method of restraint may not down to a pressure of 5 kPa which equals an affect the results of the test. The exterior over-pressure inside the packaging of 95 kPa. surface of all seams and welds must be coat The air in the testing chamber must be ana ed with a solution of soap suds or a water lyzed for traces of helium gas by means of a and oil mixture. The test must be conducted mass spectrograph. The test must be con for a period of time sufficient to pressurize ducted for a period of time sufficient to evac the interior of the packaging to the specified uate the chamber and to determine if there air pressure and to determine if there is is leakage into or out of the packaging. If he leakage of air from the packaging. A pack lium gas is detected, the leaking packaging aging passes the test if there is no leakage of must be automatically separated from non- air from the packaging. leaking drums and the leaking area deter (4) Solution over partial seams test. For other mined according to the method prescribed in than design qualification testing, the [01- § 178.604(d) of this subchapter. A packaging lowing test may be used for metal drums: passes the test if there is no leakage of he The packaging must be restrained while an lium. internal air pressure of 48 kPa (7.0 psig) is (2) Pressure differential test. The packaging applied: the method of restraint may not af shall be restrained while either pressure or a fect the results of the test. The packaging vacuum is applied internally. The packaging must be coated with a soap solution over the must be pressurized to the pressure required entire side seam and a distance of not less by § 178.604(e) of this subchapter for the ap than eight inches on each side of the side propriate packing group. The method of re seam along the chime seam(s). The test must straint must not affect the results of the be conducted for a period of time sufficient

1064 Pipeline and Hazardous Materials Safety Admin., DOT Pt. 178, App. D

to pressurize the interior of the packaging to tional three thermocouples must be used to the specified air pressure and to determine if monitor the temperature of the cylinder. there is leakage of air from the packaging. A The thermocouples must be 1/ inch, ceramic packaging passes the test if there is no leak packed, metal sheathed, type K (Chromel age of air from the packaging. Chime cuts Alumel), grounded junction with a nominal must be made on the initial drum at the be 30 American wire gauge (AWG) size con ginning of each production run and on the ductor. The thermocouples measuring the initial drum after any adjustment to the temperature inside the oven must be placed chime seamer. Chime cuts must be main at varying heights to ensure even tempera tained on file in date order for not less than ture and proper heat-soak conditions. For six months and be made available to a rep the thermocouples measuring the tempera resentative of the Department of Transpor ture of the cylinder: (1) Two of them must be tation on request. placed on the outer cylinder side wall at ap proximately )Amdt. 178—97, 55 FR 52728, Dec. 21, 1990, as 2 inches (5 cm) from the top and amended at 56 FR 66287, Dec. 20, 1991; 57 FR bottom shoulders of the cylinder; and (2) one 45466, Oct. 1, 1992] must be placed on the cylinder valve body near the pressure relief device. Alter APPENDIX C TO PART 178—NOMINAL AND natively, the thermocouples may be replaced with other devices such as a remote MINIMUM THICKNESSES OF STEEL tempera ture sensor, metal fuse on the valve, or coat DRUMS AND JERRICANs ed wax, provided the device is tested and the For each listed packaging capacity, the test report is retained for verification. Under following table compares the ISO 3574 (IBR, this alternative, it is permissible to record see §171.7 of this subchapter) nominal thick the highest temperature to which the cyl ness with the corresponding ISO 3574 min inder is subjected instead of temperature imum thickness. measurements in intervals of not more than five (5) minutes. Cor 2.3 Instrumentation. A calibrated recording responding device or a computerized data acquisition Maximum capacity (L) so nom- nat (mm) system with an appropriate range should be (mm) provided to measure and record the outputs of the thermocouples. 20 0.7 0.63 3. Test Specimen. 30 0.8 0.73 3.1 40 0.8 0.73 Specimen Configuration. Each outer 60 1.0 0.92 package material type and design must be 120 1.0 0.92 tested, including any features such as han 220 1.0 0.92 dles, latches, fastening systems, etc., that 450 1.9 1.77 may compromise the ability of the outer package to provide thermal protection. )Amdt. 178—106, 59 FR 67522, Dec. 29, 1994, as 3.2 Test Specimen Mounting. The tested amended at 68 FR 75758, Dec. 31, 2003] outer package must be supported at the four corners using fire brick or other suitable APPENDIX D TO PART 178—THERMAL means. The bottom surface of the outer RESISTANCE TEST package must be exposed to allow exposure to heat. I. Scope. This test method evaluates the 4. Preparation for Testing. thermal resistance capabilities of a com 4.1 It is recommended that the cylinder be pressed oxygen generator and the outer closed at ambient temperature and config packaging for a cylinder of compressed oxy ured as when filled with a valve and pressure gen or other oxidizing gas and an oxygen relief device. The oxygen generator must be generator. When exposed to a temperature of filled with an oxidizing agent and may be 205 C (400 °F) for a period of not less than tested with or without packaging. three hours, the outer surface of the cylinder 4.2 Place the package or generator onto may not exceed a temperature of 93 C (199 supporting bricks or a stand inside the test °F) and the oxygen generator must not actu oven in such a manner to ensure even tem ate. perature flow. 2. Apparatus. 5. Test Procedure. 2.1 Test Oven. The oven must be large 5.1 Close oven door and check for proper enough in size to fully house the test outer reading on thermocouples. package without clearance problems. The 5.2 Raise the temperature of the oven to a test oven must be capable of maintaining a minimum temperature of 205 C ± 2 °C (400 F minimum steady state temperature of 205 °C ± 5 CF). Maintain a minimum oven tempera (400 °F). ture of 205 °C ± 2 °C (400 F ± 5 °F) for at least 2.2 Thermocouples. At least three three hours. Exposure time begins when the thermocouples must be used to monitor the oven steady state temperature reaches a temperature inside the oven and an addi minimum of 205 C ± 2 C (400 F ± 5 °F). 1065 Pt. 178, App. E 49 CFR Ch. I (10—1—10 Edition)

5.3 At the conclusion of the three-hour pe (c) Test Specimens. (I) The specimen to be riod, the outer package may be removed tested must measure 16 ±½ inches (406 ±3 from the oven and allowed to cool naturally. mm) by 24±’/a inches (610±3 mm). 6. Recordkeeping. (2) The specimens must be conditioned at 6.1 Record a complete description of the 70 °F. ±5 °F. (21 °C. ±2 °C.) and 55% ±5% hu material being tested, including the manu midity for at least 24 hours before testing. facturer, size of cylinder, etc. (d) Test Apparatus. The arrangement of the 6.2 Record any observations regarding the test apparatus must include the components behavior of the test specimen during expo described in this section. Minor details of the sure, such as smoke production, apparatus may vary, depending on the model delamination, resin ignition, and time of oc of the burner used. currence of each event. (I) Specimen Mounting Stand. The mounting 6.3 Record the temperature and time his stand for the test specimens consists of steel tory of the cylinder temperature during the angles. entire test for each thermocouple location. (2) Test Burner. The burner to be used in Temperature measurements must be re tesing must— corded at intervals of not more than five (5) (i) Be a modified gun type. minutes. Record the maximum temperatures (ii) Use a suitable nozzle and maintain fuel achieved at all three thermocouple locations pressure to yield a 2 GPH fuel flow. For ex and the corresponding time. ample: An 80 degree nozzle nominally rated 7. Requirements. at 2.25 GPH and operated at 85 pounds per 7.1 For a cylinder, the outer package square inch (PSI) gauge to deliver 2.03 GPH. must provide adequate protection such that (iii) Have a 12 inch (305 mm) burner exten the outer surface of the cylinder and valve sion installed at the end of the draft tube does not exceed a temperature of 93 °C (199 with an opening 6 inches (152 mm) high and °F) at any of the three points where the 11 inches (280 mm) wide. thermocouples are located. (iv) Have a burner fuel pressure regulator 7.2 For an oxygen generator, the gener that is adjusted to deliver a nominal 2.0 GPH ator must not actuate. of #2 Grade kerosene or equivalent. Burner models which have been used suc [72 FR 4457, Jan. 31, 2008, as amended at 72 cessfully in testing are the Lenox Model OB FR 55099, Sept. 28, 2007] 32, Carlin Model 200 CRD and Park Model DPL. APPENDIX E TO PART 178—FLAME (3) Calorimeter. (i) The calorimeter to be PENETRATION RESISTANCE TEST used in testing must be a total heat flux Foil Type Gardon Gage of an appropriate range (a) Criteria for Acceptance. (1) At least three (approximately 0 to 15.0 British thermal unit specimens of the outer packaging materials (BTU) per ft.2 sec., 0—17.0 watts/cm2). The cal must be tested; orimeter must be mounted in a 6 inch by 12 (2) Each test must be conducted on a Oat 16 inch (152 by 305 mm) by ¾ inch (19 mm) thick inch x 24 inch test specimen mounted in the insulating block which is attached to a steel horizontal ceiling position of the test appa angle bracket for placement in the test stand ratus to represent the outer packaging de during burner calibration as shown in Figure sign; 2 of this part of this appendix. (3) Testing must be conducted on all design (ii) The insulating block must be mon features (latches, seams, hinges, etc.) affect itored for deterioration and the mounting ing the ability of the outer packaging to shimmed as necessary to ensure that the cal safely prevent the passage of fire in the hori orimeter face is parallel to the exit plane of zontal ceiling position; and the test burner cone. (4) There must be no flame penetration of (4) Thermocouples. The seven thermocouples any specimen within 5 minutes after applica to be used for testing must be 1/16 inch ce tion of the flame source and the maximum ramic sheathed, type K, grounded allowable temperature at a point 4 inches thermocouples with a nominal 30 American above the test specimen, centered over the wire gage (AWG) size conductor. The seven burner cone, must not exceed 205 °C (400 OF) thermocouples must be attached to a steel (b) Summary of Method. This method pro angle bracket to form a thermocouple rake vides a laboratory test procedure for meas for placement in the test stand during burn uring the capability of cargo compartment er calibration. lining materials to resist flame penetration (5) Apparatus Arrangement. The test burner with a 2 gallon per hour (GPH) #2 Grade ker must be mounted on a suitable stand to posi osene or equivalent burner fire source. Ceil tion the exit of the burner cone a distance of ing and sidewall liner panels may be tested 8 inches from the ceiling liner panel and 2 individually provided a baffle is used to sim inches from the sidewall liner panel. The ulate the missing panel. Any specimen that burner stand should have the capability of passes the test as a ceiling liner panel may allowing the burner to be swung away from be used as a sidewall liner panel. the test specimen during warm-up periods.

1066 Pipeline and Hazardous Materials Safety Admin., DOT Pt. 179

(6) Instrumentation. A recording potentiom (4) Expose the test specimen to the flame eter or other suitable instrument with an ap for 5 minutes and then turn off the burner. propriate range must be used to measure and The test may be terminated earlier if flame record the outputs of the calorimeter and penetration is observed. the thermocouples. (5) When testing ceiling liner panels, (7) Timing Device. A stopwatch or other de record the peak temperature measured 4 vice must be used to measure the time of inches above the sample. flame application and the time of flame pen (6) Record the time at which flame pene etration, if it occurs. tration occurs if applicable. (e) Preparation of Apparatus. Before calibra (h) Test Report. The test report must in tion, all equipment must be turned on and clude the following: allowed to stabilize, and the burner fuel flow (1) A complete description of the materials must be adjusted as specified in paragraph tested including type, manufacturer, thick (d)(2). ness, and other appropriate data. (f) Calibration. To ensure the proper ther (2) Observations of the behavior of the test mal output of the burner the following test specimens during flame exposure such as must be made: delamination, resin ignition, smoke, etc., in (1) Remove the burner extension from the cluding the time of such occurrence. end of the draft tube. Turn on the blower (3) The time at which flame penetration portion of the burner without turning the occurs, if applicable, for each of the three fuel or igniters on. Measure the air velocity specimens tested. using a hot wire anemometer in the center of the draft tube across the face of the opening. [72FR55099, Sept. 28, 2007] Adjust the damper such that the air velocity is in the range of 1550 to 1800 ft/mm. If tabs PART are being used at the exit of the draft tube, 179—SPECIFICATIONS FOR they must be removed prior to this measure TANK CARS ment. Reinstall the draft tube extension cone. Subpart A—Introduction, Approvals and (2) Place the calorimeter on the test stand Reports as shown in Figure 2 at a distance of 8 inches (203 mm) from the exit of the burner cone to Sec. simulate the position of the horizontal test 179.1 General. specimen. 179.2 Definitions and abbreviations. (3) Turn on the burner, allow it to run for 179.3 Procedure for securing approval. 2 minutes for warm-up, and adjust the damp 179.4 Changes in specifications for tank er to produce a calorimeter reading of 8.0 ±0.5 cars. BTU per ft.2 sec. (9.1 ±0.6 Watts/cm2). 179.5 Certificate of construction. (4) Replace the calorimeter with the ther 179.6 Repairs and alterations. mocouple rake. 179.7 Quality assurance program. (5) Turn on the burner and ensure that 179.8 Limitation on actions by states, local each of the seven thermocouples reads 1700 governments, and Indian tribes. F. ±100 °F. (927 °C. ±38 °C.) to ensure steady state conditions have been achieved. If the Subpart B—General Design Requirements temperature is out of this range, repeat steps 2 through 5 until proper readings are ob 179.10 Tank mounting. tained. 179.11 Welding certification. (6) Turn off the burner and remove the 179.12 Interior heater systems. thermocouple rake. 179.13 Tank car capacity and gross weight (7) Repeat (1) to ensure that the burner is limitation. in the correct range. 179.14 Coupler vertical restraint system. (g) Test Procedure. (1) Mount a thermo 179.15 Pressure relief devices. couple of the same type as that used for cali 179.16 Tank-head puncture-resistance sys bration at a distance of 4 inches (102 mm) tems. above the horizontal (ceiling) test specimen. 179.18 Thermal protection systems. The thermocouple should be centered over 179.20 Service equipment; protection sys the burner cone. tems. (2) Mount the test specimen on the test 179.22 Marking. stand shown in Figure 1 in either the hori zontal or vertical position. Mount the insu Subpart C—Specifications for Pressure lating material in the other position. Tank Car Tanks (Classes DOT-i D5, 109, (3) Position the burner so that flames will 112,114, and 120) not impinge on the specimen, turn the burn er on, and allow it to run for 2 minutes. Ro 179.100 General specifications applicable to tate the burner to apply the flame to the pressure tank car tanks. specimen and simultaneously start the tim 179.100—I Tanks built under these specifica ing device. tions shall comply with the requirements

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