AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

CHAPTER 1 INTRODUCTIONS, APPROVALS, AND REPORTS

CONTENTS Paragraph Subject Page 1.1 Introduction ...... C-III–3 1.1.1 Historical Record ...... C-III–3 1.1.2 Legal Authority ...... C-III–3 1.1.3 General Design Requirement ...... C-III–4 1.1.5 List of Specifications ...... C-III–5 1.2 Definitions ...... C-III–12 1.3 General Requirements...... C-III–30 1.3.1 Car Structure ...... C-III–30 1.3.2 DOT Tanks ...... C-III–30 1.3.3 AAR Tanks ...... C-III–30 1.3.4 Safety Appliances ...... C-III–30 1.3.5 Interchange...... C-III–30 1.3.6 Approvals ...... C-III–30 1.3.7 Editions of Referenced Specifications ...... C-III–31 1.3.8 Calibration and Capacity Tables ...... C-III–31 1.3.9 Gauging ...... C-III–31 1.3.10 Age Limits ...... C-III–32 1.3.11 Head Shields ...... C-III–32 1.3.12 Rebuilt Status ...... C-III–32 1.3.13 Commodity Change ...... C-III–32 1.3.14 Reporting Marks and Car Numbers ...... C-III–32 1.3.15 Documentation at the Sale of Tank Cars ...... C-III–32 1.3.16 Requirements for Tank Cars with Gross Rail Load Over 263,000 lb to 286,000 lb, Inclusive...... C-III–32 1.3.17 Maintenance Program ...... C-III–33 1.4 Procedures for Securing Approval...... C-III–33 AWW DRAFT 09/28/18 1.4.1 General ...... C-III–33 1.4.2 Approval of Precedent and Nonprecedent Tank Car Designs (Form AAR 4-2) ...... C-III–34 1.4.3 Application Form AAR 4-2 ...... C-III–38 Fig. 1.1 Form AAR 4-2 Application for Approval and Certificate of Construction...... C-III–42 Fig. 1.2 Form AAR 4-2.1 Supplementary page ...... C-III–43 1.4.4 Certificate of Construction ...... C-III–44 1.4.5 Service Equipment ...... C-III–44 1.4.6 Pressure Relief Devices ...... C-III–47 Fig. 1.3 Form AAR 4-3 Application for Approval of Pressure Relief Device ...... C-III–50 1.4.7 Valves, Closures, and Fittings...... C-III–51 Fig. 1.4 Form AAR 4-5 Application for Approval of Valves and Fittings...... C-III–53 1.4.8 Renewal of Approval for Pressure Relief Devices, Valves, Closures, and Fittings...... C-III–54

11/2014 C-III [M-1002] 1 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

Fig. 1.5 Form AAR 4-7 Application for Renewal of Approval for Pressure Relief Devices, Valves, Closures, and Fittings...... C-III–56 1.4.9 AAR Service Trials ...... C-III–57 Fig. 1.6 Form AAR 4-4 AAR Tank Car Service Trial Report ...... C-III–61 1.4.10 Final Service Trial and Inspection...... C-III–62 Fig. 1.7 Form AAR 4-6 Final Service Trial Inspection Report ...... C-III–63 1.4.11 Certified Status ...... C-III–64 1.5 Certification of Independent Third Parties ...... C-III–65 1.5.1 General...... C-III–65

1.5.2 Requirements and Qualifications ...... C-III–65 09/28/18 DRAFT AWW 1.5.3 Procedures for Obtaining Certification ...... C-III–65 1.6 Document Retention ...... C-III–66

C-III [M-1002] 2 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

CHAPTER 1. INTRODUCTIONS, APPROVALS, AND REPORTS 1.1 Introduction 1.1.1 Historical Record Specifications for Tank Cars first appeared as a report to the former Master Car Builders’ Association in 1903. The report was approved, revised, and issued by the American Railway Association in 1925 and adopted March 1, 1931, by the Association of American Railroads (AAR). On July 1, 1927, Interstate Commerce Commission specifications were issued for tank car tanks for transportation of articles classed as dangerous by ICC Regulations, and AAR specifications for such tanks became obsolete. The ICC regulations have been published and revised as a part of Title 49, Code of Federal Regulations. After passage of the Department of Transportation Act in October 1966, these regulations became the DOT Hazardous Materials Regulations, effective April 1, 1967. The Hazardous Materials Regulations currently include Title 49, Code of Federal Regulations, Parts 100–199. The specifications in this volume also prescribe AAR specifications for tank car tanks for the transportation of nonhazardous and DOT low-hazard commodities. This issue of the AAR Specifications for Tank Cars dated November 2014 supersedes the issue dated October 2007. For current issues of the DOT Hazardous Materials Regulations, refer to Title 49, CFR, Parts 100– 199 published annually, revised each year, and available from the Government Printing Office. A comprehensive compilation of the hazardous materials transportation regulations (all modes) is published annually and updated quarterly as AAR Bureau of Explosives Tariff No. BOE-6000 and can be obtained at http://www.boepublications.com. DOT’s hazardous materials regulations are available for viewing or download from their Web site at http://phmsa.dot.gov/regulations. In Canada, Transport Canada, Transport Dangerous Goods Directorate, Regulatory Affairs Branch, prepares and administers the regulations for transport of dangerous commodities. The Transportation of Dangerous Goods Regulations and Act are available for viewing or download from Transport Canada’s Web site at http://www.tc.gc.ca/eng/menu.htm. 1.1.2 Legal Authority The Department of Transportation’s hazardous materials regulations are issued under the authority of the Hazardous Materials Transportation Act as amended, 49 U.S.C. sections 1801 et seq.

AWW DRAFT 09/28/18 Transportation of Dangerous Goods Regulations are issued by Transport Canada under the authority of the Transportation of Dangerous Goods Act, 1992.

11/2014 C-III [M-1002] 3 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

1.1.3 General Design Requirement Tank cars are subject to the following: • AAR Manual of Standards and Recommended Practices (MSRP): ° Section C, “Car Construction Fundamentals,” (e.g,. S-2034, “Car Builder Certification” and S-2044, “Safety Appliance Requirements for Freight Cars”) ° Section C, Part II, “Design, Fabrication, and Construction of Freight Cars” (M-1001) ° Section C, Part III, “Specifications for Tank Cars” (M-1002) ° Section B, “Couplers and Freight Car Draft Components” ° Section D, “Trucks and Truck Details” ° Section E, “Brakes and Brake Equipment” ° Section E, Part II, “Electronically Controlled Brake Systems” (when so equipped) 09/28/18 DRAFT AWW ° Section F, “Sensors” (when so equipped) ° Section G, “Wheels and Axles” ° Section H, “Journal Bearings and Lubrication” ° Section J, “Specifications for Quality Assurance” (M-1003) ° Section L, “Lettering and Marking of Cars” ° Section S, Part I, “Castings” ° Section S, Part II, “Truck Dimensions” ° Section S, Part III, “Coupler and Yoke Dimensions” • Field Manual of the AAR Interchange Rules • Office Manual of the AAR Interchange Rules • Title 49 Code of Federal Regulations, Parts 171-180, 215, 231, 232 • Transportation Dangerous Goods (TDG) Regulations ° Transport Canada (TC) TP14877 1.1.4 Certified tank car builders must have a designated and approved facility on the North American continent where final assembly and/or acceptance inspections and tests of cars are performed prior to release for interchange service. Assembly facilities that do not qualify as certified car builders must be inspected by the Committee and may be approved as final assemblers upon demonstration of the relevant qualifications outlined in M-1002.

C-III [M-1002] 4 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

1.1.5 List of Specifications A complete list of former and present tank car specifications is given in Table 1.1.

Table 1.1 List of tank car specifications (page 1 of 6) (See end of table for footnotes) Originally Latest Obsolete for New Operational Specification Approved Revision Construction Status a/ by AAR b/ b/ c/ ARA-I Before 1903 — 1-1-03 — ARA-II 1-1-03 — 5-1-17 — ARA-III 5-1-17 — 7-1-27 — ARA-IV 5-1-17 — 7-1-27 — AAR-IV-A 10-1-25 — 7-1-27 — ARA-V 1-1-18 — 7-1-27 — ARA-VI 1-1-25 — 10-10-29 — AAR-201A35 3-1-31 1-31-55 8-1-62 — AAR-201A35W 3-1-37 — 11-13-68 — AAR-201A70W 1-31-55 — 11-13-68 — AAR-201A80W 3-22-65 — 3-22-65 — AAR-203 3-1-31 — 8-31-56 — AAR-203DW 11-10-71 — — — AAR-203W 8-1-41 11-10-71 — d/ AAR-203 Special — — 8-31-56 — AAR-204W 12-17-58 11-13-75 — d/ AAR-204X 4-27-67 — 4-27-67 d/ AAR-205A300W 6-14-51 — 6-14-51 e/ AAR-206W 6-28-62 11-10-71 — — AAR-207A20W 4-21-65 11-10-71 — — AAR-207A28W 4-21-65 11-10-71 — — AAR-207A40W 4-21-65 11-10-71 — — AAR-207A40W6 4-21-65 11-10-71 — — AAR-207A48ALW 4-22-65 11-10-71 — —

AWW DRAFT 09/28/18 AAR-207A48W 4-22-65 11-10-71 — — AAR-207A60ALW 4-22-65 11-10-71 — — AAR-207A60W 4-22-65 11-10-71 — — AAR-207A80ALW 4-22-65 11-10-71 — — AAR-207A80W 4-22-65 11-10-71 — — AAR-208 11-13-68 11-10-71 — — AAR-211A60W1 11-10-66 11-10-71 — — AAR-211A60W2 11-10-66 11-10-71 10-12-78 — AAR-211A60W7 11-10-71 — — — AAR-211A60ALW1 11-10-66 11-10-71 — — AAR-211A100W1 11-10-66 11-10-71 — — AAR-211A100W2 11-10-66 11-10-71 10-12-78 — AAR-211A100W3 Pending Implemented CPC

11/2014 C-III [M-1002] 5 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

Table 1.1 List of tank car specifications (page 2 of 6) (See end of table for footnotes) Originally Latest Obsolete for New Operational Specification Approved Revision Construction Status a/ by AAR b/ b/ c/ AAR-211A100W5 Pending Implemented CPC AAR-211A100W6 11-10-71 — — — AAR-211A200W1 11-10-66 AAR-211A100ALW1 11-10-66 11-10-71 — — AAR-211J100W1 Pending Implemented CPC ICC-103 7-1-27 — 12-19-64 — 09/28/18 DRAFT AWW DOT-103 12-19-64 ICC-103A 7-1-27 — 12-19-64 — DOT-103A-ALW 8-21-51 12-31-71 10-1-03 — ICC-103AL 11-5-37 10-6-47 8-31-56 — DOT-103ALW 8-21-51 12-31-71 10-1-03 — DOT-103ANW 8-31-56 12-31-71 10-1-03 — DOT-103AW 1-7-41 12-31-71 10-1-03 — ICC-103B 7-1-27 — 12-19-64 — DOT-103BW 1-7-41 12-31-71 10-1-03 — ICC-103B100W 12-31-52 — 12-19-64 — ICC-103C 8-15-28 — 8-31-56 — ICC-103CAL 4-20-48 11-14-49 8-31-56 — DOT-103CW 1-7-41 12-31-71 10-1-03 — DOT-103DW 8-31-56 12-31-71 10-1-03 — DOT-103EW 8-31-56 12-31-71 10-1-03 — DOT-103W 1-7-41 12-31-71 10-1-03 — ICC-104 7-1-27 — 12-19-64 — ICC-104A 7-1-27 — 8-31-56 f/ ICC-104A-ALW 10-25-52 — 9-21-54 g/ ICC-104AW 1-7-41 — 8-31-56 h/ DOT-104W 1-7-41 12-31-71 10-1-03 — ICC-105 7-1-27 — 10-19-29 — ICC-105A100 7-1-27 — 12-19-64 f/ ICC-105A300 8-15-28 — 8-31-56 — ICC-105A400 12-15-28 — 8-31-56 — ICC-105A500 12-15-28 — 8-31-56 — ICC-105A600 12-15-28 — 8-31-56 — DOT-105A100W 1-7-41 12-31-71 — h/ i/ DOT-105A200F 12-19-64 12-31-71 11-30-84 d/ DOT-105A200W 9-23-57 12-31-71 — i/ DOT-105A300W 1-7-41 12-31-71 — i/ DOT-105A400W 1-7-41 12-31-71 — i/ DOT-105A500W 1-7-41 12-31-71 — i/

C-III [M-1002] 6 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

Table 1.1 List of tank car specifications (page 3 of 6) (See end of table for footnotes) Originally Latest Obsolete for New Operational Specification Approved Revision Construction Status a/ by AAR b/ b/ c/ DOT-105A600W 1-7-41 12-31-71 — i/ DOT-105J100W 8-31-81 — — i/ DOT-105J200W 8-31-81 — — i/ DOT-105J300W 8-31-81 — — i/ DOT-105J400W 8-31-81 — — i/ DOT-105J500I 3-16-09 DOT-105J500W 8-31-81 — — i/ DOT-105J600I 3-16-09 DOT-105J600W 8-31-81 — — i/ DOT105S100W 8-31-81 DOT105S200W 8-31-81 DOT-105S300W 8-31-81 — — i/ DOT-105S400W 8-31-81 — — i/ DOT-105S500W 8-31-81 — — i/ DOT-105S600W 8-31-81 — — i/ DOT-105A100ALW 10-25-52 12-31-71 — i/ DOT-105A200ALW 9-23-57 12-31-71 — i/ DOT-105A300ALW 8-31-56 12-31-71 — i/ DOT-105J200ALW 8-31-81 — — i/ DOT-105J300ALW 8-31-81 — — i/ ICC-106A500 10-10-29 — 12-19-64 — DOT-106A500X 4-19-46 12-31-71 — j/ ICC-106A800 10-10-29 — 12-19-64 — ICC-106A800NCI 12-31-52 — 12-19-64 — DOT-106A800X 4-19-46 12-31-71 — j/ ICC-106A800XNC — — 12-19-64 —

AWW DRAFT 09/28/18 DOT-107A 1-13-32 9-15-71 — — ICC-108 7-1-27 — 8-31-56 — ICC-108A 7-1-27 — 8-31-56 — DOT-109A100ALW 6-18-57 12-31-71 — — DOT-109A200ALW 6-25-57 12-31-71 — — DOT-109A300ALW 9-23-57 12-31-71 — — DOT-109A300W 6-15-51 12-31-71 — — DOT-110A500W 8-21-51 12-19-64 — j/ DOT-110A600W 2-12-75 — — j/ DOT-110A800W 8-21-61 12-19-64 — j/ DOT-110A1000W 12-19-64 — — j/ DOT-110A3000W 11-8-61 5-19-94 12-31-78 j/ DOT-110A2000W 10-4-93 5-19-94 — j/

11/2014 C-III [M-1002] 7 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

Table 1.1 List of tank car specifications (page 4 of 6) (See end of table for footnotes) Originally Latest Obsolete for New Operational Specification Approved Revision Construction Status a/ by AAR b/ b/ c/ ICC-111A60ALW 7-19-59 12-19-64 5-27-67 — DOT-111A60ALW 5-27-67 DOT-111A60ALW1 5-27-67 12-31-71 — — DOT-111A60ALW2 5-27-67 12-31-71 — — DOT-111A60F1 2-17-63 12-31-71 11-30-84 d/ DOT-111A60W1 2-17-63 12-31-71 — — 09/28/18 DRAFT AWW DOT-111A60W2 11-11-65 12-31-71 — — DOT-111A60W5 11-11-65 12-31-71 — — DOT-111A60W6 1-10-92 — — — DOT-111A60W7 5-27-67 12-31-71 — — ICC-111A100ALW 5-22-65 — 5-27-67 — DOT-111A100ALW 5-27-67 DOT-111A100ALW1 5-22-65 12-31-71 — — DOT-111A100ALW2 5-27-67 12-31-71 — — DOT-111A100F1 9-25-63 12-31-71 11-30-84 d/ DOT-111A100F2 9-25-63 12-31-71 11-30-84 d/ DOT-111A100W1 9-23-57 12-31-71 — — DOT-111A100W2 9-23-57 12-31-71 — — DOT-111A100W3 9-23-57 12-31-71 — — DOT-111A100W4 9-23-57 12-31-71 — — DOT-111A100W5 7-19-59 12-31-71 — — DOT-111A100W6 7-19-59 12-31-71 — — DOT-111A100W7 Pending Implemented CPC DOT-111J100W1 Pending Implemented CPC DOT-111J100W3 Pending Implemented CPC DOT-111J100W4 Pending Implemented CPC DOT-111S100ALW2 Pending Implemented CPC DOT-111S100W1 Pending Implemented CPC DOT-111S100W2 Pending Implemented CPC DOT-111S100W5 Pending Implemented CPC DOT-111S100W6 Pending Implemented CPC DOT-111S60ALW1 Pending Implemented CPC DOT-111S60ALW2 Pending Implemented CPC DOT-112A200W 2-17-63 7-13-78 — k/ DOT-112A340W 2-17-63 7-13-78 — k/ DOT-112A400F 12-20-61 7-13-78 11-30-84 d/ DOT-112A400W 9-23-57 7-13-78 — k/ DOT-112A500W 6-20-60 7-13-78 — k/ DOT-112J200W 10-16-91 — — k/

C-III [M-1002] 8 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

Table 1.1 List of tank car specifications (page 5 of 6) (See end of table for footnotes) Originally Latest Obsolete for New Operational Specification Approved Revision Construction Status a/ by AAR b/ b/ c/ DOT-112J340W 10-19-77 7-13-78 — k/ DOT-112J400F 10-19-77 7-13-78 11-30-84 d/ DOT-112J400W 10-19-77 7-13-78 — k/ DOT-112J500I 3-16-09 DOT-112J500W 10-19-77 7-13-78 — k/ DOT-112S200W 10-16-91 — — k/ DOT-112S340W 10-19-77 7-13-78 — k/ DOT-112S400F 10-19-77 7-13-78 11-30-84 d/ DOT-112S400W 10-19-77 7-13-78 — k/ DOT-112S500W 10-19-77 7-13-78 — k/ DOT-112S600I 3-16-09 DOT-112T200W 10-16-91 — — k/ DOT-112T340W 10-19-77 7-13-78 — k/ DOT-112T400F 10-19-77 7-13-78 11-30-84 d/ DOT-112T400W 10-19-77 7-13-78 — k/ DOT-112T500W 10-19-77 7-13-78 — k/ DOT-113A60W 7-24-63 11-13-75 — l/ DOT-113A90W Pending DOT Approval ICC-113A120W 12-19-64 — 12-6-67 — DOT-113A175W 12-19-64 11-13-75 10-1-84 l/ DOT-113B60W 7-11-69 — 3-3-72 — DOT-113C60W 12-6-67 — 3-2-72 l/ DOT-113C120W 12-6-67 11-13-75 — l/ DOT-113D60W 12-6-67 — 3-2-72 l/ DOT-113D120W 12-6-67 11-13-75 10-1-84 l/ DOT-114A340W 12-19-64 7-13-78 — k/

AWW DRAFT 09/28/18 DOT-114A400W 11-11-65 7-13-78 — k/ DOT-114J340W 10-19-77 7-13-78 — k/ DOT-114J400W 10-19-77 7-13-78 — k/ DOT-114S340W 10-19-77 7-13-78 — k/ DOT-114S400W 10-19-77 7-13-78 — k/ DOT-114T340W 10-19-77 7-13-78 — k/ DOT-114T400W 10-19-77 7-13-78 — k/ DOT-115A60ALW 11-11-65 12-31-71 — — DOT-115A60W1 11-11-65 12-31-71 — — DOT-115A60W6 11-11-65 12-31-71 — — DOT-116A****W 11-11-65 — 5-11-72 — DOT-117A340W 11-10-66 — 5-11-72 DOT-E DOT-120A200ALW 5-11-72 — — —

11/2014 C-III [M-1002] 9 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

Table 1.1 List of tank car specifications (page 6 of 6) (See end of table for footnotes) Originally Latest Obsolete for New Operational Specification Approved Revision Construction Status a/ by AAR b/ b/ c/ DOT-120A100W 10-18-94 — — — DOT-120A200W 10-18-94 — — — DOT-120A300W 11-10-66 — — — DOT-120A400W 9-20-72 — — — DOT-120A500W 3-2-72 — — — DOT-120A600W 3-19-74 — — — 09/28/18 DRAFT AWW DOT120J100W 3-19-74 DOT120J200W 3-19-74 DOT120J600W 3-19-74 DOT-121A500W 11-13-68 — 3-2-72 m/ Emergency USG-A 6-15-42 — 8-31-56 — Emergency USG-B 6-15-42 — 8-31-56 — Emergency USG-C 6-15-42 — 8-31-56 — a/ Tank car tanks with the specification marking “ICC” placed thereon before January 1, 1970, may be continued in service as marked. b/ AAR-approved dates for AAR specifications; ICC-effective dates for ICC specifications; ICC- or DOT-effective dates for DOT specifications. c/ “DOT-E” indicates that a DOT exemption is required for any tank of the referenced specification. d/ Conversions only. e/ Specification AAR-205A300W superseded by DOT-109A300W. f/ Specification ICC-104A superseded by ICC-105A100. g/ Specification ICC-104A-ALW superseded by DOT-105A100ALW. h/ Specification ICC-104AW superseded by DOT-105A100W. i/ Specifications DOT-105A, J, and S define certain tank protective devices required by DOT 173.31. See paragraph 1.2.1.1. j/ Effective after 7/1/94, approvals are by DOT. k/ Specifications DOT-112A, J, S, and T and Specifications DOT-114A, J, S, and T define certain tank protective devices required by DOT 173.31. See paragraph 1.2.1.1. l/ See 174.83 for special handling requirements. m/ Existing cars restenciled DOT-120A500W, new construction not authorized.

C-III [M-1002] 10 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

Table 1.2 Data for tank cars in interchange service not otherwise listed in these specificationsa/ Specification AAR-201A70W 113A175Wb/ 113D120Wb/ Lading temp, °F –423 –155 Material Al Alloy ASTM A240–304, –304L, or TC133 Insulation Optional 179.400–4 Burst pressure, psi (kPa) 350 (2413) 440 (3034) 300 (2068) Tank construction Fusion-welded Fusion-welded. Impact tests req’d. (welds and plate) Minimum plate thickness 1/2 in. (5/8 in. bottom) 5/16 in. 3/16 in. Shell Heads 5/8 in. or 1/2 in. (2:1) 5/16 in. 3/16 in. Dome 1/2 in. — — Dome expansion capacity 2% — — Test pressure, psi (kPa) 70 (483) 175 (1207) 120 (827) Pressure relief devices Valve Valve and vent Valve and vent Valve S-T-D pressure, psi 35 (241) 115 (793) 75 (517) (kPa) Valve vapor-tight pressure, psi 28 (193) 95 (655) 60 (413) (kPa) Valve flow rating pressure, psi 45 (310) 125 (862) 85 (586) (kPa) Vent burst pressure, psi (kPa) — 175 (1207) 120 (827) Bottom outlet Optional — — a/ Obsolete ICC tank car specifications conform to corresponding DOT specifications except for method of tank construction or fittings arrangement. Metric equivalents shown for pressures only. b/ See also M-1002, 1982

AWW DRAFT 09/28/18

11/2014 C-III [M-1002] 11 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

1.2 Definitions (page 1 of 13) Chapter/ Term Definition Appendix AAR Association of American Railroads AAR Specification The specifications of design, fabrication, and construction of fright cars, published by 1 M-1001 the AAR. Accidental damage (AD) A physical defect of an item caused by contact with an object during the manufacture, U maintenance, or operation of the tank. Acoustic emission A nondestructive test method, utilizing sounds emitted by materials when under stress, W inspection (AE) to detect internal or surface discontinuities.

Activity Material, product, or service intended for North American Railway Interchange Service. B 09/28/18 DRAFT AWW Activity code The identifier associated with each activity. B AISI American Iron and Steel Institute Air inlet A valve or closure that is used to introduce air or other vapor into the tank. 1 Alteration A change in tank or service equipment that does not change the specification but that B, R does change the Certificate of Construction. ANSI American National Standards Institute Approach channel The passage through which the fluid must pass to reach the operating parts of a A pressure relief device. Approved (Approval) Unless otherwise specified in M-1002, means approved by the AAR Tank Car 1, B Committee. ASME American Society of Mechanical Engineers ASNT American Society for Nondestructive Testing Assemble (Assembling) The process of putting together materials, components, and/or parts without welding B into a final product that meets prescribed government regulations and AAR rules/ standards. Must be capable of disassembly without destruction of the final product. ASTM American Society for Testing and Materials Atmospheric pressure Atmosphere pressure equals 14.696 psia (101.325 kPa [abs.]). A Attachment A part or component that is joined, mated, affixed, or made integral to another part or B component by fusion welding. Audit A documented evaluation process aimed at verifying by examination that the applicable B elements of the quality program have been established, documented, and effectively implemented in accordance with specified requirements for each activity code. Audit, Compliance A type of audit, performed the second and third year of the M-1003 certification cycle, B that typically focuses on six to eight AAR quality assurance program elements. Audit, Certification A type of audit, performed the first year of the M-1003 certification cycle, that focuses B on all 24 AAR quality assurance program elements. AWS American Welding Society Bench test A leak test of a valve or fitting mounted on a test fixture to determine pressure-retention D integrity of the valve or fitting and, if required, to determine the pressure-retention integrity of the operable valve seat by a visual inspection through the valve port opening at the time of test. • Except for pressure relief devices, valves and fittings are to be tested in both the open/ plugged and non-plugged closed positions. Afterward, the valve is tested on the tank to determine the integrity of the fluid seal joint between the valve and the tank. • Reclosing pressure relief device: The purpose of this test is to ensure that start-to- discharge pressure and vapor-tight pressure settings are within tolerance.

C-III [M-1002] 12 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

1.2 Definitions (page 2 of 13) Chapter/ Term Definition Appendix Blister A lesion in an AHF tank car tank of at least 1/4 in. (6.35 mm) depth or height and of a R diameter greater than 3 in. (76.2 mm). Bottom outlet valve A device on the bottom of the tank that is operated either by a handle attached to the 1 valve or by a mechanism extending through the top of the tank. The latter is referred to as a top-operated bottom outlet valve. Bottom shell That portion of a tank car tank surface, excluding the head ends of the tank, that lies D within 2 ft, measured circumferentially, of the bottom longitudinal centerline of the tank car tank. Bottom washout A plugged and flanged opening in the bottom of a tank to facilitate cleaning of a car that A does not have a bottom outlet valve. Breaking pin An operating part that holds a disc of metal closing the inlet of a pressure relief valve A and that is designed to break in tension at a load caused by a predetermined pressure. Breather vent A device having an operating part that is a permeable disc or a disc having a breather A hole or slit. Built date (tank car) The date (month and year) that the completed car is shipped from the car builder’s 1 facility. Tank cars shipped to lining applicator, whether or not returned to the car builder after lining, are considered “built” as of the first departure from the car builder’s facility Burst pressure The value of the inlet static pressure at which a rupture disc device or breaking pin A device functions. Butt joint A joint type in which the butting ends of one or more work pieces are aligned in W/R approximately the same plane. Butt weld A nonstandard term for a weld in a butt joint. It may be either single or double welded. W/R °C Degrees Celsius Capacity (tank car) A tank car’s shell full volume. 1 Casting Manufacturing method in which a molten metal is injected or poured into a mold to form B an object of the desired shape. Certificate Written testimony of qualification. T Certification The formal act by the AAR of confirming that the facility has met the requirements of B applicable AAR Manual of Standards and Recommended Practices and federal regulations. Certification, Personnel Written testimony of qualification. The act of determining, verifying, and attesting in T

AWW DRAFT 09/28/18 writing to the qualification of personnel in conformance to specified requirements. Certified car A stub-sill, non-pressure, non-exterior coiled car built prior to July 1, 1974, and meeting 1 the requirements of paragraph 1.4.10. Certifying agency The employer of the person being certified. T Certifying authority The person or persons designated in the written practice to sign certifications on behalf T of the employer. CFR Code of Federal Regulations CGSB Canadian General Standards Board Check valve A valve that automatically closes to stop the flow of liquid or vapor in one direction. A Class (tank car) A general designation usually including several specifications (e.g., “Class DOT-111A” 1 or “Class DOT-111A***W*”). The word “class” is used if the designation embraces several specifications. Therefore, AAR-208 is a specification, not a class; but DOT- 103W is a class when used to cover W, AW, BW, etc., and a specification when the basic DOT-103W is itself referenced.

11/2014 C-III [M-1002] 13 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

1.2 Definitions (page 3 of 13) Chapter/ Term Definition Appendix Cleaning Encompasses chemical, thermal, and mechanical techniques for the preparation of the L interior surfaces of tank car tanks and/or valves and fittings. Closing pressure The pressure, measured at the valve inlet, at which the valve closes, flow is A substantially shut off, and there is no measurable lift. Closure A category of service equipment with no operating components that closes an opening A into the tank, valve, or fitting. Closure assembly An assembly of parts, semi-permanently connected, that operates together to secure 1

the closure in the closed positions, excluding a hinged and bolted manway cover. AWW DRAFT 09/28/18 DRAFT AWW Coating applicator The firm that is executing the specified work. L Coating/lining owner The party responsible for maintaining the integrity of the interior coating or lining. B, D, L, U Combination device A type of safety relief device that A (a) has a breaking pin in combination with a reclosing pressure relief valve in which the breaking pin is located between the tank and pressure relief valve. (b) has a rupture disc in combination with a reclosing pressure relief valve in which the rupture disc is located between the tank and pressure relief valve, and may be located within the pressure plate. Committee AAR Tank Car Committee 1 Company A facility or group of facilities under common ownership that utilize the same program W of welding standards and documentation. Connections A threaded or flanged configuration between the tank car and service equipment, 1, B between two or more types of service equipment, or between any combination thereof. Construct (Construction) Assembling or manufacturing the completed tank car. B Conventional unit The U.S. customary (English) units, such as the inch, pound, gallon, etc. H Conversion A change in tank or service equipment that changes the specification. B, R Corrosive to the tank or A material identified in the regulations or a material that, when in contact with the inner L service equipment shell of the tank or service equipment, has a corrosion rate on steel greater than 2.5 milli-inch per year (mpy) (0.0025 inch per year). Crack A fracture type of discontinuity characterized by a sharp tip and separation of material R extending partially but not necessarily completely through the cross-section of a member. CSA Canadian Standards Association Defects Abrasions; corrosion; cracks; dents; flaws in welds; distortions; erosion; missing, D, L, R, T, damaged, leaking, or loose components and fasteners; and other conditions or W imperfections that may make a tank car unsafe for transportation and/or require it to be removed from service. Dent A deformation that changes the tank contour from the original manufactured state. R Design level of reliability The level of reliability that is built into the tank car. Therefore, it is inherent in its D and safety specification, design, and manufacture. Director Executive Director—Tank Car Safety (AAR) Discharge channel The passage through which the fluid must pass beyond the operating parts of a A pressure relief device. This includes all piping or exhaust flue, screen, and weather covering that may be applied on the housing. Discharge flow The ratio of the actual flow to the flow of an ideal conduit with the same orifice area. A coefficient

C-III [M-1002] 14 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

1.2 Definitions (page 4 of 13) Chapter/ Term Definition Appendix Discontinuity An interruption of the typical structure of a material, such as a lack of homogeneity in T, W its mechanical, metallurgical, or physical characteristics. A discontinuity is not necessarily a defect. Discontinuities, service Any service equipment that projects beyond the shell envelope. 2, E equipment Documented The condition of being in written or electronic form. T DOT U.S. Department of Transportation B Double-welded butt joint A butt joint welded from both sides. W Effective seal Any flanged, threaded, or other gasket fitting design that, as tested using approved E NDT LT procedures, meets the acceptance criteria. Employer The corporate, private, or public entity that employs personnel for wages, salary, fees, T or other considerations. Environmental damage Corrosion, erosion, or other physical deterioration of an item’s strength or resistance to U (ED) failure because of chemical interaction with its climate or environment. Equipment, explosion Apparatus enclosed in a case that is capable of withstanding an explosion of a A proof specified gas or vapor that may occur within it; and of preventing the ignition of a specified gas or vapor surrounding the enclosure by sparks, flashes, or explosion of the gas or vapor within; and that operates at such an external temperature that a surrounding flammable atmosphere will not be ignited thereby. Equipment, intrinsically Equipment and wiring that is incapable of releasing sufficient electrical or thermal A safe energy under normal or abnormal conditions to cause ignition of a specific hazardous atmospheric mixture in its most easily ignited concentration. Equipment owner As used in this specification this term can mean tank car owner, service equipment B owner, or interior lining/coating owner. Essential variables, NDT Those NDT parameters considered critical, that if changed require new qualification T and demonstration of the NDT procedure. Essential variables, Required when notch toughness testing is part of the specification, and are in addition W supplementary to the essential variables for each welding process. Essential variables, Those variables in which a change, as described in the specific variables, is considered W welding to affect the mechanical properties of the weldment, and shall require requalification of the WPS.

AWW DRAFT 09/28/18 Evaluation A determination of the significance of a relevant indication. T Examination Conducting the NDT methods that will be performed for the employer. For practical T examinations, questions and answers need not be written, but observations and results must be documented. Excess flow valve A device designed to automatically close if the rate exceeds a specified value. 1 Experience Work activities accomplished in a specific NDT method under the direction of qualified T supervision, including the performance of the NDT method and reports, but not including time spent in organized training. Exterior heater system A half pipe system welded to the exterior of the tank that uses a fluid medium to heat 1 the lading from outside the tank for the purpose of unloading. °F Degrees Fahrenheit Fabricate (fabrication) A form of manufacturing limited to cutting, beveling, shearing, forming, rolling, pressing, W bending, or other allied process not defined under the term manufacturing. Fatigue damage (FD) The initiation and subsequent propagation of a crack or cracks due to cyclic loading. U

11/2014 C-III [M-1002] 15 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

1.2 Definitions (page 5 of 13) Chapter/ Term Definition Appendix Fill hole cover The covering for a hole in a manway cover for loading the car without removing/opening 1 the manway cover. Fillet weld A weld of approximately triangular cross-section joining two surfaces approximately at W right angles to each other, in a lap, tee, or corner joint. Fitting A category of service equipment that is in contact with the lading and has no operating 1 components, made of one or more pieces, that joins service equipment to the tank car tank or joins two pieces of service equipment. This does not include gaskets or

fasteners. AWW DRAFT 09/28/18 DRAFT AWW Fitness-for-service The tank car conforms to federal regulations, industry standards, and the owner’s U acceptance criteria, and is otherwise suitable for continued service. Flow capacity Flow capacity of a pressure relief device in cubic feet per minute (cubic meters per A second) of air at standard conditions when tested at the required flow rating pressure. Flow rating pressure The inlet static pressure at which the relieving capacity of a pressure relief device is A measured for rating purposes. Fluoroscope A phosphor screen, X-ray image intensifier, or other fluorescent medium that emits W visible light in direct proportion to the amount and distribution of radiation impinging on its input surface. Fluorotape A tape recording of an image from the output of a fluoroscope. The image is recorded W on video magnetic tape for playback on a suitable monitor. Forge welding A welding process wherein coalescence is produced by heating in a forge or other W furnace and by applying pressure or blows. FRA Federal Railroad Administration Fracture Complete separation of material extending through the entire cross-section of the plate. R Full fillet weld A fillet weld whose size is equal to the thickness of the thinner member being joined. W Fusible plug device A non-reclosing pressure relief device designed to function by yielding or melting of a A plug of suitable material. Fusion welding Any welding process that uses fusion of the base metal to make the weld. W Gauging device A system that furnishes an indication of the liquid level inside a tank, not the visual A gauge in the manway. General examination A written examination addressing the basic principles of the applicable NDT method. T Gouge A deformation caused by mechanical means that results in the loss of parent or weld R metal. Groove weld A weld made in the groove between two members to be joined. W Hard conversion When products are hard converted, the design of the item in SI metric units results in H a physical change and the product is not interchangeable with earlier products built to the conventional unit design. Heat treatment Heating and cooling a metal or alloy in such a way as to obtain desired conditions or W properties. Heating for the sole purpose of hot working is excluded from the meaning of this definition. Huddle chamber The configuration of the valve body seat and the immediately adjacent downstream A parts that redirect the flow of the effluent, causing a popping action by lifting the valve stem. ICC Interstate Commerce Commission Image quality indicator A device whose image in a radiograph is used to determine radiographic quality level. W (IQI)

C-III [M-1002] 16 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

1.2 Definitions (page 6 of 13) Chapter/ Term Definition Appendix Initiator A company or organization that is responsible for identifying and reporting inspection U results and failures of a material, product, or service. Injurious defect Any discontinuity (e.g., crack, lamination, pit, or hard spot) that results in a change in R the material’s physical properties so as not to meet specification limits. Inspection and test A careful and critical examination of an item performed by qualified personnel following B, D, U the owner’s qualified procedures. Inspector A person authorized by the tank owner or, when not authorized by the owner, W designated by the tank fabricator or car builder, to perform inspection. Installation (Install) To physically connect or set an item in position or location for initial use. B Instrument A category of service equipment used to measure the amount of lading and/or lading B temperature. Interior coating Any paint-type protective covering applied in one or more layers to the interior of a tank L car tank to act as a barrier between the base metal and the commodity. Interior heater system A piping system located within the tank that uses a thermal medium or electrical D resistance to heat the lading within the tank for the purposes of unloading. Interior lining Any sheet or laminated type material, glass, or fused metal applied to the interior of a L tank car tank to act as a barrier between the base metal and the commodity. Interpass temperature In a multipass weld, the temperature of the weld area between weld passes. R, W Interpretation (of NDT The determination of the relevance of indications. T test data) ITP Independent Third Party kPa kilopascals gauge kPa (abs.) kilopascals absolute Lap joint A joint between two overlapping members in parallel planes. W Leak test A leak test of the installed valve or fitting performed below the tank test pressure. D • Except for pressure relief devices, valves and fittings are to be tested in both the open/plugged and non-plugged closed positions. The purpose of this test is to determine the integrity of the fluid seal joint between a valve or fitting and the tank, to determine pressure retention integrity of a valve, and to determine the pressure- retention integrity of the operable valve seat by a visual inspection through the valve port opening at the time of test.

AWW DRAFT 09/28/18 • Pressure relief device: The purpose of this test is to determine the integrity of the fluid seal joint between a pressure relief device and the tank, plus the integrity of the device seals. • Non-reclosing pressure relief device: The purpose of this test is to check for through-wall corrosion pitting and leakage from threaded connections during pressurization. Leak tight An item of service equipment that shows no leakage on the downstream side when A pressure is applied to the upstream side. All service equipment including closures must be leak tight under loading conditions and during transit. Liquefied compressed A gas that, under the charged pressure, is partially liquid at a temperature of 70 °F 5 gas (21.1 °C). Liquid level control An automatic system that generates a signal to open or close valves at a A device predetermined level. Liquid penetrant A nondestructive test method utilizing contrasting liquids/dyes that penetrate to W inspection (LP) highlight discontinuities open to the surface (cracks, porosity, seams, etc.).

11/2014 C-III [M-1002] 17 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

1.2 Definitions (page 7 of 13) Chapter/ Term Definition Appendix Liquid tight All closures, except pressure relief valves, are designed to meet the test pressure of A the tank without leakage. All final closures must show no leakage at loading conditions and during transportation. Liquid valve Any valve that is opened and closed manually or automatically to permit the passage A of liquid into or out of the tank. LPWHT Local post-weld heat treatment. R Magnetic particle A nondestructive test method utilizing variations in magnetic fields to detect W

inspection (MT) discontinuities at or slightly below the surface. Limited to ferromagnetic materials. AWW DRAFT 09/28/18 DRAFT AWW Maintenance Upkeep or preservation, including repairs and/or reconditioning, to an item to ensure B, D continued conformance until its next qualification. Maintenance program The owner’s or manufacturer’s procedures to maintain fitness-for-service. U Manufacture The process of converting materials, components, and/or parts into a final product that B (Manufacturing) meets prescribed government regulations and AAR rules/standards. As used in this specification, the term manufacture (manufacturing) includes the processes of fabrication, welding, machining, casting, and forging. Manway The opening on the top of the tank to allow access to the interior for inspection and 1 maintenance or loading and unloading. Manway cover The closure for the manway that is either a hinged and bolted manway cover or a semi- 1 permanently bolted manway cover or pressure plate. Marked Applied with either stencil or decal. C Marked pressure The pressure indicated on the nameplate of a piece of service equipment. A Material Group (MG) A general category of approved tank car tank plate material. B, M, W Method One of the disciplines of NDT (e.g., ultrasonic testing) within which many techniques T may be included. Mobile unit A vehicle that is supplied with the equipment, material(s), and personnel to perform B certain activities from a tank car facility. Modification Any change to a tank car that affects the certificate of construction including an 1, B alteration or conversion. MSRP Manual of Standards and Recommended Practices All NACE NACE International, formerly National Association of Corrosion Engineers. L NDT Level III An individual certified by the company as qualified to administer the NDT program. T Self-certified or appointment by the company is deemed as not meeting the requirements of Appendix T. Only an individual meeting the testing requirements of Appendix T, paragraph 1.8.4, can be certified as an NDT Level III. NGT National Gas Taper Thread Nondestructive See Nondestructive testing (NDT) T examination (NDE) Nondestructive testing A process that involves the inspection, testing, or evaluation of materials, components, T (NDT) or assemblies for discontinuities, properties, and/or other flaws without impairing or destroying the parts’ serviceability. Non-liquefied A gas that, under the charged pressure, is entirely gaseous at a temperature of 70 °F 5 compressed gas (21.1 °C). Nozzle A walled cylinder of circular or oval cross-section that is attached to the tank shell or 1 tank head at design opening (see Appendix E). A nozzle projects away from the tank attachment and terminates at a connection. NPT American standard taper pipe thread

C-III [M-1002] 18 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

1.2 Definitions (page 8 of 13) Chapter/ Term Definition Appendix Operator/user A facility that loads or unloads a tank and then offers the car for transportation. U Outside agency A company or individual who provides NDT services and whose qualifications to T provide these services have been reviewed and approved by the employer contracting the company or individual. Pad An attachment welded directly to the tank under a bracket or light structure for the R purpose of preventing damage to the tank through fatigue, over-stressing, denting, puncturing, or tearing. Padding The introduction of an inert gas under pressure into the vapor space of a tank car tank 2 to create a nonflammable or moisture-free atmosphere. Patch plate A steel plate applied as an overlay in a corroded area. R Pit A surface defect resulting from localized corrosion where the cavity diameter at the R metal surface is equal to or less than the cavity depth. Pits (grouped) Adjacent pits that are separated by a distance less than two times their average R diameter. Pits (random) Adjacent pits that are separated by a distance greater than six times the material R thickness. Plug weld A weld made in a circular hole in one member of a joint, fusing that member to another W member. A fillet-welded hole is not to be construed as conforming to this definition. Postweld heat treatment Any heat treatment subsequent to welding. W Practical examination An examination used to demonstrate an individual’s ability in conducting the NDT T methods that will be performed for the employer. For practical examinations, questions and answers need not be written, but observations and results must be documented. Preheat The heat applied to the base metal or substrate to attain and maintain the preheat R, W temperature. Preheat temperature, The temperature of the base material in the volume surrounding the point of welding R, W welding immediately before welding is started. In a multi-pass weld, it is also the temperature immediately before the second and subsequent passes are started. Pressure plate A bolted manway cover that is designed for the mounting of pressure relief devices, 1 valves, and other closures. Pressure regulator at The pressure 10 psig higher than the start-to-open pressure; the regulator is adjusted A 10 scfm air and set to flow 10.0 scfm ± 1.0 scfm of air at this pressure.

AWW DRAFT 09/28/18 Pressure regulator start- The pressure at which the flow is 0.2 scfm to 0.6 scfm of air as measured with a flow A to-open pressure meter or by collecting a timed volume of air by the displacement of water. Pressure regulator The pressure with a flow of less than 0.1 scfm and nearly bubble tight. The lower limit A reclosing pressure for an acceptable reclosing pressure is 80% of the start-to-open pressure. Pressure regulator valve A device used to maintain a constant pressure in a tank car. As the pressure in the tank A car increases, the valve opens to relieve pressure. Pressure relief valve A type of safety relief device that is spring-loaded closed and actuated by inlet static A pressure; relieves excess pressure inside the tank car tank; and recloses after normal conditions are restored. Primary valve or closure The first device after the tank that closes the flow of liquid or vapor. Examples include 1 valves, pipe plugs, caps, and blind flanges. Procedure A detailed, written instruction for conducting nondestructive testing. Procedures shall T be approved by an NDT Level III certified in the applicable method. Procedure qualification A document providing the actual welding variables used to produce an acceptable W record (PQR) procedure qualification test weld and the results of tests conducted on the weld.

11/2014 C-III [M-1002] 19 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

1.2 Definitions (page 9 of 13) Chapter/ Term Definition Appendix psi pounds per square inch gauge psia pounds per square inch absolute Purging The replacement of air or other vapors in a tank car by introducing gaseous nitrogen or 2 other cryogenic liquids under low pressure and venting the resulting gas mixture. Purging is generally used as part of the cleaning operation for tank cars or for cars being prepared for a change in commodity service. Qualification An event that consists of one or more inspections and tests to determine if the item B, D, U

conforms to the applicable requirements of federal regulations and AAR specifications AWW DRAFT 09/28/18 DRAFT AWW for tank cars and to the owner’s acceptance criteria. Qualification, NDT The education, skills, training, knowledge, and experience required for personnel to T personnel properly perform to a specified NDT level. Qualification, welder The demonstration of a welder’s or welding operator’s ability to produce welds meeting W performance prescribed standards. Qualification, welding A record of welding variables used to produce an acceptable test weldment and the W procedure results of tests conducted on the weldment to qualify a welding procedure specification. Qualified The welder, welding operator, or welding procedure qualification requirements of W, 6/3 Appendix W have been met. Radiograph The film transparency or paper image obtained by development of a sensitized W emulsion film after passage of radiation (X-rays or gamma rays) through an object to expose the emulsion. Radioscopy (RT) A nondestructive test method of observing the internal characteristics of objects that W are opaque to light with X-rays or gamma rays, specifically with radiographic or fluoroscopic techniques. Radiotape A film or paper radiograph or fluorotape. W Reactive to the tank or A material that, in contact with the inner shell of the tank or with the service equipment, B, L service equipment may react to produce heat, gases, and/or pressure that could substantially reduce the effectiveness of the packaging or the safety of its use. Rebuild A form of reconditioning not performed by, or with approval of, the original equipment D manufacturer (OEM). Recondition To rebuild or remanufacture an item back to a conforming condition in accordance with A applicable AAR specifications and federal regulations. Refresher training Training to refresh and/or update the theoretical knowledge and skills of the technician T as deemed necessary by the Level III. Registration An acknowledgment from the AAR that a tank car facility has stated and submitted B checklists indicating that the facility meets all the applicable requirements of the AAR Manual of Standards and Recommended Practices, Section C, Part III, Appendix B. Reinforced tank shell A nonstandard term for a weld in a butt joint; the portion of a butt weld (butt joint, groove R, W butt weld (butt joint, weld) covered by a reinforcing pad. groove weld) Reinforcing pad An attachment welded directly to the tank to support structural components. R Reliability The quantified ability of an item or structure to operate without failure for the specified D period of its design life or until its next qualification. Remanufacture A form of reconditioning performed only by, or with approval of, the original equipment D manufacturer (OEM). Removal (Remove) Physical separation of an item from its current position or location. B Replacement in-kind Replacement with the same manufacturer, model, size, and capacity. 1

C-III [M-1002] 20 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

1.2 Definitions (page 10 of 13) Chapter/ Term Definition Appendix Repair To restore a defective item back to a conforming condition in accordance with R applicable AAR specifications and federal regulations. Repair Level (RL) A category assigned to a tank car facility that indicates their weld repair capability. B Representation Attesting through documenting, in writing or by marking on the tank (or jacket), that a D tank car is qualified. Reseal A disassembly of a valve or fitting as necessary to access resilient components, D followed by an inspection of the sealing surfaces, replacement of resilient components, and reassembly of the valve or fitting. Rules AAR interchange rules. C Rupture disc The operating part of a rupture disc device that is designed to burst at rated pressure. A Rupture disc device A type of safety relief device that consists of a rupture disc and a rupture disc holder. A This device is non-reclosing, actuated by inlet static pressure, and relieves excess pressure inside the tank car tank until it is equal to atmospheric pressure. Safety relief device A category of service equipment that is designed to protect the tank car tank from B internal pressure or vacuum in excess of specified settings. Safety system Thermal protection systems, insulation systems, tank head puncture-resistance D systems, coupler vertical-restraint systems, and systems used to protect discontinuities (e.g., skid protection and protective housings) as required per 49 CFR Part 180 Subpart F. Sample valve A valve that is opened and closed manually to allow collection of a small amount of 1 lading for analysis. Score A narrow deformation caused by mechanical means wherein parent or weld metal is R upset and relocated. Seat That part of the pressure relief valve in its orifice area that forms a seal with the stem A and adjacent parts. Secondary valve or The first device downstream from the primary closure that closes the flow of liquid or 1 closure vapor if the primary closure would be normally operated. Examples include valves, pipe plugs, caps, and blind flanges. Service equipment Devices that are used for loading and unloading (including all types of heating system), 1, B, C, D sampling, venting, vacuum relief, pressure relief, and measuring the amount of lading and/or lading temperature. For purposes of this specification, service equipment is grouped into the following major categories: safety relief device, valves, closures,

AWW DRAFT 09/28/18 instruments, and fittings. Service equipment The party responsible for maintaining the integrity of the service equipment. B, U owner Service reliability A systematic evaluation of an item based on an analysis of collected information from U assessment in-service experience to verify an item’s resistance to failure and deterioration. Set pressure The pressure, measured at the valve inlet, at which a pressure relief valve is set for A start-to-discharge. Shell-full The liquid volume at the transition point at which air or vapor becomes entrapped in a 1 location that is not in direct communication with all top fittings. See Fig. E.14 for examples.

11/2014 C-III [M-1002] 21 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

1.2 Definitions (page 11 of 13) Chapter/ Term Definition Appendix SI unit The official abbreviation, in all languages, for the International System of Units. The H International System is not the old centimeter gram-second system, but a modernized version of it. It is a coherent system in which there is a one-to-one correspondence among all the base units and derived units. The SI style for writing large numbers calls for eliminating commas and writing numerals in groups of three on either side of the decimal point. Significant digit Any digit that is necessary to define the specific value or quantity. When measured to H the nearest 1 meter (m), a distance may be recorded as 157 m; this number has three significant digits. If the measurement had been made to the nearest 0.1 meter (m), the 09/28/18 DRAFT AWW distance may have been 157.4 m; this number has four significant digits. Single-welded butt joint A butt weld with filler metal added from one side only. W Size (fillet) For equal leg fillet welds, the leg lengths of the largest isosceles right triangle that can W be inscribed within the fillet weld cross-section. For unequal leg fillet welds, the leg lengths of the largest right triangle that can be inscribed within the fillet weld cross- section. Slot weld A weld made in an elongated hole in one member of a joint, fusing that member to W another member. The hole may be open at one end. A fillet-welded slot is not to be construed as conforming to this definition. Soft conversion When conventional units are soft converted, the physical dimensions of an item remain H unchanged and the units of measurement are in SI terms. Specific examination A written examination to determine an individual’s understanding of procedures, codes, T standards, specifications, and equipment or instrumentation for an NDT method used by the employer. Spring-loaded check A check valve that has its valve maintained in the closed position by a spring and that T valve is opened by the valve mounted above it. Stamped Steel-stamped. C Standard conditions 60 °F (15.56 °C) and 14.696 psia (101.325 kPa [abs.]). A Start-to-discharge The pressure, measured at the valve inlet, at which there is a measurable lift of the A pressure closure device on a pressure relief valve or at which discharge becomes continuous as determined by seeing, feeling, or hearing. Start-to-leak pressure The pressure, measured at the valve inlet of a pressure relief valve, at which the A relieved fluid is first detected at the down-stream side of the seat. Start-to-open pressure The pressure, measured at the valve inlet of a vacuum relief valve, at which the relieved A fluid is first detected at the downstream side (internal to the tank) of the valve seat. Station stencil The unique identifier assigned by the AAR to each certified tank car facility, which is the B AAR M-1003 QA Code Stenciled Applied with paint or decal. C Stress-relief heat Uniform heating of a structure or a portion thereof to a sufficient temperature to relieve W treatment the major portion of the residual stresses, followed by uniform cooling. Stripping Encompasses chemical, thermal, and mechanical techniques of removal of existing L linings or coatings from tank car tanks and/or valves and fittings. Stub sill A type of underframe that is non-continuous between truck centers and incorporates B the super structure (tank car tank) as part of the design. Subcontract A documented binding agreement between a tank car facility and another entity for B products, services, and/or equipment for the sole purpose of supporting the tank car facility in its activity(ies).

C-III [M-1002] 22 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

1.2 Definitions (page 12 of 13) Chapter/ Term Definition Appendix Supply container A container that complies with DOT specifications for cargo tanks, portable tanks, or 5 compressed gas cylinders. Surface area • The tank surface area of a single-unit, single-compartment tank car tank is the A outside area of the tank shell, the end-closure heads, and, in the case of an expansion dome-type tank, the dome cylinder and dome head, but in either case does not include any appurtenances. • The tank surface area of a single-unit, multiple-compartment tank car tank constructed with single or dual internal heads, or of separate tanks banded together, is the total outside surface area of each of the individual tanks so formed. Surface crack Separation of material extending 1/16 in. or less through the tank plate thickness. R Surge pressure A device incorporated into the design of a tank car or attached thereto that, by design, A reduction device reduces the internal surge pressures at the pressure relief device interface. Tack weld A weld made to hold the parts of a weldment in proper alignment until the final welds W are made. Tack welder One who performs manual or semiautomatic welding to produce tack welds. W Tank car A tank car tank mounted on or forming part of a car structure, including all components B necessary and proper for railroad service [reference §179.1(a)]. Tank car facility An entity, at a fixed geographical location, that manufactures, repairs, inspects, tests, B qualifies, or maintains a tank car; alters the certificate of construction of the tank car; or performs any activities listed in or for which it otherwise has received certification or registration under Appendix B of M-1002. Tank car owner The party responsible for the continued qualification and maintenance of the tank car B, D, U whose primary reporting mark is identified in the Equipment Management Information System (Umler) element UMOW. Tank car tank Consists of a shell, heads, nozzles, sumps, flanges, outlet saddles, any other B attachments containing the lading, and all welds joining them. Where used in this specification, the term “tank car tank” is synonymous with the term “tank.” Where used in this specification, the term “tank car tank component” refers to the components listed in this definition. Tank design The specific designation to which the tank car is built (e.g., DOT-117A100W) as specification identified on Form AAR 4-2 line item 7 and Umler element A072. Tank stenciled The specific designation to which the tank car operates (e.g., DOT-117J100W) as AWW DRAFT 09/28/18 specification identified on Form AAR 4-2 line item 8 and Umler element A237. Tank test date (initial The date of test of the tank on the completed car must be the same year as the built 1 stenciled) date of the car. The car builder must record the test data and provide it to the original owner. The initial tank test date may be the same as the built date, provided the tank test was conducted within 6 months prior to the built date. Tanks As used in this specification means tank car tank. B Technical performance The demonstration of competence in an NDT method or technique by a qualified T individual. The NDT-qualified individual has demonstrated the ability to apply NDT technical knowledge and complete NDT assignments. Technique A specified process within an NDT method, for example magnetic particle ‘yoke T technique.’ Temporary weld A weld made to attach a piece or pieces to a weldment for temporary use in handling, R, W fitting, or working on the weldment. Temperature sensing A part or parts that permit the determination of the temperature of a tank’s contents. A equipment

11/2014 C-III [M-1002] 23 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

1.2 Definitions (page 13 of 13) Chapter/ Term Definition Appendix Thermometer well A closed pipe filled with a fluid medium that extends through a cover plate into the tank 1 that allows the insertion of a thermometer and is closed with a threaded cap. Throat (fillet) Theoretical throat. The distance from the beginning of the joint root perpendicular to the W hypotenuse of the largest right triangle that can be inscribed within the cross-section of a fillet weld. Top shell The tank car tank surface, excluding the head ends and bottom shell of the tank car D tank.

Training An organized program developed to impart the knowledge and skills necessary for T AWW DRAFT 09/28/18 DRAFT AWW qualification. Type (tank car) Designates the approving authority (e.g., AAR, ARA, ICC, DOT, or USG). Preferred 1 usage is, for example, “DOT tank cars.” Ultrasonic inspection A nondestructive test method that transmits ultrasonic energy through the test material W (UT) to detect internal and surface discontinuities. Used also for thickness measurements. UMLER Universal Machine Language Equipment Register Vacuum relief valve A type of safety relief device designed to prevent excessive internal vacuum in the tank A car tank and reclose after normal conditions have been restored. Valve stem A central movable shaft attached to an integral head or multiple-piece assembly that A contains pressure at the orifice of a pressure relief valve. Valves A category of service equipment designed to control flow of lading into and out of the A tank car tank. Vapor valve Any valve that is opened or closed manually or automatically to permit the passage of A vapor into or out of the tank. Vaporizer A device used to evaporate liquefied compressed gases, usually where the required 5 flow rate exceeds the normal flow rate achieved by natural heat transfer from the atmosphere. Vapor-tight pressure The pressure, measured at the valve inlet after closing, at which no further fluid flow is A detected at the downstream side of the seat of a pressure relief valve. Visual An inspection of valves, fittings, and closures, without disassembly, for obvious signs D of defects. Visual inspection A nondestructive test method utilizing vision to detect surface imperfections in W materials (including welds). Weld surfacing or weld The application by welding of a layer, or layers, of material to a surface to obtain desired R, W buildup dimensions or properties, as opposed to making a joint. Welder One who performs manual or semiautomatic welding. W Welding operator One who operates adaptive control, automatic, mechanized, or robotic welding W equipment. Welding procedure A document providing in detail the required variables for specific application to ensure W specification (WPS) repeatability by properly trained welders and welding operators. Wheel burn Damage to tank shell due to frictional contact with a rotating wheel, resulting in metal R flow and/or discoloration due to frictional heat. Written practice A document prepared by the employer to specify methods, requirements, examination, T records, certifying official, etc., for a company’s NDT personnel certification program. 1.2.1 Tank Car Definitions Tank cars currently in service are of three types: DOT, AAR, and ICC. See paragraph 1.1.5 for specifications in effect for new construction.

C-III [M-1002] 24 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

1.2.1.1 DOT Tank Cars DOT tank car specification numbers consist of a class designation followed by identifying letters and numbers. In all classes except 103, 104, and 113, the class designation is followed by an “A,” which has no special significance. Suffix “W” denotes a fusion-welded tank; suffix “F” denotes a forge-welded tank; and suffix “X” has special significance as discussed below. The absence of a suffix indicates seamless tank construction. Class DOT-103*W tank cars are insulated or uninsulated nonpressure cars with an expansion dome. The expansion capacity in the dome is listed below. Class 103*W cars built for specific services or requiring special fittings or materials of construction are designated by letters interposed for the asterisk. Table 1.3 Class DOT-103*W expansion capacity and suffix letters Bottom Bottom Minimum Percentage Tank Outlet Washout Expansion (No Ltr.) 2 A Carbon steel No 1 AL Aluminum alloy 2 A-AL Aluminum alloy No 1 AN Nickel No 1 B Carbon steel, elastomer lined No No 1 C Alloy steel No No 1 D Alloy steel 2 E Alloy steel No 1

Class DOT-104W tank cars are insulated carbon steel nonpressure cars with an expansion dome and having a minimum expansion capacity of 2% in the dome. Class DOT-105A, J, or S***W tank cars are insulated carbon or alloy steel pressure cars, with a manway nozzle, designed for top loading and unloading; bottom outlet or washout prohibited. Class 105A or J***ALW tank cars are similar except that they have aluminum alloy tanks. Class 105A***F has forge-welded tanks. Table 1.4 Class DOT-105A, J, or S***W suffix letters A = equipped with top-and-bottom shelf couplers J = equipped with jacketed thermal protection, tank head puncture resistance, and top-and-bottom shelf couplers S = equipped with tank head puncture resistance and top-and-bottom shelf AWW DRAFT 09/28/18 couplers

Class DOT-106A***X tanks are uninsulated carbon steel tanks designed to be removed from the car structure for filling or emptying and designed to a maximum stress level in the shell. Table 1.5 Class DOT-106A***X suffix letters X = Fusion-welded longitudinal tank seam and forge-welded head seams XNC = Nickel clad NCI = Nickel—chromium—iron

Class DOT-107A**** tank cars are uninsulated high-pressure service cars having several permanently mounted seamless, forged, and drawn steel tanks designed to a maximum stress level in the shell. Class DOT-109A***W tank cars are insulated or uninsulated carbon steel pressure cars with a manway nozzle, designed for top loading and unloading, bottom washout optional.

11/2014 C-III [M-1002] 25 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

Class DOT-109A***ALW tank cars are similar except they have aluminum alloy tanks. Class DOT-110A***W tanks are uninsulated carbon steel tanks designed to be removed from the car structure for filling or emptying and designed to a burst pressure. Class DOT-111A***W* tank cars are insulated or uninsulated nonpressure cars without an expansion dome. The expansion capacity in the tank is 2%. Class DOT-111A***W* tank cars built for specific services or requiring special fittings or materials of construction are designated by suffix letters or numerals. Class DOT-111A***F* have forge-welded tanks converted from Specification ICC-105A300, 400, or 500. Suffix letters are shown in Table 1.6. Table 1.6 Class DOT-111A***W* suffix letters Bottom Bottom Tank Outlet Washout 09/28/18 DRAFT AWW ALW1 Aluminum alloy ALW2 Aluminum alloy No W1 Carbon steel W2 Carbon steel No W3a/ Carbon steel W4a/ Carbon steel No No W5 Carbon steel, elastomer lined No No W6 Alloy steel W7 Alloy steel No No F1 Carbon steel F2 Carbon steel No a/ Insulation required.

Table 1.7 Class DOT-111A, J, or S***W* delimiter letters A = equipped with top-and-bottom shelf coupler J = equipped with top-and-bottom shelf coupler, tank head puncture-resistance system, and thermal protection S = equipped with top-and-bottom shelf coupler and tank head puncture- resistance system

Class DOT-112A, J, S, or T***W tank cars are insulated or uninsulated carbon or alloy steel pressure cars, with a manway nozzle and without bottom connections, designed for top loading and unloading. Table 1.8 Class DOT-112A, J, S, or T***W suffix letters A = equipped with top-and-bottom shelf couplers J = equipped with jacketed thermal protection, tank head puncture resistance, and top-and-bottom shelf couplers S = equipped with head shields and top-and-bottom shelf couplers T = equipped with nonjacketed thermal protection system, top-and-bottom shelf couplers, and head shields

C-III [M-1002] 26 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

Class DOT-113****W tank cars are vacuum-insulated cars having an inner container and carbon steel outer shell. The insulation system is designed for a holding time. Class DOT-113 cars are designed for specific loading and shipping temperatures and have certain materials and fittings requirements as designated by the intermediate letter. Table 1.9 Class DOT-113****W suffix letters A = Minus 423 °F (–253 °C) loading; high alloy steel inner container; special fittings and insulation for refrigerated (cryogenic) liquid hydrogen C = Minus 260 °F (–162 °C) loading; high alloy steel inner container; special fittings for refrigerated (cryogenic) liquid natural gas, refrigerated (cryogenic) liquid methane (DOT exemption required), or refrigerated (cryogenic) liquid ethylene D = Minus 155 °F (–104 °C) loading; nickel alloy steel inner container; special fittings for refrigerated liquid ethane (DOT exemption required) or refrigerated (cryogenic) liquid ethylene

Class DOT-114A, J, S, or T***W tank cars are insulated or uninsulated carbon or alloy steel pressure cars with a manway nozzle and optional noncircular cross-section. An additional group of valves and fittings may be provided in another location. Table 1.10 Class DOT-114A, J, S, or T***W suffix letters A = equipped with top-and-bottom shelf couplers J = equipped with jacketed thermal protection, tank head puncture resistance, and top-and-bottom shelf couplers S = equipped with head shields and top-and-bottom shelf couplers T = equipped with nonjacketed thermal protection system, top-and-bottom shelf couplers, and head shields

Class DOT-115A***W* tank cars are insulated nonpressure cars having an inner container and carbon steel outer shell with optional bottom connections. Suffix letters are shown in Table 1.11. Table 1.11 Class DOT-115A***W* suffix letters W1 = Steel inner container W6 = Alloy steel inner container ALW = Aluminum inner container

Class DOT-120A, J, or S***W tank cars are insulated pressure cars with a manway nozzle. An AWW DRAFT 09/28/18 additional group of valves and fittings may be provided in another location Class DOT-120***ALW tank cars are similar except that they have aluminum alloy tanks.

11/2014 C-III [M-1002] 27 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

1.2.1.2 AAR Tank Cars Most AAR tank cars have DOT/TC counterparts, the main specification differences being that only partial postweld heat treatment is required and radioscopy is not required for carbon steel tanks. Suffix “W” denotes a fusion-welded tank. Class AAR-201A**W tank cars, now obsolete for new construction, are insulated or uninsulated aluminum nonpressure cars with an expansion dome. Class AAR-203*W tank cars are insulated or uninsulated nonpressure cars with an expansion dome. These cars conform, with certain exceptions, to Class DOT-103W. Table 1.12 Class AAR-203*W suffix letters

(No letter) = carbon steel AWW DRAFT 09/28/18 DRAFT AWW D = alloy steel

Class AAR-204 tank cars are vacuum-insulated cars having an inner container and carbon steel outer shell. They are designed for loading of liquid argon, nitrogen, or oxygen. Specification AAR- 204W tank cars are similar in concept to Class DOT-113****W cars. Suffix letters are shown in Table 1.13. Table 1.13 Class AAR-204 suffix letters X = Conversion from XT boxed tank cars W = Fusion-welded alloy steel inner container and carbon steel outer shell

Specification AAR-205A300W tank cars are now designated DOT-109A300W Specification AAR-206W tank cars are insulated nonpressure cars having an inner container and carbon steel outer shell. These cars conform, with certain exceptions, to Class DOT- 115A***W*. Table 1.14 Specification AAR-206W suffix letters A = equipped with top-and-bottom shelf couplers J = equipped with jacketed thermal protection, tank head puncture resistance, and top-and-bottom shelf couplers S = equipped with head shields and top-and-bottom shelf couplers

Class AAR-207A**W* pressure-differential covered hopper cars are designed for 15 psig (103 kPa) minimum internal pressure and are used for the transportation of granular commodities that are unloaded pneumatically. Suffix letters are shown in Table 1.15. Table 1.15 Class AAR-207A**W* suffix letters W = Carbon steel fusion-welded tank ALW = Aluminum alloy fusion-welded tank W6 = Alloy steel fusion-welded tank

Specification AAR-208 tank cars are nonpressure cars having wood-staved metal hooped tanks for the transportation of certain food-grade materials.

C-III [M-1002] 28 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

Class AAR-211A***W* tank cars are insulated or uninsulated nonpressure cars without an expansion dome. The numeral after “W” designates specific outlet and bottom connection options. These cars conform, with certain exceptions, to Class DOT-111A***W*. Suffix letter or numerals are shown in Table 1.16. Table 1.16 Class AAR-211A***W* suffix letters W1 = Carbon steel tank 2% minimum expansion capacity in tank Optional bottom outlet or washout W2 = Carbon steel tank No bottom outlet Optional bottom washout W3 = Carbon steel tank 2% minimum expansion capacity in tank Insulation required Optional bottom outlet or washout W4 = Carbon steel tank No bottom outlet washout Elastomer lining W5 = Carbon steel, elastomer lined No bottom outlet No washout W6 = Alloy steel Optional bottom outlet or bottom washout W7 = Alloy steel No bottom outlet or bottom washout ALW = Aluminum alloy tank

1.2.1.3 ICC Tank Cars ICC tank car specifications, in general, were redesignated DOT specifications. Those tank cars not so redesignated have riveted or forge-welded tanks, but conform in other respects to corresponding DOT classes. Class ICC-103 and Class ICC-104 have riveted tanks. Specification ICC-103 CAL has a triple-riveted aluminum tank with 1% minimum expansion capacity dome.

AWW DRAFT 09/28/18 Class ICC-105A*** have forge-welded carbon steel tanks. Class ICC-106A*** tanks are identical to DOT-106A***X except they have forge-welded longitudinal seams. 1.2.1.4 Emergency USG Tank Cars Emergency USG* tank cars are insulated or uninsulated carbon steel nonpressure cars with 2% capacity expansion domes. They were built during World War II for transportation of petroleum products limited to 8 lb/gal (0.959 kg/L), and vapor pressure not exceeding 16 psia at 100 °F (110 kPa [abs.] at 37.8 °C). They became obsolete for new construction in 1956.

11/2014 C-III [M-1002] 29 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

1.3 General Requirements 1.3.1 Car Structure All car structure details must comply with these specifications and with related specifications and publications listed in AAR Specification M-1001, paragraph 1.1.2. 1.3.2 DOT Tanks All tanks and appurtenances constructed for use in transporting materials classed as dangerous by the DOT must comply with the applicable DOT specifications and supplementary AAR requirements. The DOT specifications are general and minimum for tanks and equipment therefor.

1.3.3 AAR Tanks AWW DRAFT 09/28/18 DRAFT AWW AAR-specification tanks are for use in the transportation of materials not classed as dangerous by the DOT, except that certain low- and medium-hazard materials are permitted in AAR- specification tanks, reference 49 CFR 173.240, 173.241, and 173.242. Such tanks and appurtenances must comply with all applicable AAR specifications and requirements in effect at the time of construction. 1.3.4 Safety Appliances Safety appliances must comply with the current issue of DOT Railroad Safety Appliance Standards, 49 CFR 231. Appurtenances such as platforms and ladders for loading and unloading must comply with Appendix S. 1.3.5 Interchange Any tank car tank that does not meet prescribed test and qualification requirements is not authorized in railroad interchange. A valid Certificate of Construction and, when applicable, Exhibit R–1 reports (see Appendix R) must exist for any completed tank car in railroad service. The Field Manual of the AAR Interchange Rules, Rule 90.A.1, prohibits the use of freight cars (including tank cars) in interchange over 40 years from date built except as otherwise provided for in the Office Manual of the AAR Interchange Rules, Rule 88. 1.3.6 Approvals 1.3.6.1 Design and materials for fabrication, alteration, conversion, or welded repairs must be approved, per paragraph 1.4 of this chapter. Design and materials of all valves and closures on tank cars must be in accord with Appendix A and must be approved. Design, materials, and flow capacity ratings of pressure relief devices used on tank cars must be approved. 1.3.6.2 Revision or substitution for any valve or fitting, except substitution of equivalent kind approved on the Certificate of Construction, or the addition of supplemental valves or fittings to the tank or to those fittings covered by the certificate constitutes an alteration as defined in Appendix R and must be approved. 1.3.6.3 Closures manufactured according to a nationally recognized standard may replace a valve or closure without AAR approval of the arrangement, except for bottom outlet valves and bottom outlet closure. Such an application requires an R1 listing the fitting removed and the type of closure applied. 1.3.6.4 Replacement of an AAR-approved valve or closure with another AAR-approved valve or closure requires car owner approval.

C-III [M-1002] 30 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

1.3.6.5 In addition to valves and/or closures approval requirements, the fittings arrangement on the tank car also requires approval. The fittings arrangement is identified on the Form AAR 4-2 and is approved as part of the tank car design. If the fittings arrangement is altered, the alteration must be approved. The alteration of the fittings arrangement must be submitted using the Form AAR 4-2. 1.3.7 Editions of Referenced Specifications Unless a specific year is recorded after the specification number, wherever AAR, ASTM, AWS, or other specifications are noted, the latest editions are approved. 1.3.8 Calibration and Capacity Tables 1.3.8.1 Calibration The procedures for tank car calibration are set forth in API Standard 2554, “Measurement and Calibration of Tank Cars.” For all cars constructed after May 1, 2001, gauged or strapped capacities shall be rounded to the nearest 10-gal and 50-L increments. Rounding is to be performed after any conversion of units. For cars constructed prior to May 1, 2001, conformance to this standard is optional. 1.3.8.2 Capacity Tables For all cars constructed after May 1, 2001, capacity tables shall be provided by the car builder. Capacity tables shall conform to the following: 1.3.8.2.1 Tables shall list outage volumes (volume of air or vapor above the surface of a liquid) corresponding to distances measured downward from the shell-full (zero-outage) level. 1.3.8.2.2 Tables shall begin at the shell-full (zero-outage) level and continue for the full depth of the tank. 1.3.8.2.3 If English units are used, volumes shall be whole U.S. gallons and distances shall be inches in one-quarter-inch increments. If metric units are used, volumes shall be whole liters and distances shall be whole centimeters. 1.3.8.2.4 All tables must show an effective date. 1.3.8.2.5 For reference, the following conversion factors are to be used: • Multiply U.S. gallons by 3.785 to convert to liters. • Multiply imperial gallons by 1.201 to convert to U.S. gallons. • Multiply imperial gallons by 4.545 to convert to liters. • Multiply inches by 2.540 to convert to centimeters.

AWW DRAFT 09/28/18 1.3.8.2.6 Tank cars may be grouped when assigning capacity tables if the measured (water gauged or strapped) shell-full capacity of the tank is within 0.1% of the shell-full capacity used in the gauge table. 1.3.9 Gauging Tank car tanks can be gauged by built-in gauge marker, tell-tale valve, or electronic or magnetic gauging device as may be in accordance with the specification. Gauging can alternatively be accomplished by scale weighing, liquid metering, or by use of poles and outage/innage tables, depending upon the commodity and class of car involved. Procedures for gauging tank car tanks are detailed in API Measurement Standard 3.2, “Tank Gauging—Gauging Petroleum and Petroleum Product in Tank Cars.” Effective August 1, 2005, tank cars equipped with slip tube gauging devices must have them removed no later than the next tank qualification event. Cars altered under this rule need not meet the capping kit requirements of Appendix E, paragraph 3.1.6.

11/2014 C-III [M-1002] 31 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

1.3.10 Age Limits There is no life limit on a tank car tank if the tank conforms to both the federal regulations and the AAR requirements. Underframes built prior to July 1, 1974, have an AAR life limit of 40 years, unless the underframe is rebuilt or has received extended service status. Underframes built since July 1, 1974, have an AAR life limit of 50 years. When applying a tank to a new or existing underframe, the Tank Car Committee must approve the application. After applying a tank to a new or existing underframe, the tank must be qualified to verify tank integrity. 1.3.11 Head Shields Head shields must be applied by certified facilities and appropriate reports submitted. 1.3.12 Rebuilt Status

Requests for rebuilt status for tank cars must be made in accord with the Office Manual of the 09/28/18 DRAFT AWW AAR Interchange Rules, Rule 88, and not on Form AAR 4-2. 1.3.13 Commodity Change If a tank car is designated for a specific commodity on its Certificate of Construction and is used to transport another commodity or class of commodities, the commodity change alters the Certificate of Construction and therefore must be approved by the car owner and meet all federal regulations. 1.3.14 Reporting Marks and Car Numbers Changes in reporting marks and car numbers affect the validity of the Certificate of Construction and must be reported on Exhibit R–1. Both old and new numbers must be reported. This is in addition to UMLER procedures and the requirements of the Office Manual of the AAR Interchange Rules, Rule 88, for such changes. 1.3.15 Documentation at the Sale of Tank Cars At the sale of a tank car, the car owner must transfer the documents outlined in paragraph 1.6.4 to the new car owner. 1.3.16 Requirements for Tank Cars with Gross Rail Load Over 263,000 lb to 286,000 lb, Inclusive This subsection applies to tank cars with gross rail load over 263,000 lb to 286,000 lb, inclusive. It specifies requirements for new construction and alterations to existing cars that increase gross rail load. It does not apply to upgrades of cars from 70 ton to 100 ton or to existing six- or eight-axle equipment. New construction and gross rail weights of tank cars in excess of 286,000 lb are prohibited. Compliance with this subsection is required for cars ordered after July 25, 1997. 1.3.16.1 All Cars 1.3.16.1.1 Cars must be in conformance with the Office Manual of the AAR Interchange Rules, Rule 88. 1.3.16.1.1.1 Cars must be in conformance with the truck requirements located in S-286 as required in the Office Manual of the AAR Interchange Rules, Rule 88. 1.3.16.1.2 AAR cars must be stenciled AAR Class-211W or Class-204W. 1.3.16.1.3 Cars must be registered in UMLER with Star Code “L” or “M” as appropriate. 1.3.16.2 New Cars Form AAR 4-2, Application for Approval and Certificate of Construction, must specify the gross rail load for which the cars are designed and must certify that all of the requirements of paragraph 1.3.16.1 are met.

C-III [M-1002] 32 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

1.3.16.3 Existing Cars 1.3.16.3.1 Form AAR 4-2, Application for Approval and Certificate of Construction, must be submitted to the Tank Car Committee for approval to increase the gross rail load above 263,000 lb if cars were not so originally approved. This application must specify the gross rail load to which the cars are being altered and must be accompanied by a letter from a certified car builder stating that all of the requirements of paragraph 1.3.16.1 are met or by complete documentation, specifications, and stress analysis as described in Office Manual of the AAR Interchange Rules, Rule 88, Section C.3. 1.3.16.3.2 Cars that are altered to increase gross rail load must have trucks, center sills or stub sills, body bolsters, and draft systems inspected in accord with the Field Manual of the AAR Interchange Rules, Rule 88, Section B.2 and structural elements inspected in accord with 49 CFR 180.509(e). 1.3.16.3.3 Existing cars may have gross rail load increased above 263,000 lb if originally designed for the higher load and so noted on the Certificate of Construction. 1.3.16.3.4 Tank cars that exceed 263,000 lb due to the addition of approved safety features must be in compliance with paragraph 1.3.16.3.1 but need not comply with paragraph 1.3.16.3.3. 1.3.17 Maintenance Program The provisions of Appendix U apply to the following entities: •Tank car owner • Service equipment owner • Lining or coating owner • Tank car manufacturing facility • Tank car repair facility • Operator/User • Subcontractor 1.4 Procedures for Securing Approval 1.4.1 General Paragraph 1.3.6 of this specification and U.S. Department of Transportation (DOT) and Transport Canada (TC) regulations require AAR Tank Car Committee (Committee) approval of designs and materials used for the construction, conversion, alteration, or welded repair of tank car tanks. The Committee has delegated to the AAR Safety and Operations Department the authority on its behalf to approve applications provided that

AWW DRAFT 09/28/18 • they have been reviewed and deemed to be in accord with AAR, DOT, and TC requirements by an independent third party (ITP) that has been certified by the Committee in accord with paragraph 1.5, or, • they meet the requirements for precedent approval outlined in paragraph 1.4.2.3. The AAR may elect to request a Committee ballot on any application for approval. Such a request should be made within 10 days of receipt of the application. Applications for approval of service equipment will continue to be approved by the Tank Car Committee in accord with paragraphs 1.4.6 and 1.4.7.

11/2014 C-III [M-1002] 33 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

1.4.1.1 AAR Tank Car Application for Approval and Certificate of Construction Web-Based System Effective January 1, 2015, applicants are required to use the AAR Tank Car Application for Approval and Certificate of Construction Web-Based System for submittal of applications for tank car designs. This system encompasses the entire process of seeking approval of tank car designs. Tank car design applicants, AAR, and certified ITPs are required to obtain access to this system and will use it in processing applications through the approval process, including the certificate of construction submittal. A system user guide is available to those who obtain access. To obtain access to the Tank Car Application for Approval and Certificate of Construction Web-Based System, contact Railinc’s Customer Support Center (CSC) where the application is hosted and maintained on behalf of the AAR. Customer support can be reached at 877-724-5462 or

via email to [email protected]. AWW DRAFT 09/28/18 DRAFT AWW 1.4.1.1.1 Drawings and Supporting Documents In addition to the Form AAR 4-2, which must be completed in its entirety by the applicant, all applicable drawings and supporting documents must also be uploaded following the outlined instructions within the system. These drawings/documents must all be in PDF format. 1.4.2 Approval of Precedent and Nonprecedent Tank Car Designs (Form AAR 4-2) All applications for approval, both nonprecedent and precedent (as defined herein), must be submitted to the Executive Director—Tank Car Safety using Form AAR 4-2, Application for Approval and Certificate of Construction. Form AAR 4-2 is reproduced in this manual in Fig. 1.1, and paragraph 1.4.3.1 contains instructions for its completion. Precedent applications (i.e., applications based on prior Committee-approved applications) will be evaluated by AAR staff as described in paragraph 1.4.2.3. Nonprecedent applications (and listed major deviations from precedent applications) will be reviewed and evaluated by a certified ITP, selected by AAR staff from a list of contractors approved by the Tank Car Committee. Handling of nonprecedent applications is further described in paragraph 1.4.2.2. 1.4.2.1 Fees Application fees are listed in the Office Manual of the AAR Interchange Rules, Appendix E. In addition, applicants are responsible for the cost associated with the review of applications by an ITP. Applicants will receive invoices for fees related to the application process. 1.4.2.2 Nonprecedent Applications Nonprecedent applications are those not based on previously approved designs. When required by AAR Specification M-1001 or paragraph 1.4.2.5 of this specification, one copy of the application with multiple sets of drawings must also be furnished to the AAR Technical Services Section for approval of brake systems and car structure. The certified ITP assigned by AAR staff will review the application for compliance with AAR and DOT/TC requirements and will deal directly with the applicant to resolve any discrepancies. The Director must receive copies of all correspondence related to resolution of questions on the application. The AAR will be notified by the certified ITP through the web-based system that the application is satisfactory. The ITP is required to respond to either the applicant or AAR, as appropriate, within 21 days of receipt of the application. If a discrepancy leads to an application revision, the ITP is required to respond to the applicant or AAR within 14 days of receipt of the revised application. In the event that an ITP and the applicant cannot resolve discrepancies in an application and the ITP recommends against approval, the applicant may request Tank Car Committee review of the application in accord with the process outlined in paragraph 1.4.2.12.

C-III [M-1002] 34 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

1.4.2.3 Precedent Applications Precedent approval may be requested on car designs where the tank and attachments thereto do not incorporate major changes from designs previously approved. Precedent applications may reference a design identical to that for which approval is requested or they may contain limited revisions to the original design as listed in paragraph 1.4.2.4. Deviations from the previously approved design must be summarized and submitted with the application. Drawings that clarify changes that fall within the scope of precedent approval also may be attached. AAR staff may approve a request for precedent approval without ITP review provided that the referenced precedent certificate of construction was approved within the preceding 10 years. The application may include changes listed in paragraph 1.4.2.4. The AAR is required to respond to the applicant, as appropriate, within 21 days of receipt of the application. 1.4.2.4 Design Differences Acceptable for Precedent Approval Subject to the limitations outlined in paragraph 1.4.2.3, permitted design differences from previously approved designs may include the following: • Changes in tank length only, provided that the rail load limit is not increased • A reduction in rail load limit • A change in arrangement or number of heater coils, including deletion of the entire system or application of a previously approved system • Changes to appurtenances used for loading and unloading, provided that they are in compliance with Appendix S and the AAR Interchange Rules • Changes to trucks, braking systems, or draft systems, provided that they are in compliance with the AAR Interchange Rules • Use of previously approved tank opening reinforcements, nozzles, and protective housings, provided that the approved design and application were for tanks of equal or greater test pressure • Application or rearrangement of previously approved fittings, provided that they had been approved for tank cars of equal or greater test pressure • Changes to materials of previously approved fittings that are necessary for compatibility with lading, provided the changes do not reduce the strength of the fitting or its components (see paragraph 1.4.5.3.3) • Application of previously approved head shields, thermal protection systems, or insulation systems or the deletion of such systems • Changes to approved head shields, thermal protection systems, or insulation systems necessary to conform to changes in tank geometry

AWW DRAFT 09/28/18 • Changes to car structure that are not in violation of paragraph 1.4.2.5 • Changes necessary to accommodate tank geometry that do not reduce the strength of a previously approved underframe

11/2014 C-III [M-1002] 35 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

1.4.2.5 Design Differences That May Not be Approved by Precedent Design differences from previously approved designs that constitute major changes and categorize an application as one requiring Committee or ITP review include the following: • Changes in tank shell diameter, shell thickness, or alloy • Changes to structural stiffeners used in or on tanks • An increase in the rail load limit • Design changes to full-length and stub sill underframes, other than those required to accommodate changes in tank geometry • Substitution of a lower strength alloy for a previously approved higher strength material for tank shell and heads or car underframe

• Use of fittings not previously approved 09/28/18 DRAFT AWW • Use of tank openings, reinforcements, nozzles, or protective housings not previously approved • Changes to closures and covers, other than those required to apply previously approved fittings • Use of head shields, thermal protection systems, or insulation systems not previously approved 1.4.2.6 Structural Requirements All tank cars for which AAR approval is requested must comply with the car structure, design, and testing requirements outlined in 6 of this specification and AAR Specification M-1001. Tank cars designed for gross rail loads in excess of 263,000 lb on four axles must have the car structure approved by the Equipment Engineering Committee. 1.4.2.7 New and Untried Types Applications for approval of new and untried types of tank cars must be made to the Tank Car Committee and must include a completed Form AAR 4-2 with all drawings and data pertaining to the tank shell, heads, and appurtenances. Approval by the Tank Car Committee is required for completion of the Certificate of Construction. Applications for approval of designs where the components of the car structure, whose primary function is to support loadings exclusive of internal tank pressure, are of a new and untried type as defined in paragraph 1.2.1 of the Manual of Standards and Recommended Practices, Section C-II, Specification M-1001, require approval of the Equipment Engineering Committee. Applicant must submit a cover letter with 15 sets of applicable arrangement and detail drawings and other supporting data to the Director for distribution to that committee. Applications for approval of designs where the brake equipment or its operation are of a new and untried type, as defined in paragraph 1.2.1 of MSRP Specification M-1001, require approval of the Equipment Engineering Committee and the Braking Systems Committee. Applicant must submit a cover letter with 25 sets of brake arrangement drawings and other supporting data to the Director for distribution to the committees. When tests are conducted in support of new and untried cars designs or of cars incorporating changes of a new and untried type, tests must comply with applicable chapters of MSRP Specification M-1001. 1.4.2.8 Alteration, Conversion, or Repair For alterations, conversions, or welded repairs using previously approved procedures and materials, an Exhibit R–1 report in compliance with Appendix R must be submitted. For alterations, conversions, or welded repairs using procedures or materials that have not been previously approved, an application must be submitted on Form AAR 4-2. Such applications will be handled as outlined in paragraph 1.4.2 and related subsections.

C-III [M-1002] 36 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

1.4.2.9 Safety Appliances Safety appliances must be in accord with U.S. Department of Transportation Federal Railroad Administration (FRA) regulations. Questions pertaining to safety appliances or their application to the car must be handled directly with the FRA Office of Safety. 1.4.2.10 Approval of Applications Upon confirmation from the ITP and any involved Technical Services Committee that an application is in good order, AAR will process the application for approval and so notify the applicant. The approved application will become the Certificate of Construction for the car or cars identified thereon when certified per paragraph 1.4.3.3 and serves as notice of approval to all parties. 1.4.2.11 Committee Process Applications that are referred to the Tank Car Committee pursuant to paragraph 1.4.1 or paragraph 1.4.2.3 will be handled by mail ballot and will be approved by majority vote unless advised by any member of the Committee or by AAR staff that approval appears to be in violation of the specifications or will represent a hazardous condition. In the event such advice is received, all committee members will be notified, and those members previously voting to approve the application will be asked to reconsider their vote. A Committee member having comments on any application being considered must, within 15 days of receipt of the application, direct his or her comments to the applicant with copies to the balance of the Committee and to the Director. The applicant must respond to Committee comments within 30 days, directing his or her response to each member of the Committee and to AAR staff. Failure to respond will be cause for disapproval of the application. Once an applicant has furnished all additional information requested in Committee comments, all Committee member(s) initially commenting on the application must resubmit a ballot within 15 days of the applicant’s response. A Committee member having taken exception to an application and then approving it based on satisfactory applicant response to comments must direct approval to the Director with copies to the applicant and the balance of the Committee. If sufficient ballots to constitute action have not been received within 45 days from receipt of the application by AAR, staff will poll each member of the Committee to expedite response. AAR staff must notify the applicant of the status of his or her application within 60 days of receipt of the application. A written explanation must be provided for any application that is disapproved or held pending additional information. 1.4.2.12 Disapproved Applications If an application is disapproved pursuant to action of the Tank Car Committee, the applicant may, by written notice to the Director, petition the Committee for review of the application at a regular

AWW DRAFT 09/28/18 or special meeting of the Committee to be held not later than 90 days from receipt of the notice. The applicant must attend any such meeting and will be granted the right to present additional information is support of the application. AAR must notify the applicant of the action of the Committee within seven business days following the meeting. If tank cars covered by formally disapproved applications are subsequently offered for interchange service, the Director will notify all AAR member railroads and appropriate movement restrictions will be placed in the Universal Machine Language Equipment Register (UMLER) file.

11/2014 C-III [M-1002] 37 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

1.4.3 Application Form AAR 4-2 1.4.3.1 Instructions 1.4.3.1.1 The following line-by-line instructions are provided for completing the “application” portion of Form AAR 4-2:

Line Instruction 1. Indicate by an “X” in the appropriate block whether nonprecedent or precedent approval, based on a precedent already approved by the Committee, is requested. AAR staff will assign nonprecedent requests to the Committee or to an ITP, as appropriate. 2. Indicate if the application concerns construction, conversion, alteration, repair, or other

(provide description for “other”). 09/28/18 DRAFT AWW 3. Enter the application number, which will be provided by the Director on request. The number will be prefixed to indicate the nature of the application according to the following code. This application number will become the certificate number upon receipt of certification.

Code Description Code Description Code Description A Construction—Nonprecedent F Construction—Precedent L Construction—Nonprecedent Committee Ballot AAR Approve AAR Approve B Conversion—Nonprecedent G Conversion—Precedent M Conversion—Nonprecedent Committee Ballot AAR Approve AAR Approve C Alteration—Nonprecedent H Alteration—Precedent N Alteration—Nonprecedent Committee Ballot AAR Approve AAR Approve D Welded Repair—Nonprecedent J Welded Repair—Precedent P Welded Repair—Nonprecedent Committee Ballot AAR Approve AAR Approve E Other— Nonprecedent K Other—Precedent Q Other—Nonprecedent Committee Ballot AAR Approve AAR Approve

In the event that the method of approval changes after submission, the AAR staff will revise the prefix to correspond to the proper code. 4. Enter the date of the original application. Dates of revisions to the application must be shown under “Revisions.” 4.1 Enter the date the order was made with the Tank Car Builder. MM/DD/YYYY 5. Enter a file number or builder lot number. 6. Enter the name of the applicant. For new construction, the applicant must be the tank car builder. For conversion, alteration, or repair, the applicant must be the car owner or the facility authorized to perform such work. 7. Enter the tank specification to which the tank is to be built (e.g., DOT-111A100W1). 8. If the car is to be operated under a specification other than the one shown on Line 7, the stenciled specification must be entered here (e.g., AAR-211A100W1). 9. The reporting marks and car numbers entered here must be those that are or will be recorded in the “Official Railway Equipment Register” covering the car or cars in question. 10. Enter the total number of cars represented by the car numbers or series shown on Line 9. 11. If the car is designed for a specific commodity, enter its proper shipping name. If the car is not designed for a specific commodity or is limited to certain commodities, enter the words “(Initial lading) and products authorized by DOT Part 173 for which there are no special commodity requirements and nonregulated commodities compatible with this class of car.” If special commodity stenciling is required, it must be shown under “Notes.”

C-III [M-1002] 38 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

Line Instruction 12. If the car is designed for a specific commodity, enter the weight of the commodity in pounds per gallon or pounds per gallon and kilograms per liter. When Line 11 shows “DOT Part 173” and an initial commodity, show the weight of the initial commodity. 13. Enter the tank capacity in U.S. gallons or U.S. gallons and liters. For nonpressure cars, record shell-full volume. For pressure cars, record shell-full volume plus volume of manway nozzle. 14. Enter the as-designed outage in U.S. gallons or U.S. gallons and liters. 15. Enter the material specifications for tank shell and heads and their respective through specifications and thicknesses. 16. 18.17. 15.1 Indicate whether or not the tank head material is normalized. (Yes= normalize; No=not normalized) 15.2 Indicate whether or not the tank head is spliced. (Yes or No) 15.3 When transverse Charpy impact tests are required per paragraph 2.2.1.2, indicate the impact test temperature. 16.1 Indicate whether or not the tank shell material is normalized. (Yes= normalize; No=not normalized) 16.2 When transverse Charpy impact tests are required per paragraph 2.2.1.2, indicate the impact test temperature. 19. Where linings are required by the specification, the lining material and thicknesses must be shown. 20. Enter tank inside diameter, in inches, at center and at tank ends. May also be submitted 21. in both inches and millimeters. 22. This item refers to dished heads and, when such heads are used, the main radius in inches or inches and millimeters must be entered. 23. Enter the actual test pressure for which the tank is designed, including maximum pressure relief device setting permitted by 49 CFR 179.15. Use psi or psi and kPa. 24. Enter the type of insulation used (e.g., fiberglass, cork, polyurethane, etc.) 25. Enter the thickness of insulation in inches, or inches and millimeters, for all insulated tanks. 26. The thermal conductivity of the insulation must be shown in the units indicated at 60 °F (15.6 °C). (Mineral wool, ceramic fiber, or other thermal protection materials are not

AWW DRAFT 09/28/18 considered insulation.) SI equivalent units are kJ•mm/h•m2•°C. 27. These items must indicate whether the pressure relief device is a valve, vent, or breather 28. vent. The number of such devices and the start-to-discharge pressure or bursting pressure must be shown in psi or psi and kPa. 27.1 Enter the number of safety relief devices. 29. For pressure relief devices, the required flow capacity in cubic feet per minute, or cubic feet per minute and cubic meters per second, must be entered. 30. When pressure relief devices are used, enter the actual flow capacity provided. 31. Enter the exterior tank surface area in square feet or square feet and square meters. 32. For tank cars with an underframe, enter “full.” For stub sill cars, enter the code for the stub sill style (see Appendix R, Exhibit R-2, fourth page, for builder and sill codes).

11/2014 C-III [M-1002] 39 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

Line Instruction 33. Enter the height from top of rail to the center of gravity of the tank car in inches or inches and millimeters. If the center of gravity height exceeds 84 in. (2130 mm) on cars with four- wheel trucks having 6 1/2 in. × 12 in. journals or larger, an asterisk must be used to refer to a comment under “Notes,” indicating car truck centers or truck spring travel. 34. Enter the estimated light weight of the completed car in pounds or pounds and kilograms. 35. Indicate if car is constructed to AAR Clearance Diagram Plate B, C, E, or F. 36. The rail load limit must be shown and must be compatible with the truck capacity for the number and size of axles used. If gross weight on rail exceeds 263,000 lb with 6 1/2 in. × 12 in. journals, approval of the AAR Equipment Engineering Committee is

required (see paragraph 1.4.2.6). 09/28/18 DRAFT AWW 37. Enter the truck capacity in tons. 38. If the car is fitted with head shields, indicate whether “half” or “full.” 38.1 Enter the thickness in inches of the head shield material. 39. Drawings. Enter the drawing number of all drawings relevant to the application in the through first column headed “Drawing Number.” Enter information in the next two columns 53. concerning prior approvals in accord with the following instructions. a. If a cited drawing is being submitted for ITP or Committee consideration without reference to a previously approved drawing, leave the second and third columns blank. Prints must be furnished and an explanation provided by letter or separate sheet. b. If a cited drawing has been previously approved by an ITP or the Committee and nothing has changed on that drawing, enter the application number of the prior approval in the third column and leave the second column blank. Submission of these precedent drawings is not required unless the application includes both precedent and nonprecedent drawings that will require ITP review, in which case all drawings are to be submitted, including the precedent drawings. c. If a cited drawing is based on a previously approved drawing, but with changes permitted under paragraph 1.4.2.4, enter the precedent drawing number in the second column and its approved application or certificate number in the third column. Prints of the new drawings must be furnished with the application, and deviations from the precedent drawing must be explained by letter or on an attached sheet. d. Applications prefixed F, G, H, J, or K may not be referenced. Only applications under which a drawing has been reviewed and approved may be referenced. e. If a precedent drawing is from a current application that is pending approval, indicate “Pend” after the application number in the third column. f. If drawings cited as prior approvals have not been approved within the past 10 years, such drawings must be resubmitted with the application. g. All prints of drawings and calculations submitted with Form AAR 4-2, must carry a current approval signature or initial by the proponent, and must be marked with the application number with which they are submitted. 54. Applications for new construction must include a drawing that indicates structural welds to be inspected during requalification. For jacketed cars, the drawing must include dimensions referenced to a visible area of the car.

C-III [M-1002] 40 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

1.4.3.1.2 Application for approval of new tanks to be mounted on existing car structures must be accompanied by a statement under “Notes” that “Car structure complies with all requirements of the AAR Interchange Rules and is suitable for continued service.” 1.4.3.1.3 Applications for conversion, alteration, or repair must indicate current specification, former lading, date built new, and previous certificate number(s) under “Notes” and must show specification and new commodity on Line 7 and Line 11, respectively. Supply a supplemental sheet, if necessary, to associate the car numbers with their previous certificate numbers. 1.4.3.1.4 For applications covering welded repairs on tanks using procedures or materials that have not been previously approved, fill in Lines 1 through 38, inclusive. Description of damage to tank, date, place, and circumstances of damage, together with proposed method of making repairs, must also be submitted under “Notes” on a continuation sheet. 1.4.3.1.5 For applications covering reconditioning of manway covers for tank cars covered by DOT 179.100, submit data on original construction, certificate numbers, and car specification, with drawing numbers used in original construction. Application must include drawings and a detailed explanation of how repairs are to be made. 1.4.3.1.6 Applications submitted by facilities other than the fabricator of tank shell and heads for assembly of new tank cars must be accompanied by a statement under “Notes” that “Tank shell and head fabrication by... (certified facility). Completed car will comply with all applicable AAR and DOT requirements.” 1.4.3.1.7 Certain car designs, appurtenances, valves, fittings, or attachments may be declared by the Tank Car Committee to be subject to service trials before general acceptance for new construction. Such service trials and their restrictions must be identified by the applicant or AAR under “Notes.” Service trial numbers are assigned by the Director. See paragraph 1.4.9. 1.4.3.1.8 DOT exemptions, special approvals (SAs), or Canadian special permits applicable to the car or commodity must be identified under “Notes.” A copy of the latest revision must be submitted with the application. 1.4.3.1.9 Applications for increased truck capacity must be supported by justification (with calculations if necessary) to verify the structural adequacy of the car for increased capacity and braking requirements. 1.4.3.1.10 Valves are to be identified by manufacturer, size, and identification number on the drawings or application, whether or not supplied by the proponent. 1.4.3.1.11 The method of anchoring the jacket of an insulated car must be submitted with Form AAR 4-2.

AWW DRAFT 09/28/18 1.4.3.2 Approval AAR staff complete the “Approval” section of Form AAR 4-2 based on action taken on the application. 1.4.3.3 Certification The “Certification” section of Form AAR 4-2 is to be completed only after the approved application has been received from AAR and the referenced construction, alteration, conversion, or repair has been completed. Certification is accepted only from a responsible Quality Control representative acting for the facility performing the work, from an officer of the company performing the work, or from the car owner. When signed by all parties, the completed Form AAR 4-2 is recognized as the Certificate of Construction for the car or cars identified thereon.

11/2014 C-III [M-1002] 41 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

APPLICATION FOR APPROVAL AND CERTIFICATE OF CONSTRUCTION  1. APPROVAL REQUESTED OF: ܆ PRECEDENT 2. TYPE: ܆ CONSTRUCTION ܆ WELDED REPAIRS 3. AAR NO. ܆ NONPRECEDENT ܆ ALTERATION ܆ OTHER 4. DATE ܆ CONVERSION 4.1 ORDER DATE 5. APPLICANT NO. 6. APPLICANT 7. TANK SPECIFICATION 8. STENCILLED SPEC 9. REPORTING MARKS AND NUMBERS 10. NUMBER OF CARS

11 Initial Commodity 12 Density (Lb Per Gallon) 13 Full Water capacity, (Gallons) 14 Dome Capacity or Outage (Gallons) 15 Material –Type / Grade Heads 15.1 Head Material Normalized 15.2 Tank Head Spliced 15.3 Charpy Requirements 16 Material Type and Grade Shell 16.1 Tank Shell Material Normalized 16.2 Charpy Requirements 17 Material Thickness Heads (Inches) 18 Material Thickness Shell (Inches) 19 Lining Type 09/28/18 DRAFT AWW 20 Inside Diameter – Center (Inches) 21 Inside Diameter – End Rings (Inches) 22 Head Radius, Main (Inches if not 2:1) 23 Test Pressure (PSI) 24 Insulation Type 25 Insulation Thickness (Inches) 26 Thermal Conductivity (BTU – in/hr. – ft sq. – degree F) 27 Type of Safety Relief Devices 27.1 Number of Safety Relief Devices 28 Pressure Relief Device Start-to-Discharge (PSI) 29 Pressure Relief Device Flow Capacity (CFM Required) 30 Pressure Relief Device Flow Capacity (CFM Actual) 31 Tank Surface Area (Sq Ft) 32 Underframe or Stub Sill Type 33 Center of Gravity Loaded (Inches)loaded 34 Estimated Light Weight (lb) 35 AAR Clearance Diagram 35 Rail Load Limit. (lb) 37 Truck Capacity (Tons) 38 Head Shield Type 38.1 Head Shield Thickness (inches) Notes: Original certificate Builder Date Former lading

The Following Prior Approval Apply The Following Drawings Apply Drawing Number Drawing Number Application / Certificate no. 39 General Arrangement 40 Tank Arrangement 41 Reinforce Openings Including Calculations 42 Anchorage, Including Calculations 43 Fittings Arrangement 44 Manway Assembly 45 Protective Housing 46 Venting, Loading, and Discharge Valves 47 Pressure Relief Devices 48 Heater Systems (Int. ܆ Ext. ܆) 49 Gauging Devices 50 Bottom Outlet Valve 51 Repairs 52 Manway Cover 53 Calculations 54 Tank Qualification Drawing

REVISIONS: APPLICATION BY:

I certify the foregoing conforms to all applicable DOT and AAR requirements. Including specifications, regulation, rules of interchange and the DOT Railroad Safety Appliance Standards.

SIGNATURE

TITLE

APPROVAL - AAR Tank Car Committee Date Approved: (Signature) on behalf of Tank Car Committee

CERTIFICATION: The cars enumerated below conform to the above approved description and to all applicable DOT and AAR requirements, including specifications, regulations, rules of interchange, and the DOT Railroad Safety Appliance Standards. Copy of this Certificate of Construction will be furnished to the owner and others as required by 49 CFR Part 179.5 before these cars are placed in service. Initials and Car Numbers

Name Date

Title

Form AAR 4-2 Revised10.2014

Fig. 1.1 Form AAR 4-2 Application for Approval and Certificate of Construction

C-III [M-1002] 42 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

AAR No. ______

Applicant’s No. ______

Date ______

AWW DRAFT 09/28/18

APPLICATION BY: ______I certify that the foregoing conforms to all applicable DOT and AAR requirements, including specifications, regulations, rules of interchange, and the DOT Railroad Safety Appliance Standards. SIGNATURE ______TITLE______

APPROVAL—AAR Tank Car Committee

Date Approved ______(signature) on behalf of the Tank Car Committee

Form AAR 4-2.1 Revised 7/30/2014 Page of

Fig. 1.2 Form AAR 4-2.1 Supplementary page

11/2014 C-III [M-1002] 43 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

1.4.4 Certificate of Construction 1.4.4.1 Certificate of Construction for Tank Car Tank, Equipment, and Complete Car 1.4.4.1.1 See DOT 179.5. The Certificate of Construction is the lower portion of Form AAR 4-2. After receipt of the approved application from the Director, the applicant must complete the Certificate of Construction on the original, furnish copies as required below, and store the original information in such a way that a printable electronic copy or paper copy can be obtained and that changes to the original information can be detected. 1.4.4.1.1.1 Effective January 1, 2015, applicants are required to use the AAR Tank Car Application for Approval and Certificate of Construction Web-Based System for completing the

Certificate of Construction. AWW DRAFT 09/28/18 DRAFT AWW 1.4.4.1.2 For all tank cars built, the facility assembling the completed cars must furnish a Certificate of Construction, Form AAR 4-2, to the owner and the Director certifying that tank, equipment, and car comply with all the requirements of the specifications. (For Class DOT-107A, see also paragraph 1.4.4.2.) For alterations, conversions, or welded repairs requiring approval, the Certificate of Construction portion of Form AAR 4-2 must be completed and submitted as required above. 1.4.4.1.3 When cars or tanks identical in all details are covered on one application and are built in series, one certificate will suffice for each series when submitted to the owner and to the Director. One copy of the Certificate of Construction must be furnished to the Director for each car number or consecutively numbered group or groups covered by the original application. 1.4.4.1.4 Cars or tanks must not be placed in service until the Certificate of Construction has been submitted. 1.4.4.2 Certificate of Construction for Class DOT-107A Tank Cars For Class DOT-107A tank cars, in addition to the Certificate of Construction Form AAR 4-2, certified inspector’s reports as required by DOT 179.500-18 must be submitted. 1.4.5 Service Equipment Service equipment as used in this section is inclusive of the terms pressure relief devices, valves, closures, and fittings. 1.4.5.1 Closures and Fittings 1.4.5.1.1 Any special closure assembly design having operating parts requires Tank Car Committee approval. 1.4.5.1.2 Any modification to a bottom outlet closure as defined in Appendix E, Figs. E.24.1 through E.24.9, requires Tank Car Committee approval. 1.4.5.1.3 Tank car closures do not require Tank Car Committee approval if they are manufactured in accordance with a nationally recognized standard (e.g., AAR, SAE, ASME, ANSI, MIL). 1.4.5.1.4 Manway covers, if manufactured in accordance with Appendix E, do not require approval by the Tank Car Committee; otherwise, they must be approved. 1.4.5.1.5 Nonmetallic fittings require Tank Car Committee approval.

C-III [M-1002] 44 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

1.4.5.1.6 Metallic fittings require Tank Car Committee approval unless all of the following conditions are met: • Parts are manufactured in accordance with a nationally recognized standard (e.g., SAE, ASME, ANSI, MIL) or Appendix M. • Parts are designed to meet or exceed the operating pressure rating of a tank car. • Parts are designed to be leak tight. • Parts must be joined in accordance with Appendix E, as specified by the tank car manufacturer or owner, or ASME Section 8, Division 1. • Fitting must be marked with the name of the manufacture and pressure rating and with additional markings as agreed to by purchaser and manufacturer. • Approval is granted for the application of the fitting to the tank car when the Form AAR 4-2 for the tank car is approved for a specific application for new construction, alteration, conversion, or repair. 1.4.5.2 Approval of Service Equipment Tank car service equipment must be approved by the Tank Car Committee. Approvals of service equipment must be renewed every 10 years. Approvals will be marked with the expiration date, which shall be the end of the month in which the approval was executed plus 10 years. Table 1.17 outlines the devices by group, committee approval, and what form is to be used. The application process, instructions, and forms are provided within this chapter.

Table 1.17 Service equipment approvals (page 1 of 2) Device Group Committee Approval Form Air inlet Valve Yes 4-5 Air inlet Closure No N/A Bottom outlet valve Valve Yes 4-5 Bottom washout Closure Yes 4-5 Breather vent Valve Yes 4-5 Check valve Valve Yes 4-5 Closure, metallic Closure No N/A Closure, nonmetallic Closure Yes 4-5 Closure assembly Closure Yes 4-5 Combination device PRD Yes 4-3 Excess flow valve Valve Yes 4-5

AWW DRAFT 09/28/18 Fill hole cover, metallic Closure No N/A Fill hole cover, nonmetallic Closure Yes 4-5 Fitting, metallic Fitting No N/A Fitting, nonmetallic Fitting Yes 4-5 Fusible plug device PRD Yes 4-3 Gauging device Closure Yes 4-5 Liquid valve Valve Yes 4-5 Manway cover Closure Yes 4-5 Manway cover assembly Closure Yes 4-5 Pressure plate Closure No N/A Pressure-regulator valve PRD Yes 4-3 Pressure-relief device PRD Yes 4-3

11/2014 C-III [M-1002] 45 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

Table 1.17 Service equipment approvals (page 2 of 2) Device Group Committee Approval Form Pressure-relief valve PRD Yes 4-3 Primary valve Valve Yes 4-5 Primary closure, metallic Closure No N/A Primary closure, nonmetallic Closure Yes 4-5 Rupture disc Closure No N/A Sample valve Valve Yes 4-5 Secondary valve Valve No N/A

Secondary closure Closure No N/A 09/28/18 DRAFT AWW Surge-suppression device No N/A Spring-loaded check valve Valve Yes 4-5 Temperature-sensing equipment Closure Yes 4-5 Thermometer well Closure Yes 4-5 Vacuum-relief valve Valve Yes 4-5 Valve Valve Yes 4-5 Vapor valve Valve Yes 4-5

1.4.5.3 Renewal of Service Equipment Approvals Applicant shall submit application packages for renewal at least 60 days prior to the expiration date of the most recent approval. The most recent approval shall remain in effect until such time the applicant is notified of disapproval or the renewal is approved. 1.4.5.3.1 Previously approved service equipment for which the current approval has lapsed may continue in service for the life of the tank car on which it was originally applied and may be replaced in-kind on existing tank cars without reapproval. Manufacture of such service equipment is not authorized. To manufacture once the current approval has lapsed, the applicant must reapply. 1.4.5.3.2 Any changes to an approved device require submission to the Executive Director—Tank Car Safety for approval unless paragraph 1.4.5.3.3 of this chapter applies. 1.4.5.3.3 The following changes to an approved device, if they do not affect the operation of the device, do not require submission to the Tank Car Committee and may be listed under the current approval: • External changes to previously approved devices • Changes in materials of construction • Changes in materials that are compatible with the intended commodity service • Changing a spring with another spring having the same spring constant • Changing a coating on a valve designed to be coated • Designs previously approved but of smaller sizes or lower pressure ratings • Secondary closures of generic design • For devices that are flow rated, see additional requirements in Appendix A, paragraph 5.1. Any other change requires submission to the Executive Director—Tank Car Safety for approval.

C-III [M-1002] 46 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

1.4.5.4 Sale of Previously Approved Design 1.4.5.4.1 Sale of the company manufacturing the approved design where the design will continue to be manufactured by the same facility under the same processes and quality assurance only requires notification of the committee of the change of ownership. 1.4.5.4.2 Sale of an approved design to a company with a current C4 certification, Appendix B, paragraph 3.1: the purchasing company may manufacture the approved device after notification of the committee of the purchase of the design. 1.4.5.4.3 Sale of an approved design to a company without a current C4 certification, Appendix B, paragraph 3.1: the purchasing company must gain a C4 certification and committee approval before manufacturing the design. 1.4.6 Pressure Relief Devices 1.4.6.1 Procedures for Approval of Pressure Relief Devices (Form AAR 4-3) 1.4.6.1.1 To secure approval of pressure relief devices as required by paragraph 1.3.6, the application package as defined in paragraph 1.4.6.1.2 must be submitted to the following: Executive Director—Tank Car Safety Association of American Railroads 425 Third Street S.W., Suite 1000 Washington, D.C. 20024

Note: All submitted materials must be marked with an assigned AAR number. 1.4.6.1.2 The application package for pressure relief devices shall consist of the following: • Form AAR 4-35 • Test results required in Appendix A, paragraph 5.3 • Drawings (assembly drawing and any additional drawing necessary to describe the device including a Bill of Material) • Flow test facility’s report, if applicable • Supplemental information as applicable • Application fee per Appendix E of the Office Manual of the AAR Interchange Rules

AWW DRAFT 09/28/18

11/2014 C-III [M-1002] 47 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

1.4.6.2 Instructions 1.4.6.2.1 The following instructions must be followed by the applicant when completing the application and certification portions of the form: • The applicant must request an AAR number from the Executive Director. • The applicant must be the valve manufacturer or its agent. • The date must be that on which the application is completed. • The applicant’s number blank is for the convenience of the applicant. • The device identification number is for the convenience of the applicant (e.g., catalog number).

1.4.6.2.1.1 The numbered items must be entered as follows: AWW DRAFT 09/28/18 DRAFT AWW

Line Instruction 1. Identify the manufacturer of the device. 2. Record the test facility used to determine the flow capacity of pressure relief valves, as required in Appendix A. 3. Record the location of the test facility. 4. Record the date the flow rating tests were conducted. 5. Write the authorized observer’s name here. 6. Record the identity of each device tested, as required in Appendix A, paragraph 5.2. 7. Record the start-to-discharge pressure in psi (or psi and kPa) of each device tested. 8. Record the flow rating pressure in psi (or psi and kPa) of each device tested. 9. Record the vapor-tight pressure in psi (or psi and kPa) of each device tested. 10. Record the flow capacity in cfm (air) or cfm and m3/s (air). 11. Record the official flow capacity in scfm (air) or scfm and standard m3/s (air), obtained at the required flow rating pressure in psi (or psi and kPa) by an approved method (see Appendix A, paragraph 5.2). 12. Enter Regulated Commodity, Non-Regulated Commodity, or Specific Commodity. 13. Drawings. Under these items, all drawings relevant to the application must be listed in through the first column headed “Drawing Number.” Information for columns two and three under 14. 16.15. “Precedent” shall be determined by the appropriate following instructions: a. If a drawing has been previously approved by the Tank Car Committee, enter the certificate number of the approval in the third column and leave the second column blank. Prints need not be submitted. b. If a new drawing is submitted for Committee consideration, leave the second and third columns blank. Prints must be furnished and an explanation provided by letter or separate sheet. c. If a new drawing is submitted for Committee consideration and a precedent drawing is appropriate, enter the precedent drawing and its application or certificate number in columns two and three. If the precedent is pending before the Committee, indicate “Pend” after the application number. Prints of the new drawing must be furnished and deviations must be explained by letter or separate sheet. d. If a precedent is pending before the Committee, indicate “Pend” after the application number. Prints of the new drawings are not required to be submitted, but deviations must be explained by letter or separate sheet. e. Under b, c, or d above, if the same new drawing and precedent are shown on another pending application, this information must also be indicated by letter or separate sheet. The first approval received must be the approval of record for the drawing.

C-III [M-1002] 48 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

Line Instruction f. All drawings submitted with Form AAR 4-3 must carry a current approval signature or initial by the proponent. 14 Note: When the design of a pressure relief device is such that the spring follower is guided by the mounting nozzle, the mounting nozzle shall be considered as a required part of the application and a drawing of the nozzle in sufficient detail to show critical dimensions shall be included. When the pressure relief device design does not require the mounting nozzle to act as a guide for the spring follower, the word “None” can be used in the space for this item. 1.4.6.2.2 Certification The applicant signs the form under “Certification” attesting to the above entries. 1.4.6.2.3 Approval by AAR Tank Car Committee 1.4.6.2.3.1 The Executive Director—Tank Car Safety completes the approval section of the form based on action taken on the application. 1.4.6.2.3.2 The Approval of Service Trial section is designated for approving the device for a service trial. 1.4.6.2.3.3 The Approval of Design section is designated for approving the device either after successful completion of a service trial or in the case where a service trial is not required and the device is approved without a service trial.

AWW DRAFT 09/28/18

11/2014 C-III [M-1002] 49 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

APPLICATION FOR APPROVAL OF PRESSURE RELIEF DEVICE

AAR NO. PRD- Applicant’s No. APPROVAL REQUESTED OF AAR TANK CAR COMMITTEE Date Device identification No. Applicant

1. Manufacturer Address 2. Test facility name 3. Test facility location

4. Test date 5. Observer 09/28/18 DRAFT AWW 6. Device 7. Start-to-discharge 8. Flow rating 9. Vapor-tight 10. Flow capacity Number psi kPa psi kPa psi kPa SCFM std.m3/s

11. Official flow capacity (air) scfm ( std. m3/s) at flow rating pressure psi ( kPa) Test medium 12. Commodity: † Regulated Commodity † Nonregulated Commodity † Specific Commodity

Precedent The following drawings apply Drawing number Application/ Latest revision Drawing number Certificate 13. Valve Assembly…………………………………….. 14. Valve Mounting Nozzle…………………………….. 15. ………………………………………………………. 16. ………………………………………………………. REVISIONS: CERTIFICATION: The above data is correct. The capacity test complies with AAR Specifications for Tank Cars, Appendix A and the devices tested conform with the drawings listed above.

By: Title APPROVAL of Service Trial by AAR Tank Car Committee AAR Service Trial Required Service Trial Number: ST-______

Date Approved for Service Trial (Signature) on behalf of Tank Car Committee APPROVAL of Design by AAR Tank Car Committee AAR Service Trial Required Service Trial Number: ST-______Date Service Trial Completed Date AAR Received )RUPAAR 4-6 Date Approved Expiration Date (Signature) on behalf of Tank Car Committee Form AAR 4-3 Revised 8/1/2014

Fig. 1.3 Form AAR 4-3 Application for Approval of Pressure Relief Device

C-III [M-1002] 50 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

1.4.7 Valves, Closures, and Fittings 1.4.7.1 Procedures for Approval of Valves, Closures, and Fittings—Application Form AAR 4-5 1.4.7.1.1 To secure approval of valves, closures, and fittings as required by paragraph 1.3.6, the application package as defined in paragraph 1.4.7.2.2 must be submitted to the following: Executive Director—Tank Car Safety Association of American Railroads 425 Third Street SW, Suite 1000 Washington, DC 20024

1.4.7.1.2 The application package for valves, closures, and fittings shall consist of the following: • Form AAR 4-5 • Drawings (assembly drawing and any additional drawing necessary to describe the device including a Bill of Material) • Flow test facility’s report, if applicable • Supplemental information as applicable • Application fee per Appendix E of the Office Manual of the AAR Interchange Rules Note: All submitted materials must be marked with an assigned AAR number. 1.4.7.2 Instructions 1.4.7.2.1 The following instructions must be followed by the applicant when completing the application and certification portions of the form. • The applicant must request an AAR number from the Executive Director. • Applicant must be the manufacturer of the device or its agent. • The date must be that on which the application is completed. • Describe the device and its function in accord with the definitions and requirements of Appendix A. • Spaces for the applicant’s number and the device identification number are for the convenience of the applicant (e.g., index, catalog, or type numbers). 1.4.7.2.2 The numbered items must be entered as follows:

Line Instruction AWW DRAFT 09/28/18 1. Identify the manufacturer of the device. 2. Record the test facility that tested the device, if other than the manufacturer’s. 3. Record the date testing was completed for subject device. 4. Indicate the applicant’s observer’s name and title. 5. Indicate the procedure used to test the prototype device and the number of devices tested. 6. Indicate the number of cycles to which a device was subjected at high and low temperatures and at the given pressure, as well as the specific test medium used (e.g., air, water, etc.). 7. Indicate the commodity or commodity type. 8. Indicate the flow rate of the device in gallons per minute, or gallons per minute and liters per minute, if applicable. 9. Indicate the drawing number showing the application of the device to the car and the basic material. When applicable, reference a precedent drawing with AAR application number.

11/2014 C-III [M-1002] 51 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

Line Instruction 10. Indicate the drawing number of the device assembly and basic material and, when applicable, reference a precedent drawing with AAR application number. 11. Indicate the drawing number and material specification of individual parts. 12. Provide a basic statement that the facility has a quality control program to provide compliance with drawings and specifications. 1.4.7.2.3 Revisions/Certification • The “Revisions” space is provided to indicate any revisions to the original application. • The applicant signs the form under “Certification,” attesting to the above entries.

1.4.7.2.4 Approval by AAR Tank Car Committee 09/28/18 DRAFT AWW The Executive Director—Tank Car Safety completes the approval section of the form based on action taken on the application. The Approval of Service Trial section is designated for approving the device for a service trial. The Approval of Design section is designated for approving the device either after successful completion of a service trial or in the cases where service trial is not required and the device is approved without a service trial.

C-III [M-1002] 52 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

APPLICATION FOR APPROVAL OF VALVES, CLOSURES, AND FITTINGS  Applicant AAR No. Description of Device

Applicant No. Device Ident. No. Date

1. Manufacturer 2. Address City State Zip 3. Test facility if other than the manufacturer Address 4. Test date 4. Observer Title: . TEST PROCEDURE 5. Description of prototype testing:

 6. Cycles Min. Temp. @ Pressure Cycles Max. Temp. @ Pressure Test Medium Remarks ºF psi ºF _psi ºC _kPa ºC kPa

Cycles Min. Temp. @ Pressure Cycles Max. Temp. @ Pressure Test Medium Remarks ºF psi ºF _psi ºC _kPa ºC kPa

Cycles Min. Temp. @ Pressure Cycles Max. Temp. @ Pressure Test Medium Remarks ºF psi ºF _psi ºC _kPa ºC kPa  7. Commodity: Regulated Commodity___ Non Regulated Commodity ___ Specific Commodity 8. Flow rate (if applicable) gpm ( L/min)    Drawing Number Precedent Applicable drawings Material latest revision Drawing Number Application/Certificate 9. Device application ......  10. Device assembly ......  11. Device details ......  12. Quality Control Statement

REVISIONS: CERTIFICATION: The above data is correct and conforms with AAR Specifications for Tank Cars, Appendix A. The devices tested conform with drawings listed above.

AWW DRAFT 09/28/18  By Title APPROVAL AAR Tank Car Committee Service Trial Required Date Approved for Service Trial Service Trial Number  (Signature) on behalf of Tank Car Committee

 APPROVAL AAR Tank Car Committee Service Completed / Not Required Date Service Trial Completed Date AAR Received Form AAR 4-6 . Date Approved ______Expiration Date ______(Signature) on behalf of Tank Car Committee Form AAR 4-5 Revised 10/2014

Fig. 1.4 Form AAR 4-5 Application for Approval of Valves and Fittings

11/2014 C-III [M-1002] 53 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

1.4.8 Renewal of Approval for Pressure Relief Devices, Valves, Closures, and Fittings 1.4.8.1 Procedures for Renewal—Application Form AAR 4-7 1.4.8.1.1 To secure approval for renewal of approval for pressure relief devices, valves, closures, and fittings as required by paragraph 1.3.6, the completed application package as defined in paragraph 1.4.8.1.2 must be submitted to the following: Executive Director—Tank Car Safety Association of American Railroads 425 Third Street SW, Suite 1000

Washington, DC 20024 AWW DRAFT 09/28/18 DRAFT AWW 1.4.8.1.2 The application package for renewals shall consist of the following: • Form AAR 4-7 • Drawings (assembly drawing and any additional drawing necessary to describe the device including a Bill of Material) • Flow test facility’s report, if applicable • Supplemental information as applicable • Application fee per Appendix E of the Office Manual of the AAR Interchange Rules Note: All submitted materials must be marked with an assigned AAR number. 1.4.8.2 Instructions 1.4.8.2.1 The following instructions must be followed by the applicant when completing the application and certification portions of the form. • The applicant must request an AAR number from the Executive Director • Applicant must be the manufacturer of the device, or its agent. • The date must be that on which the application is completed. • Spaces for the applicant’s number and the device identification number are for the convenience of the applicant (e.g., index, catalog, or type numbers). 1.4.8.2.2 The numbered items must be entered as follows:

Line Instruction 1. Enter the AAR Number assigned by the Executive Director. 2. Enter the date which the application is completed. 3. Enter the previous AAR approval number under which the device was approved by the Tank Car Committee. 4. Enter the applicant’s name. 5. Enter the applicant’s Address, City, State, and ZIP. 6. Provide an applicable drawing number. 7. Enter the latest revision. 8. Enter the date of the latest revision. 9. Enter detail description of the device. 10. For convenience of the applicant, enter the device ID No. (e.g., index, catalog, type numbers). 11. If the subject device is unchanged, the applicant signs the certification attesting to the entries on the form and enters the applicant’s title. 12. Identify the previous and current drawings, and if on service trial the service trial number.

C-III [M-1002] 54 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

Line Instruction 13. Indicate whether or not the change supersedes the drawings. 14. Describe the changes and the reasons for making the changes. 15. Provide a statement about the operational effect of the changes. 16. Identify the drawing submitted with this application. 17. If the device has changed, then the applicant signs the certification that the data is correct and conforms with AAR Specifications for Tank Cars and the device conforms with drawing listed on the form 1.4.8.3 Certification The applicant signs the “Certification,” attesting to the entries. Enter the applicant’s title. Applies to Line 11 or 17, whichever is applicable. 1.4.8.4 Approval The Executive Director completes the approval section of the form based on action taken on the application.

AWW DRAFT 09/28/18

11/2014 C-III [M-1002] 55 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

APPLICATION FOR RENEWAL OF APPROVAL FOR PRESSURE RELIEF DEVICES, VALVES, CLOSURES, AND FITTINGS

1. AAR APPROVAL No. 2. Date of Application 3. Previous AAR Approval 4. Applicant: 5. Address: 6. Drawing No. 7. Latest rev. 8. Date of latest rev. 9. Description of device: 10. Device ID No.

AWW DRAFT 09/28/18 DRAFT AWW CERTIFICATION: The subject device is unchanged from the previous approval, and conforms with the latest revision of AAR Specifications for Tank Cars, Appendix A. The device conforms with drawing listed above.

11. By: Title:

If device is changed since latest approval, fill in the following blanks

12. Reference Previous Drawing New Drawing If on Service Trial No. Rev. Date No. Rev. Date S.T. No. No. Rev. Date No. Rev. Date S.T. No. No. Rev. Date No. Rev. Date S.T. No.

13. New drawing supersedes previous one or does not obsolete it

CHANGES REASONS FOR CHANGES

14. a. a. b. b. c. c. d. d. (if needed use supplemental sheet)

15. Normal operational effect of changes of device:

16. Drawing submitted with this application:

CERTIFICATION: The above data is correct and conforms with AAR Specifications for Tank Cars, Appendix A. The device conforms with drawing listed above.

17. By: Title:

APPROVAL AAR Tank Car Committee:

Date Approved: (Signature) on behalf of Committee

Form AAR 4-7 8/1/2014

Fig. 1.5 Form AAR 4-7 Application for Renewal of Approval for Pressure Relief Devices, Valves, Closures, and Fittings

C-III [M-1002] 56 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

1.4.9 AAR Service Trials A service trial is an in-service examination that evaluates the performance of a specified number of tank cars or its service equipment for a defined period of time. 1.4.9.1 Authorization for Service Trials for Tank Cars 1.4.9.1.1 The first cars built by a new manufacturer of tank cars or a new production facility of an established manufacturer or tank cars are subject to a service trial. 1.4.9.1.2 The number of tank cars subject to a service trial shall be • 50—new tank car manufacturer • 25—new tank car facility of an existing builder These may be increased by the Tank Car Committee depending on the circumstances at time of build. 1.4.9.1.3 The following requirements apply to tank cars under service trial: • Notification to the AAR of the date the cars are placed in service • Minimum 100,000 miles or 10 years, first qualification • Annual visual inspection of draft sill and bolster • Annual report by tank car giving, miles and trips for the year, and results of annual inspection • Stub sill inspection at the conclusion of the service trial • Final report by tank car having total mileage, trips, and results of stub sill inspection 1.4.9.2 Authorization for Service Trials for Service Equipment 1.4.9.2.1 All new devices may be subjected to service trials. Service trials, when required by the Tank Car Committee, must be reported on Form AAR 4-4. The service trial may be waived by the Tank Car Committee after considering the supporting material in the application. The applicant has 30 days to appeal the request for service trial. In its challenge appeal, the applicant must provide reasons why a service trial in unnecessary. The appeal must be filed with the Executive Director for disposition by the Tank Car Committee. 1.4.9.2.2 The requirements for a service trial are as follows: 1.4.9.2.2.1 The sample size and post-trial teardown requirements are provided in Table 1.18.

Table 1.18 Service trial parameters

AWW DRAFT 09/28/18 Minimum Subject Minimum Sample to Post-Trial Maximum That Device Sizea/ Teardown May Be Applied Pressure relief valve or bottom outlet valve 25 5 50 Top valve or excess flow valve 15 3 200 Other primary closure 15 3 50 Sample line valve, gauging device, or vacuum relief 10250 device Thermometer well or auxiliary fittingb/ 5250 a/ Devices destroyed accidentally during a service trial do not need to be replaced provided the minimum required for a teardown remain in service. b/ Teardown does not require a Tank Car Committee-designated observer.

11/2014 C-III [M-1002] 57 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

1.4.9.2.2.2 The maximum number of units that can be applied to tank cars may be exceeded if authorized by the Executive Director or his designee. After receipt of approval for non-regulated service, the maximum number of units that may be applied in regulated service is no longer restricted. 1.4.9.2.2.3 The devices in the service trial must average 5,000 loaded miles and 10 loaded trips per year. If at the 1-year anniversary one or both of these averages are not being met, the applicant may apply to the Tank Car Committee for modification of these averages. 1.4.9.2.2.4 For non-regulated commodities, each car set of the device must be subjected to a trial of 1 year minimum duration. 1.4.9.2.2.5 For regulated commodities, each car set of the device must be subjected to a trial of

2 years minimum duration. 09/28/18 DRAFT AWW 1.4.9.2.2.6 Successful completion of 1 year, 5,000 loaded miles, and 10 load cycles in regulated commodity service may be used to qualify the device for non-regulated service. 1.4.9.2.2.7 In cases where a proponent believes that the standard field service trial format is not applicable when considering the intended application of the service equipment in the field, the applicant can propose an alternate field service trail format as an attachment to the applicable Form AAR 4-3 or 4-5. Proper justification, including applicable test data, must be submitted as part of the attachment to Form AAR 4-3 or 4-5. 1.4.9.2.2.8 If the service trial is not completed within 3 years from the start date, the service trial will be terminated and any approvals will be revoked unless continuation is requested from the applicant and approved by the AAR Tank Car Committee. 1.4.9.2.2.9 Difficulties experienced during the service trial (e.g., leakage, breakage, or performance problems) must be reported as soon as known to the Executive Director for review by the Tank Car Committee and reported on the next submitted Form AAR 4-4. The report should include a description of the issue along with the corrective action. If the analysis indicates an operational issue (failure to close or otherwise secure the device) and does not affect the functionality of the device, report as such on the next Form AAR 4-4 and no further analysis is required as part of the service trial. 1.4.9.2.3 Teardown Inspection The purpose of the teardown is to examine a number of devices at the conclusion of their service trial and determine from signs of wear what should be the qualification interval for the device. 1.4.9.2.3.1 Observer of Teardown Unless the Tank Car Committee has specified their observer of the teardown, the observer shall be the QA manager of the applicant. 1.4.9.2.3.2 Teardown of Device Before tearing down a device, it must be subjected to the applicant’s acceptance test of manufacture and must be cycled one time with the device meeting the test requirements of Appendix D. All components of a torn-down device must be kept together for 180 days pending Tank Car Committee request to examine the device.

C-III [M-1002] 58 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

1.4.9.2.3.3 Documentation Copies of any tests and notes of conditions found shall be kept. Photographs of each step of the teardown process and each individual component must be kept. A copy of the test and inspection procedure and copies of each bench test and appropriate photographs shall be included with the submission of the Form AAR 4-6. 1.4.9.2.3.4 At the conclusion of a service trial, Form AAR 4-6 “Final Service Trial Inspection Report,” with any design changes the service trial indicates are necessary must be submitted to the Tank Car Committee for approval with a copy of the original application. The Tank Car Committee may request additional tests to supplement the manufacturer’s tests or service trials prior to acceptance of the device. 1.4.9.3 Service Trial Report Form AAR 4-4 Service trial data must be submitted to the Executive Director on Form AAR 4-4, AAR Tank Car Service Trial Report, at 6 month intervals before the April and October meetings of the Tank Car Committee, no later than April 1 and October 1. Failure to submit the report may result in cancellation of service trial authorization and revocation of all approvals. The Executive Director shall be notified when the service trial starts; 90 days before the 2-year service trial ends; and 90 days before teardown is planned. 1.4.9.3.1 Instructions 1.4.9.3.1.1 The following instructions must be followed by the proponent when completing the Service Trial Report. • AAR number is the same number used on Forms AAR 4-2, AAR 4-3, or AAR 4-5. • AAR docket number is the number assigned by the Director to review a specific item when requested by the Tank Car Committee. • AAR service trial number is the number issued by the Director at the time the application is processed. • Reporting company is the applicant or applicant’s representative having knowledge of the performance and service of the device. • The date must be the date on which the report is completed. • Period covered is the period from the date of application or date of last report to the required reporting date as specified above. 1.4.9.3.1.2 Enter the numbered items as follows:

Line Instruction AWW DRAFT 09/28/18 1. The applicant’s number blank is for the convenience of the applicant. 2. The device identification number is for the convenience of the applicant (e.g., catalog number). 3. Record the date the device was initially installed on the car. 4. Describe the device as it was described on Form AAR 4-2, 4-3, or 4-5, giving function in accord with the definitions and requirements of Appendix A. 5. Record the total number of cars authorized by the Tank Car Committee to have device applied and the number of cars covered by the individual report. 6. Record the specific car numbers. 7. Indicate the commodity or commodity type. 8. Indicate the date of initial installation of the device. 9. Indicate the number of loaded trips and total miles the car moved in the period covered by the report.

11/2014 C-III [M-1002] 59 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

Line Instruction 10. Show the total number of loaded trips and the total distance for each car to date for this service trial. Indicate the average trips and distance for all cars. 11. Indicate the loading temperature of commodity, if known and applicable. 12. Indicate the unloading temperature of commodity, if known and applicable. 13. Indicate the loading pressure, if applicable. 14. Indicate the unloading pressure, if applicable. 15. Indicate the operational or performance difficulties encountered. Specify by car number. 16. These items provide recommendations to the Tank Car Committee.

through AWW DRAFT 09/28/18 DRAFT AWW 18.17.

C-III [M-1002] 60 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

AAR TANK CAR SERVICE TRIAL REPORT*  AAR No. AAR Docket No. Reporting company AAR Service Trial No. Address Date Covering Period   1. Applicant’s No. 2. Device Identification. No. 3. Description of device 4. Number cars authorized to applicant 5.Number of cars this report 9. This Report 10. To Date 8. Date Initial 6. Reporting Marks 7. Commodity Installation Loaded Distance Loaded Distance Trips (Miles) Trips (Miles)

AVERAGES

11. Loading temperature ºF ( ºC) 12. Unloading temperature ºF ( ºC) 13. Loading Pressure psi ( kPa) 14. Unloading pressure psi ( kPa) 15. Maintenance required (specify by reporting mark and car no.)

16. General performance remarks

AWW DRAFT 09/28/18

17. Continue test 18. Discontinue test  Final acceptance subject to Tank Car Committee Approval on Form AAR 4-6.   *This report is to be completed and submitted to the Executive Director every six months as required in Chapter 1 of M-1002. Failure to submit report may result in cancellation of service trial authorization, and revocation of all approvals.   Submitted by Title   Form AAR 4-4 Revised 8/2014

Fig. 1.6 Form AAR 4-4 AAR Tank Car Service Trial Report

11/2014 C-III [M-1002] 61 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

1.4.10 Final Service Trial and Inspection 1.4.10.1 Procedures for Acceptance of Final Service Trial and Inspection—Report Form AAR 4-6 The acceptance of a service trial is based on the report of post-trial teardown, which must be filed on Form AAR-4.6. 1.4.10.2 Instructions 1.4.10.2.1 The following instructions must be followed by the applicant when completing the Final Service Trial Inspection Report. This form must be submitted to the Executive Director for distribution to the Tank Car Committee. (Note: RPI representatives serving on the Tank Car Committee will not receive sensitive information.) • AAR number is the same number used on Forms AAR 4-3 or AAR 4-5. 09/28/18 DRAFT AWW • AAR docket number is the number assigned by the Executive Director to review a specific item when requested by the Tank Car Committee. • AAR service trial number is the number assigned to the device for which this report is presented. • The date must be the date on which this report is completed, signed, and forwarded to the Tank Car Committee for approval. 1.4.10.2.2 The numbered items must be entered as follows:

Line Instruction 1. Enter the name and address of the applicant to whom service trial is assigned. 2. Enter the name and address of the device manufacturer, if different than that of the applicant. 3. The description designation and/or model number of the device should be the same as 4. shown on Form AAR 4-3 (see Fig. 1.3) or Form AAR 4-5 (see Fig. 1.4). 5. Enter the total number of devices of this description or model number in the service trial sample. 6. Enter the number of devices from the service trial sample that are included in the tests and inspections reported. 7. Enter the total load/unload cycles, total loaded mileage, and total service time for the service trial sample and average for the devices to be torn down. (Details for each device or car should be available on Form AAR 4-4 submitted during the service trial.) 8. Enter actual test conditions to which each teardown sample is subjected (see Chapter 1, paragraph 1.4.9 for teardown sample size). Comment on test results, physical condition, corrosion, wear, etc. Compare critical dimensions to original. 9. Show drawing numbers and indicate revisions made during service trial. 10. Conclusions are those of the proponent after the tear down. 11. Recommendations are those of the designated Tank Car Committee observer. 12. The form is signed by the applicant or manufacturer (or agent) performing the tests and inspections. The signature of the independent observer (if designated by the Committee) also appears. 13. Upon successful completion based on the comments in Lines 10 and/or 11, the Executive Director will approve the Final Service Trial Inspection Report and complete the approval of the Form AAR 4-3 or 4-5, as appropriate. 1.4.10.2.3 The samples examined must have had the full range of service trial experience.

C-III [M-1002] 62 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

FINAL SERVICE TRIAL INSPECTION REPORT

1. Applicant AAR No. Address AAR Docket No. 2. Manufacturer AAR Service Trial No. Address Date

3. Description of device 4. Device designation or model no. 5. Total number of devices in service 6. Number of devices for teardown 7. Service data for service equipment under this inspection Total load/unload cycles and average Total loaded mileage and average Total service time and average

8. Teardown data Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 From car number Last lading Model no. Serial no. Test pressure psi (kPa) Test temp F (ºC) Test medium STD psi (kPa) Vapor tight, psi (kPa)

Test remarks……………...

Physical condition…….….

Compare critical final dimensions to original.….. 9. Drawing numbers…….…....

(Ref. Form AAR 4-3 or AAR 4-5)

Revisions made…….….....

Revision date…….…......

10. Conclusions

11. Recommendations to Tank Car Committee

12. CERTIFICATION The above data is correct and complies with the AAR Specifications for Tank Cars, Appendix A. Devices tested AWW DRAFT 09/28/18 conform to the drawings listed above.

MANUFACTURER or APPLICANT INDEPENDENT OBSERVER/QA MANAGER

(Signature) (Signature) Title Title Company Company

13. APPROVAL AAR Tank Car Committee

Date approved (Signature) on behalf of Tank Car Committee

Form AAR 4-6 Revised 2-8-2014

Fig. 1.7 Form AAR 4-6 Final Service Trial Inspection Report

11/2014 C-III [M-1002] 63 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

1.4.11 Certified Status 1.4.11.1 Requirements for Obtaining Certified Status A car owner/builder may elect to obtain certified status for stub sill, nonpressure, nonexterior- coiled tank cars built prior to July 1, 1974, per Field Manual of the AAR Interchange Rules, Rule 88B.12.c. A petition for such status can be made to the Director and must be submitted as follows: 1.4.11.1.1 A special drawing approximately 8 1/2 × 11 in. for each type of stub sill (underframe) to be certified must be submitted, covering general details including the following ranges: • Length over strikers • Truck centers

• Inside tank diameters AWW DRAFT 09/28/18 DRAFT AWW • Truck capacity • Typical variations in reinforcements • Type of materials • Typical welding details Variations in details, such as slabbing materials, tank head and shell materials, length of slabs, etc., are to be tabulated on the drawing. 1.4.11.1.2 Two tabulations are to be prepared as follows: 1.4.11.1.2.1 Car tabulation(s) by type of stub sill (underframe) showing car numbers (or car number series where applicable). 1.4.11.1.2.2 Tabulation by car number, showing the following: • Type of stub sill construction • Length over strikers • Truck centers • Truck capacity • Capacity, gallons (liters) • Tank materials—at end of stub sill and/or at the end of the stub sill slabbing plate. • Shell thickness • Length of stub sill slabbing, within 10 in. (254 mm) increments • Test data reference (by test number and date) • Tank shell diameter (inside) • Year built new 1.4.11.1.3 Submit test data as specified in paragraph 6.3 of AAR Specification M-1001. 1.4.11.1.4 Submit stress calculations as specified in paragraph 6.2 of AAR Specification M-1001. Include a comparison summary of calculated and measured stresses. 1.4.11.2 Approval 1.4.11.2.1 When approved by the Equipment Engineering Committee and the Tank Car Committee, the Technical Services Section of the AAR will assign a certified status number in accord with Office Manual of the AAR Interchange Rules, Rule 88, and advise the applicant. 1.4.11.2.2 The car owner must periodically submit to the AAR a listing of car modifications and stenciling dates, if so requested. 1.4.11.2.3 In the event forthcoming tests or in-service operation proves the design inadequate, a reevaluation of a certified status approval will be made.

C-III [M-1002] 64 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

1.5 Certification of Independent Third Parties 1.5.1 General 1.5.1.1 Paragraph 1.4.1 of this specification provides for review of applications for construction, conversion, or alteration of tank cars by a certified, independent third party (ITP) who verifies that the applications meet all AAR, DOT, and Transport Canada requirements. This section sets forth the minimum qualifications for ITPs and outlines the procedures to be followed by a prospective ITP to obtain Tank Car Committee certification. 1.5.1.2 An ITP may be either an individual, a partnership, or a larger organization employing individuals who possess the necessary qualifications and meet other requirements as further described below. 1.5.2 Requirements and Qualifications 1.5.2.1 A certified ITP must possess, or utilize individuals who possess, at least a Bachelor of Science degree in an engineering discipline conferred by an ABET-accredited college or university. Registration as a professional engineer (PE) in the state in which the ITP practices is also required. In addition, a prospective ITP must document a minimum of 5 years of experience in tank car design, construction, operation, and/or repair or a related discipline, as deemed acceptable by the Tank Car Committee. At the discretion of the Committee, the requirement for PE registration may be waived in consideration of higher levels of technical knowledge and experience related to tank cars. 1.5.2.2 A certified ITP must demonstrate a comprehensive working knowledge of U.S. and Canadian federal regulations governing tank car design, construction, and repair, AAR Interchange Rules, and AAR Standards and Recommended Practices—particularly M-1002. An ITP must possess or have access to the above documents as well as to relevant American Welding Society (AWS) and American Society of Testing and Materials (ASTM) standards. 1.5.2.3 A certified ITP may not review an application that he/she, or an entity with which he/she is affiliated, has submitted. 1.5.2.4 A certified ITP must agree to be bound by terms of a standard AAR contract. 1.5.3 Procedures for Obtaining Certification The following procedures are to be followed by an applicant who desires to be certified as an ITP by the AAR Tank Car Committee: 1.5.3.1 A letter of application must be filed with the Director, stating a desire to become certified as an ITP for review of tank car applications and providing the technical background and general

AWW DRAFT 09/28/18 business history of the applicant. The application must specifically address each item outlined in paragraph 1.5.2. 1.5.3.2 The Director will arrange an opportunity for the applicant to meet with the AAR Tank Car Committee at a scheduled meeting to discuss the application and address any questions from members of the Committee. 1.5.3.3 Approval of the applicant must be by unanimous vote of the Committee. In the event unanimous approval is not achieved, the applicant shall be advised of the reason(s) and may request a second meeting with the Committee to further clarify the application. 1.5.3.4 Upon approval by the Tank Car Committee, the applicant will enter into a written contract with AAR to review and verify applications, as an independent third party, on behalf of the Committee. 1.5.3.5 Independent third party contracts will be subject to periodic review and renewal at the discretion of the Tank Car Committee.

11/2014 C-III [M-1002] 65 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars CHAPTER 1 M-1002

1.6 Document Retention 1.6.1 This section describes the minimum documentation requirements for certified and registered facilities and for tank cars in interchange service, and the minimum retention periods of those documents. In general, documents that pertain to individual tank cars must be retained by the owners of those cars; documents that pertain to linings and coatings must be kept by the owners of those components; documents that pertain to the qualification of facilities to perform work on tank cars must be retained by those facilities; and documents that pertain to approvals of valves and fittings must be retained by the manufacturers of those components. “While valid” means • the document has not expired; and

• the document is not preceded by another document containing the same subject matter. AWW DRAFT 09/28/18 DRAFT AWW 1.6.2 This standard is mandatory after January 1, 2008. 1.6.3 Documents may be retained as paper originals, as copies of originals, or in electronic format, and must be available upon request by AAR or government representatives. 1.6.4 Table 1.19 lists the documents that must be retained by the car owner. Upon the sale of a car, the documentation pertaining to that car must be transferred to the new owner. The table lists the document by type and references the requirements for such document, the parties responsible for retaining the document, and the minimum retention period for each type of document.

Table 1.19 Documents retained by car owner (page 1 of 2) Document Retention Period Original and subsequent certificates of construction Life of car Forms AAR 4-2, R-1, and R-2 for modifications and repairs Life of car General arrangement, tank, and fittings drawings Life of car Drawings used for precedent for repairs 10 years Tank head and shell plate mill test certificates None Tank head and shell plate material identification None Radiographs and radiographic reports or UT reports 10 years Postweld heat treatment record (consistent with radiograph retention time) 5 years Impact, corrosion, and harness tests when required by specification 5 years Thermal analysis of thermal protection systems Life of car Capacity table (gauge table) Life of car Tank maintenance and qualification records Next qualification inspection •Visual •Structural • Thickness • Service equipment • D-3 form: Certificate of tank test • Certificate of pressure relief device test • Certificate of interior heater coil test •Leak testing • Safety systems NDT inspection records Next Inspection Service reliability assessment data Life of car + 10 years SS-1 and SS-3 stub sill inspection forms (inboard and outboard of the bolster) Next Inspection

C-III [M-1002] 66 11/2014 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars M-1002 CHAPTER 1

Table 1.19 Documents retained by car owner (page 2 of 2) Permits While valid FRA/TC alternative inspection and test protocol. This does not transfer the approved While valid alternative inspection and test protocol, but merely acknowledges that alterative means of compliance exist. New owners must apply under the terms of 49 CFR 180.509(k), 180.509(j), and Transport Canada (TC) TP14877. Ductile iron castings 5 years Certified inspector’s reports for Class DOT-107A tanks Life of tank

1.6.4.1 Table 1.20 lists the documents that must be retained by each certified and registered tank car facility:

Table 1.20 Documents retained by certified and registered tank car facility Document Retention Period Certification/registration of facilities 6 years Welding procedure and procedure qualification While valid Performance qualification of welders and operators While valid, plus 90 days Procedure qualification While valid NDT written practice While valid NDT certification records While valid, plus 90 days NDT procedure requirements While valid Results of radiographic examinations (radiographs may be retained or discarded) 5 years Exhibit B-1 Subcontractor’s evaluation sheet (requires an annual review) While valid

1.6.4.2 Table 1.21 lists the documents that must be retained by each registered manufacturer of a tank car pressure relief device, and service equipment:

Table 1.21 Documents retained by registered manufacturer of tank car pressure relief device and service equipment Document Retention Period Final service trial inspection report 2 years Service trial report Duration of trial Approval of pressure relief devices 10 years Approval of valves and fittings 10 years

AWW DRAFT 09/28/18 1.6.4.3 Table 1.22 lists the documents that must be retained by each lining or coating owner:

Table 1.22 Documents retained by lining or coating owner Document Retention Period Rubber lining qualification report While valid Application/removal or lining inspection While valid

11/2014 C-III [M-1002] 67 AAR Manual of Standards and Recommended Practices Specifications for Tank Cars

CHAPTER 1 M-1002 AWW DRAFT 09/28/18 DRAFT AWW

THIS PAGE LEFT BLANK INTENTIONALLY

C-III [M-1002] 68 11/2014