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Guidelines for the Operation, Assembly, Repair, Testing and Inspection of Hazardous Material Cargo Tanks

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Guidelines for the Operation, Assembly, Repair, Testing and Inspection of Hazardous Material Cargo Tanks FINAL REPORT Submitted to: U.S Department of Transportation Federal Motor Carrier Safety Administration June 2009 FOREWORD The purpose of this report is to assist the Federal Motor Carrier Safety Administration (FMCSA) in identifying factors that affect the service life of a cargo tank and to assist in the development of industry-informed guidelines to provide methods, programs, processes, and procedures that will minimize the effects of factors that reduce the service life of a cargo tank. The basis for these guidelines includes industry comments, regulatory documents, and professional organizations’ guidance. NOTICE This document is disseminated under the sponsorship of the Department of Transportation in the interest of information exchange. The United States Government assumes no liability for its contents or the use thereof. The contents of this Report reflect the views of the contractor, who is responsible for the accuracy of the data presented herein. The contents do not necessarily reflect the official policy of the Department of Transportation. This Report does not constitute a standard, specification, or regulation. The United States Government does not endorse products or manufacturers named herein. Trade or manufacturers’ names appear herein only because they are considered essential to the objective of this document. 1. Report No. 2. Government Accession No. 3. Recipient's Catalog No. 4. Title and Subtitle 5. Report Date Guidelines for the Operation, Assembly, Repair, Testing and June 30, 2009 Inspection of Hazardous Material Cargo Tanks 6. Performing Organization Code 7. Author(s) 8. Performing Organization Report No. Darrell Bowman, Andrew Marinik, Tammy Trimble, Stephanie Baker, and Allen Selz (Pressure Sciences, Inc.) 9. Performing Organization Name and Address 10. Work Unit No. (TRAIS) Virginia Tech Transportation Institute 3500 Transportation Research Plaza 11. Contract or Grant No. Blacksburg, Virginia 24061 VTRC # 08-0669-10 FMCSA # TMC75-07-H-00008 Task Order # 2 12. Sponsoring Agency Name and Address 13. Type of Report and Period Covered Department of Transportation Federal Motor Carrier Safety Administration Draft Report. Hazardous Materials Division West Wing, MC-ECH 14. Sponsoring Agency Code 1200 New Jersey Ave. SE FMCSA Washington, DC 20590 15. Supplementary Notes This program was administered through the Federal Motor Carrier Safety Administration (FMCSA) and the Virginia Transportation Research Council (VTRC). The FMCSA Authorized Organizational Technical Representative (AOTR) is James Simmons and the VTRC Principal Investigator (PI) is Mike Perfater. 16. Abstract This document consists of guidelines and recommendations related to operations, assembly, repair, testing and inspection of cargo tanks hauling hazardous materials. This document is the result of research findings from the project titled: Research to Identify the Factors that Affect the Service Life of Cargo Tanks [VTRC # 08-0669-10, FMCSA # TMC75-07-H-00008 Task Order # 2]. 17. Key Words 18. Distribution Statement Hazardous Materials, Specification Cargo Tanks, Maintenance, Repair, Assembly, Testing, Inspection, Operations 19. Security Classif. (of this 20. Security Classif. (of this page) 21. No. of 22. Price report) Pages Unclassified N/A Unclassified 105 Form DOT F 1700.7 (8-72) Reproduction of completed page authorized. SI* (MODERN METRIC) CONVERSION FACTORS APPROXIMATE CONVERSIONS TO SI UNITS Symbol When You Know Multiply By To Find Symbol LENGTH in inches 25.4 millimeters mm ft feet 0.305 meters m yd yards 0.914 meters m mi miles 1.61 kilometers km AREA in2 square inches 645.2 square millimeters mm2 ft2 square feet 0.093 square meters m2 yd2 square yard 0.836 square meters m2 ac acres 0.405 hectares ha mi2 square miles 2.59 square kilometers km2 VOLUME fl oz fluid ounces 29.57 milliliters mL gal gallons 3.785 liters L ft3 cubic feet 0.028 cubic meters m3 yd3 cubic yards 0.765 cubic meters m3 NOTE: volumes greater than 1000 L shall be shown in m3 MASS oz ounces 28.35 grams g lb pounds 0.454 kilograms kg T short tons (2000 lb) 0.907 megagrams (or "metric ton") Mg (or "t") TEMPERATURE (exact degrees) oF Fahrenheit 5 (F-32)/9 Celsius oC or (F-32)/1.8 ILLUMINATION fc foot-candles 10.76 lux lx fl foot-Lamberts 3.426 candela/m2 cd/m2 FORCE and PRESSURE or STRESS lbf poundforce 4.45 newtons N lbf/in2 poundforce per square inch 6.89 kilopascals kPa APPROXIMATE CONVERSIONS FROM SI UNITS Symbol When You Know Multiply By To Find Symbol LENGTH mm millimeters 0.039 inches in m meters 3.28 feet ft m meters 1.09 yards yd km kilometers 0.621 miles mi AREA mm2 square millimeters 0.0016 square inches in2 m2 square meters 10.764 square feet ft2 m2 square meters 1.195 square yards yd2 ha hectares 2.47 acres ac km2 square kilometers 0.386 square miles mi2 VOLUME mL milliliters 0.034 fluid ounces fl oz L liters 0.264 gallons gal m3 cubic meters 35.314 cubic feet ft3 m3 cubic meters 1.307 cubic yards yd3 MASS g grams 0.035 ounces oz kg kilograms 2.202 pounds lb Mg (or "t") megagrams (or "metric ton") 1.103 short tons (2000 lb) T TEMPERATURE (exact degrees) oC Celsius 1.8C+32 Fahrenheit oF ILLUMINATION lx lux 0.0929 foot-candles fc cd/m2 candela/m2 0.2919 foot-Lamberts fl FORCE and PRESSURE or STRESS N newtons 0.225 poundforce lbf kPa kilopascals 0.145 poundforce per square inch lbf/in2 *SI is the symbol for the International System of Units. Appropriate rounding should be made to comply with Section 4 of ASTM E380. (Revised March 2003) TABLE OF CONTENTS 1. INTRODUCTION.................................................................................................................1 1.1 THE CARGO TANK INDUSTRY ..................................................................................1 1.2 CARGO TANK REGULATIONS, STANDARDS, AND CODES .................................1 1.3 METHODS .......................................................................................................................2 1.3.1 Participants ........................................................................................................... 2 1.3.2 Data Collection .................................................................................................... 3 1.3.3 Data Analysis ....................................................................................................... 3 1.4 RESULTS AND DISCUSSION .......................................................................................4 1.5 STRUCTURE OF THE GUIDELINES DOCUMENT ....................................................4 2. CARGO TANK FLEET/FACILITY OPERATIONS .......................................................5 2.1 INTRODUCTION ............................................................................................................5 2.2 FLEET MANAGEMENT .................................................................................................5 2.2.1 Lading Management ............................................................................................ 5 2.2.2 Record Keeping/Tracking Key Measures ............................................................ 6 2.2.3 Safety Policies/Procedures ................................................................................... 7 2.2.4 Fleet/Facility Investment ..................................................................................... 8 2.3 DRIVER MANAGEMENT ..............................................................................................9 2.3.1 Driver Training .................................................................................................. 10 2.3.2 Driver Inspection ............................................................................................... 12 2.4 MAINTENANCE ...........................................................................................................14 2.4.1 Preventative Maintenance .................................................................................. 14 2.4.2 Maintenance: Protective Coating ....................................................................... 17 2.4.3 Cleaning ............................................................................................................. 18 2.4.4 Maintenance Training ........................................................................................ 19 3. CARGO TANK ASSEMBLY ............................................................................................21 3.1 INTRODUCTION ..........................................................................................................21 3.2 MOUNTING OF CARGO TANKS ON FRAMES........................................................21 3.2.1 Mounting ............................................................................................................ 21 3.2.2 Attachments ....................................................................................................... 22 3.3 INSTALLATION OF EQUIPMENT AND COMPONENTS (DOT 406/DOT 407/ DOT 412) .....................................................................................................................23 3.3.1 Manhole Assemblies .......................................................................................... 24 3.3.2 Accident Damage Protection ............................................................................. 24 vi 3.3.3 Pressure Relief ..................................................................................................
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